EGES2352 A

SERVICE MANUAL
SERVICE MANUAL
INTERNATIONAL® VT 365
DIESEL ENGINE
2002 and 2003 Model Years
DIESEL ENGINE
INTERNATIONAL® VT 365
EGES-235-2
2002 and 2003 Model Years

EGES-235-2
© 2006 International Truck and Engine Corporation

Printed in the United States of America
ENGINE SERVICE MANUAL I
Table of Contents
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
MOUNTING ENGINE ON STAND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Mounting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
ELECTRONICALLY CONTROLLED VARIABLE GEOMETRY TURBOCHARGER (VGT). . . . . . . . . . . . . . . . . . . . . .51

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
MANIFOLDS AND EXHAUST GAS RECIRCULATION (EGR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
CYLINDER HEAD AND VALVE TRAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Component Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100.
Component Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 .
FRONT COVER, VIBRATION DAMPER, and GEROTOR OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 .

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
.
Cleaning, Inspection, and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143 .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
.
OIL PAN, UPPER OIL PAN, and OIL PICKUP TUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153 .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
.
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157 .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
.
POWER CYLINDERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161 .

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
.
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
.
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166.
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171.
CRANKCASE, CRANKSHAFT and BEARINGS, CAMSHAFT and BUSHINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179 .

Component Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
.
Cleaning, Inspection, and Reconditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188 .
EGES235-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
II ENGINE SERVICE MANUAL
Component Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192

.
OIL COOLER and FILTER HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201 .

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
.
Cleaning, Inspection, and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208 .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
.
ENGINE ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213 .

Engine Electronic Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215 .
Engine Sensors and Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221 .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224
.
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231
.
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .231.
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233.
HIGH-PRESSURE OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241 .

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
.
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249
.
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249
.
FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255

.
Fuel System Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258 .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259.
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261 .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261 .
REAR COVER, FLYWHEEL, and POWER STEERING GEAR DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267 .

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
.
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275
.
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276.
IN-CHASSIS PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287 .

Branch Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289 .
Rocker Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302
.
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311
.
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313 .
Appendix A – Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .319

.
Appendix B – Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .331

.
Appendix C – Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .347

.
EGES235-2
ENGINE SERVICE MANUAL 1
Foreword Technical Service Literature

International Truck and Engine Corporation is 1171765R2 VT 365 Engine Operation and
committed to continuous research and development Maintenance Manual
to improve products and introduce technological
EGES-235-2 VT 365 Engine Service Manual
advances. Procedures, specifications, and parts
defined in published technical service literature may EGES-240 VT 365 Engine Diagnostic Manual
be altered.
EGED-140 Supplemental Coolant Level Ref.
NOTE: Photo illustrations identify specific parts or Chart (for conventional “green”
assemblies that support text and procedures; other coolant)
areas in a photo illustration may not be exact. EGED-245 VT 365 Hard Start and No Start
This manual includes necessary information Diagnostic Form
and specifications for technicians to maintain EGED-250 VT 365 Performance Diagnostics
International® diesel engines. See vehicle manuals Form
and Technical Service Information (TSI) bulletins for
additional information. EGED-255 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
EGES235-2
2 ENGINE SERVICE MANUAL
Service Diagnosis • Knowledge of the principles of operation for

engine application and engine systems
Service diagnosis is an investigative procedure that
must be followed to find and correct an engine • Knowledge to understand and do procedures in
application problem or an engine problem. diagnostic and service publications
If the problem is engine application, see specific Technical Service Literature required for Effective
vehicle manuals for further diagnostic information. Diagnosis
If the problem is the engine, see specific Engine • Engine Service Manual
Diagnostic Manual for further diagnostic information.
• Engine Diagnostic Manual
Prerequisites for Effective Diagnosis
• Performance Diagnostics Forms
• Availability of gauges and diagnostic test
• Electronic Control Systems Diagnostics Forms
equipment
• Service Bulletins
• Availability of current information for engine
application and engine systems
EGES235-2
ENGINE SERVICE MANUAL 3
Safety Information Protective measures
This manual provides general and specific service • Wear protective glasses and safety shoes.
procedures essential for reliable engine operation and • Wear appropriate hearing protection.
your safety. Since many variations in procedures,
tools, and service parts are involved, advice for all • Wear correct work clothing.
possible safety conditions and hazards cannot be • Do not wear rings, watches, or other jewelry.
stated.
• Restrain long hair.
Read safety instructions before doing any service and
test procedures for the engine or vehicle. See related Fire prevention
application manuals for more information. • Make sure charged fire extinguishers are in the
Disregard for Safety Instructions, Warnings, Cautions, work area.
and Notes in this manual can lead to injury, death or NOTE: Check the classification of each fire
damage to the engine or vehicle. extinguisher to ensure that the following fire types
can be extinguished.
SAFETY TERMINOLOGY
1. Type A — Wood, paper, textiles, and rubbish
Three terms are used to stress your safety and safe
operation of the engine: Warning, Caution, and Note 2. Type B — Flammable liquids
Warning: A warning describes actions necessary to 3. Type C — Electrical equipment

prevent or eliminate conditions, hazards, and unsafe Batteries
practices that can cause personal injury or death.
Batteries produce highly flammable gas during and
Caution: A caution describes actions necessary after charging.
to prevent or eliminate conditions that can cause
damage to the engine or vehicle. • Always disconnect the main negative battery
cable first.
Note: A note describes actions necessary for correct,
efficient engine operation. • Always connect the main negative battery cable
last.
SAFETY INSTRUCTIONS • Avoid leaning over batteries.
Vehicle • Protect your eyes.
• Make sure the vehicle is in neutral, the parking • Do not expose batteries to open flames or sparks.
brake is set, and the wheels are blocked before
doing any work or diagnostic procedures on the • Do not smoke in workplace.
engine or vehicle. Compressed air
Work area • Limit shop air pressure for blow gun to 207 kPa
• Keep work area clean, dry, and organized. (30 psi).
• Keep tools and parts off the floor. • Use approved equipment.
• Make sure the work area is ventilated and well lit. • Do not direct air at body or clothing.
• Make sure a first aid kit is available. • Wear safety glasses or goggles.
Safety equipment • Wear hearing protection.
• Use correct lifting devices. • Use shielding to protect others in the work area.
• Use safety blocks and stands.
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4 ENGINE SERVICE MANUAL
Tools Fuel
• Make sure all tools are in good condition. • Do not over fill the fuel tank. Over fill creates a fire
hazard.
• Make sure all standard electrical tools are
grounded. • Do not smoke in the work area.
• Check for frayed power cords before using power • Do not refuel the tank when the engine is running.
tools.
Removal of tools, parts, and equipment
Fluids under pressure
• Reinstall all safety guards, shields, and covers
• Use extreme caution when working on systems after servicing the engine.
under pressure.
• Make sure all tools, parts, and service equipment
• Follow approved procedures only. are removed from the engine and vehicle after all
work is done.
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ENGINE SYSTEMS 5
Table of Contents
Engine Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Emission Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine Component Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Engine Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Air Management System (AMS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Air Induction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Variable Geometry Turbocharger (VGT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Exhaust Gas Recirculation (EGR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Fuel Management. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Fuel Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Injection Control Pressure (ICP) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Fuel Supply System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Fuel Filter Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Pressure Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Lubrication System (Low Pressure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Electronic Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Electronic Control System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Injection Drive Module (IDM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Engine and Vehicle Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Glow Plug Controller System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
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6 ENGINE SYSTEMS
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ENGINE SYSTEMS 7
Engine Identification
Engine Serial Number
Figure 2 50 – State Exhaust Emissions Label

(example)
NOTE: The 50 – State Exhaust Emissions Label

Figure 1 Engine serial number
includes engines certified for sale in California.
The engine serial number is stamped on the

crankcase pad on the rear left side of the crankcase
below the cylinder head.
The engine serial number is also on an identification
sticker on the valve cover.
Engine serial number examples

6.0HM2Y0000500
6.0HA2U0000508
Engine serial number codes
6.0 – Engine displacement
H – Diesel, turbocharged, Charge Air Cooled, and
electronically controlled Figure 3 49 – State Low Emission Vehicle (LEV)
M2 – Truck Label (example)
A2 – Service
U – USA NOTE: The 49 – State Low Emission Vehicle (LEV)
Y – USA Huntsville Label excludes engines certified for sale in California.
7 digit suffix – Engine serial number sequence
The 50 – State Exhaust Emissions Label and the 49
– State Low Emission Vehicle (LEV) Label include the
Emission Labels following:
A 50 – State Exhaust Emissions Label or a 49 – • Year the engine was certified to meet EPA
State Low Emission Vehicle (LEV) Label and a U.S. emission standards
Federal Family Emission Limits Label are issued for • Engine model code
International® VT 365 diesel engines. These labels
are on top of the right valve cover. • Service applications
• Advertised brake horsepower ratings
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8 ENGINE SYSTEMS
Engine accessories
The following engine accessories may have
manufacturer’s labels or identification plates:
• Air compressor (for brake or suspension system )
• Air conditioning compressor
• Alternator
Figure 4 U.S. Federal Family Emission Limits • Cooling fan clutch
label (example)
• Variable Geometry Turbocharger (VGT)
• Power steering and fuel pump
The U.S. Federal Family Emission Limits Label
identifies the engine family and emission limits • Starter motor
established by the manufacturer and certified by the Labels or identification plates include information
EPA. and specifications helpful to vehicle operators and
technicians.
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ENGINE SYSTEMS 9
Engine Description
Table 1
International® VT 365 engine features and specifications
Engine Diesel, 4 cycle

Configuration 4 OHV/1 Cam-in-Crankcase V8
Displacement 365 cu. in (6.0L)
Bore and stroke 95 mm x 105 mm (3.74 in x 4.134 in)
Compression ratio 18.0:1
Aspiration VGT turbocharged and Charge Air Cooling (CAC)
1
Rated power @ rpm 175 bhp @ 2600 rpm
1
Peak torque @ rpm 460 lbf•ft @ 1400 rpm
Engine rotation, facing flywheel Counterclockwise
Combustion system Digital Direct Injection (DDI)
Total engine weight (auto with oil) 459 kg (1094 lb)
Cooling system capacity (engine only) 10.2 liters (10.8 qts)
Lube system capacity (including filter) 18 liters (19 qts)
Lube system capacity (dry) 21.8 liters (23 qts)
Firing order 1–2–7–3–4–5–6–8
1
Base rating shown. See Appendix A for other ratings.
Major features The firing order is 1-2-7-3-4-5-6-8. When viewing the

engine from the rear (flywheel end), the right side
Air Management System (AMS)
cylinders are numbered 1, 3, 5, and 7. Number one
• Variable Geometry Turbocharger (VGT) is the front position. The left side is numbered 2, 4, 6,
and 8.
• Exhaust Gas Recirculation (EGR) system
A two piece crankcase has been specially designed
• Chassis mounted Charge Air Cooling (CAC)
to withstand the loads of diesel operation. The lower
Digital Direct fuel Injection (DDI) crankcase has integral main bearing caps. Coolant
and oil passages are cast and machined in the
Two piece crankcase
crankcase and front cover housing.
One piece cylinder head with four valves per cylinder
The crankshaft has five main bearings with fore and
Dual timing aft thrust controlled at the upper half of the number 4
main bearing. Two connecting rods are attached to
Rear gear train
each crankshaft journal. The piston pin moves freely
Closed crankcase ventilation inside the piston and rod. Piston pin retaining rings
secure the piston pin within the piston.
Oil cooler
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10 ENGINE SYSTEMS
One piece aluminum alloy pistons are fitted with The VGT is electronically controlled and hydraulically
one keystone cut compression ring, one rectangular actuated. The VGT provides boost control at low and
intermediate compression ring, and a two piece oil high speeds for improved throttle response.
control ring. The combustion bowl (in the piston
An exhaust gas recirculation valve allows water
crown) reduces exhaust emissions.
cooled exhaust gases to be fed into the inlet air
The camshaft is supported by five insert bushings stream to reduce exhaust emissions.
pressed into the crankcase. Two cam lobes, cam
A closed crankcase breather system recirculates
followers, push rods and valve bridges control four
crankcase vapors back into the intake air system.
valves per cylinder. The camshaft is gear driven
from the rear end of the crankshaft. A thrust flange A chassis mounted Charge Air Cooler (CAC), an
is located between the camshaft gear and the air-to-air heat exchanger, increases the density of the
crankcase. Camshaft thrust is controlled with the rear air charge.
surface of the number 5 cam journal and the cam
Engine operation is controlled by two engine mounted
gear.
control modules:
Hydraulic cam followers maintain zero valve lash
• Electronic Control Module (ECM)
and minimize engine noise. This eliminates periodic
adjustment of valve lash. The hydraulic cam followers • Injector Drive Module (IDM)
have rollers which provide excellent cam lobe and
The ECM receives signals from engine and chassis
cam follower durability.
mounted sensors. The ECM controls engine
The lubrication system uses a crankshaft driven operation with the following actuators:
gerotor pump mounted on the front cover. The oil
• IPR
pressure regulator is built into the front cover and
is accessible from outside the engine. Lube oil is • VGT control valve
routed through an oil cooler equipped with a pressure
• EGR
controlled bypass valve. Lube oil moves through
passages in the crankcase to lubricate all internal • Glow plug relay
components and to supply the piston cooling tubes
The IDM controls fuel injector operation using data
and high pressure pump reservoir. The VGT and air
from the ECM.
compressor use external oil lines.
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ENGINE SYSTEMS 11
Engine Component Locations
Figure 5 Engine components – Front

1. Manifold Absolute Pressure 5. Fuel supply 9. Front cover assembly
(MAP) sensor 6. Engine Coolant Temperature 10. Power steering line
2. Lube oil pressure test port (ECT) sensor 11. Crankshaft vibration damper
3. Fuel filter assembly 7. Port for coolant deaeration tank 12. Coolant inlet
4. Fuel return 8. Coolant outlet and thermostat 13. Water pump pulley
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12 ENGINE SYSTEMS
Figure 6 Engine components – Left

1. Fuel filter drain lever 5. Injector Driver Module (IDM) 10. Camshaft Position (CMP) sensor
2. Lube oil fill tube 6. Valve cover 11. Engine Coolant Temperature
3. Engine Control Module (ECM) 7. Rear cover (ECT) sensor
4. Exhaust Back Pressure (EBP) 8. Glow plug harness rail 12. Breather hose assembly with
sensor 9. Exhaust manifold pitot tube
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ENGINE SYSTEMS 13
Figure 7 Engine components – Rear

1. Injection Control Pressure (ICP) 3. Exhaust tube assembly, right 6. Shielded tube exhaust assembly
test port 4. Flywheel or flexplate assembly 7. Exhaust Back Pressure (EBP)
2. Turbocharger exhaust 5. Reinforcement ring sensor
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14 ENGINE SYSTEMS
Figure 8 Engine components – Right

1. Valve cover 6. Crankshaft Position (CKP) 10. Fuel supply pump (transfer)
2. Glow plug harness rail sensor 11. Power steering line
3. Glow plug relay 7. Fuel tube assembly (supply) 12. Power steering pump
4. Oil filter housing 8. Fuel tube assembly (return)
5. Exhaust manifold 9. Fuel filter strainer
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ENGINE SYSTEMS 15
Figure 9 Engine components – Top

1. Fuel filter assembly 5. Intake manifold 10. Variable Geometry Turbocharger
2. Intake manifold air inlet 6. Manifold Air Temperature (MAT) (VGT) control valve
3. Exhaust Gas Recirculation sensor 11. Variable Geometry Turbocharger
(EGR) valve 7. Turbocharger air outlet (to CAC) (VGT)
4. Manifold Absolute Pressure 8. EGR cooler 12. Air inlet duct
(MAP) sensor 9. Glow plug relay 13. Oil filter housing
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16 ENGINE SYSTEMS
Engine Systems
The primary engine systems are Air Management and • The ICP system uses lube oil for hydraulic fluid to
Fuel Management, which share some subsystems or actuate the fuel injectors.
have a subsystem that contributes to their operation.
• The Fuel Supply System pressurizes fuel for
• The Electronic Control System controls the Air transfer to the fuel injectors.
Management System and Fuel Management
• The Lube Oil System provides lubrication and
System.
heat transfer to engine components.
• The Coolant System provides heat transfer for
EGR gases and lubrication oil.
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ENGINE SYSTEMS 17
Air Management System (AMS)
Figure 11 Air management system

1. Intake manifold 5. Shielded tube exhaust assembly 8. Right cylinder head
2. EGR cooler 6. Turbocharger assembly with 9. Right exhaust manifold
3. Left cylinder head mounting bracket 10. Exhaust tube assembly, right
4. Left exhaust manifold 7. Air inlet duct
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18 ENGINE SYSTEMS
The Air Management system includes the

following:
• Air filter assembly
• Closed crankcase breather
• Chassis mounted Charged Air Cooler (CAC)
• Variable Geometry Turbocharger (VGT)
• Intake manifold
• Exhaust Gas Recirculation (EGR) system
• Exhaust system
• Catalytic converter– dependent on application
• Catalyzed Diesel Particulate Filter (CDPF) –
dependent on application
Figure 12 Air flow diagram
Air Induction System when it needs servicing. As filtered air approaches

the turbocharger, it passes over the pitot tube creating
Ambient air is drawn into the air cleaner assembly and
a vacuum and draws engine blow-by gases through
passes through a paper element filter. A filter minder
a breather element located under the left side valve
monitors air filter restriction and is calibrated to warn
EGES235-2
ENGINE SYSTEMS 19
cover. Air entering the turbocharger inlet is then serves to cool the charge air. The resulting cooler
pressurized and directed to the charge air cooler. intake air is denser than heated air, allowing for an
improved fuel/air ratio during combustion. This results
Air from the turbocharger is pushed through a network
in improved emission control and power output.
of heat exchanging tubes prior to entering the intake
manifold. Outside air flowing over the tubes and fins
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20 ENGINE SYSTEMS
Variable Geometry Turbocharger (VGT)
Figure 13 VGT
1. Actuator 3. Unison ring
2. Control valve 4. Vanes
The key feature of the Variable Geometry Exhaust

Turbocharger (VGT) is the introduction of adjustable
The exhaust system includes the following
vanes within the turbine housing to modify the flow
components:
characteristics of exhaust gases onto the turbine
wheel. The net benefit is to provide optimized boost • Exhaust valves
pressure to accommodate all engine speed and load
• Exhaust manifold
conditions. An additional benefit is lower emissions.
The VGT relies on electronic feedback loops provided • Turbine side of the turbocharger
by the Exhaust Back Pressure (EBP) sensor via the
• Exhaust piping
Electronic Control Module (ECM).
Exhaust gas from combustion passes around two
The turbocharger assembly contains a series of
exhaust valves, through the exhaust manifold and is
actuated vanes, a unison ring, and piston. The vanes
directed through pipes to the turbocharger exhaust
regulate the flow of exhaust gases across the turbine.
inlet. As hot expanding exhaust gases flow into
The only serviceable item on the turbocharger
the turbocharger, they pass over the turbine wheel,
assembly is the control valve.
causing it to spin in direct relation with the amount
of exhaust gases being produced. The right side
cylinders also provide a portion of their exhaust gases
to supply the exhaust gas recirculation system.
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ENGINE SYSTEMS 21
Exhaust Gas Recirculation (EGR) Valve seat interface when the valve is actuated. The valve
group moves outward from its fail-safe closed position.
The EGR system includes:
• Cooler assembly
• EGR valve actuator / Pintle position sensor
Exhaust Gas Recirculation (EGR) reduces peak
combustion temperatures and oxides of nitrogen
(NOX).
NOX formation in diesel engines is the result of
combustion in the presence of oxygen. In the diesel
engine, combustion starts when fuel is injected into
the cylinder just prior to or slightly after the piston
reaches top-dead-center.
The EGR Cooler
With EGR, a portion of the engine’s exhaust gases
are cooled and then recirculated back into the inlet
air stream. This increases the engine’s tolerance for
EGR and reduces the amount of smoke formed by
exhaust gas dilution of the mixture.
The EGR Valve Actuator / Pintle Position Sensor
The EGR valve is an electromechanical device that
uses a linear actuator to control the relative position
of the valve’s pintle. This device also has a built-in
pintle position sensor that functions to provide the
ECM with a feedback signal. This output signal
provides information on valve position relative to its
seat. The advantage of this “closed loop” feedback
is the ability to continuously vary exhaust gas flow to
match operating conditions. Figure 14 Exhaust gas flow
The EGR valve uses a position feedback sensor to 1. Actuator coil

provide pintle position data to the ECM. The signal, 2. Valve head (2)
based on a 5 volt (VREF) is directly proportional to the 3. Common shaft
valve opening.
The exhaust enters the valve assembly between the
two pintle heads and exits through each pintle and
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22 ENGINE SYSTEMS
Fuel Management
Fuel Injection
The engine uses an electrohydraulic injector as part
of its fuel system. This ECM controlled injector
uses high-pressure lube oil to provide the necessary
force to inject fuel into the combustion chamber
at pressures up to 144 MPa (21,000 psi) at rated
horsepower.
The injector fits into a sleeved bore machined into
the cylinder head. The injector bore intersects with
a machined fuel passage that runs the length of the
head. Each injector has two O-rings around the outer
body, one above the fuel passage, and one below.
A fuel inlet port between the O-rings allows fuel
under transfer pump pressure to enter the pressure
amplification area of the injector. High-pressure
engine oil enters the injector through the top. The
high-pressure oil rail assembly is mounted on top of
the injectors.
The injector is composed of 3 sections with the
following components:
1. Oil control
a. Spool valve
b. Opening coil
c. Closing coil
d. Control valve body
2. Pressure amplification
a. Intensifier piston and plunger
Figure 15 Fuel Injector
b. Piston return spring
1. Closing coil
c. Inlet check valve
2. Control valve body
d. Outlet check valve 3. Intensifier piston (7:1 ratio)
4. Piston return spring
3. Fuel injection
5. Plunger
a. Nozzle tip 6. Valve opening pressure spring, 260 bar (3,770 psi)
7. Needle
b. Valve Opening Pressure (VOP) spring
8. Opening coil
c. Fuel strainers 9. Spool valve (control valve)
10. Casenut
d. Casenut
11. Fuel strainer (3)
12. Nozzle assembly
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ENGINE SYSTEMS 23
The injection operation is divided into three major pressure is about 7 MPa (1,000 psi), then the plunger
stages or cycles: movement creates a fuel pressure of approximately
48-49 MPa (7,000 psi). The increased fuel pressure
• Fill stage
causes the inlet check valve to close, trapping the
• Injection stage fuel from moving back into the head.
• End of injection The high pressure fuel from the plunger travels
down the injector to the nozzle area where it works
The oil control section uses a spool valve to direct
against the bevel on the nozzle valve. When fuel
high-pressure oil from the injection control pressure
pressure reaches 18 MPa (2,700 psi) the thrust of
system into and out of the injector. The spool valve
the pressurized fuel overcomes the nozzle valve
floats in a bore machined into the valve housing, and is
spring and lifts the nozzle valve off its seat, allowing
positioned by the magnetic field created when voltage
fuel under extremely high pressure to enter the
is applied to either the opening or closing coils.
combustion chamber through the nozzle tip holes.
When voltage is applied to the opening coil, the Fuel continues to flow until the proper amount of fuel
spool valve opens, allowing high-pressure oil from enters the combustion chamber. At that point, the
the inlet port to enter the pressure amplification area closing coil is energized, the spool valve moves, and
of the injector. With the spool allowing oil to enter the the oil flow stops. When fuel pressure drops, the
injector, pressure begins to push on the intensifier valve opening pressure spring forces the nozzle valve
piston. The large diameter intensifier piston and small closed and fuel flow stops. Combustion gases will be
diameter plunger are pushed downward together. The restricted from entering the injector past the fuel outlet
upper piston surface area is open to the high-pressure check valve. The injector is again in a static position
oil and the lower plunger surface area pushes against to allow fuel to enter past the inlet check valve and
a column of fuel. The ratio of the surfaces areas refill the lower area of the plunger.
are approximately 7 to 1. Therefore, if the ICP oil
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24 ENGINE SYSTEMS
Injection Control Pressure (ICP) System
Figure 16 High-pressure oil system

1. Hydraulic pump assembly 4. Hydraulic pump cover 9. Crankcase to head tube
(high-pressure), w/discharge 5. Fuel injector assembly (8) assembly (2)
tube 6. Oil rail assembly (2) 10. Branch tube assembly
2. IPR valve 7. Oil rail fitting w/ check valve (2) 11. Oil hose (left side)
3. ICP sensor 8. Oil hose (right side)
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ENGINE SYSTEMS 25
General System Flow of the oil rail assemblies. Oil from the rails enter
the injectors through O-ring sealed ports at the top
The high-pressure oil system is composed of two
of each injector. When the injector opening coil is
subsystems:
energized, high-pressure oil is used to push fuel into
• Injection Control Pressure (ICP) system the combustion chamber. After injection is complete,
the oil inside the injector is vented through the top
• Fuel injector assembly
portion of the injector and allowed to drain back to the
The hydraulic force necessary to inject fuel into the oil sump.
combustion chamber is provided by the ICP system.
The fuel injectors on the engine are hydraulically
actuated and electronically controlled (Fuel Injection,
page 22).
The ICP system is composed of the following
components:
• Oil reservoir
• Hydraulic pump assembly, high-pressure
• Hydraulic pump cover
• High-pressure tubes and hoses
• High-pressure rail assemblies
• Injection Control Pressure (ICP) sensor
Figure 17 ICP closed loop system
• Injection Pressure Regulator (IPR) valve
• Check valves
ICP System Operation
The high-pressure hydraulic pump receives engine
lube oil from a reservoir cast into the vee of the Electronic control of the high pressure oil system
crankcase. This reservoir makes available a constant consists of the following components:
supply of engine oil for the pump. Oil for this reservoir • ECM
is constantly refilled by the low-pressure lube oil
system with filtered oil from a passage in the oil cooler • IDM
housing. • ICP sensor, located on the hydraulic oil pump
The high-pressure hydraulic pump is mounted at the cover, at the rear of the engine.
rear of the crankcase and is driven by the camshaft • IPR valve, located on the hydraulic oil pump cover,
gear. Oil for the pump is drawn from the oil reservoir at the rear of the engine.
through a 150 micron screen and into a passage to
the pump inlet port. High-pressure oil from the pump The ECM controls the injection control pressure
is distributed to the injectors through a series of pipes by operating the IPR regulator. The results are
and hoses. continuously monitored by the ECM using the
ICP sensor. The injection control pressure sensor
The high-pressure discharge tube is mounted to the provides pressure information in the form of an analog
pump and serves to connect the oil flow from the voltage signal to the ECM at any given time. The
high-pressure hydraulic pump to the rear engine tube pressure signal obtained from the ICP allows the
assembly. This tube assembly divides oil flow into two ECM to know the actual injection control pressure at
pipes or branches, one for each side of the engine. all times of engine operation, or even during cranking
Rigid pipes thread into each branch and direct oil up mode. This operation is known as Closed Loop.
into the rocker carrier of each cylinder head. Flexible
hoses with quick disconnect ends connect the rigid Diagnostic codes can be set by the ECM if the ICP
pipes to check valves, which are mounted on each signal is out of range or if the ICP signal received
EGES235-2
26 ENGINE SYSTEMS
corresponds to an out of range value for the injection and maintains desired injection control pressure by
control pressure at a given operating condition. dumping excess oil through a set of main dump ports
into the crankcase and back to the oil pan.
Should any of these occur, the ECM will ignore the
ICP signal and control the IPR valve operation from As the demand for injection control pressure
programmed default values. This condition is known increases, the ECM increases the pulse width (duty
as Open Loop. cycle %) to the IPR valve. This action forces the
poppet against the drain orifice, increasing the
IPR
pressure behind the poppet valve. As oil pressure
The IPR is an electrically controlled pilot operated increases behind the poppet valve, it moves forward
(small flow that controls a large flow) pressure and blocks the drain ports on the sides of the IPR
control valve. The IPR controls injection control valve.
pressure from approximately 3 - 20 MPa (500 - 3,000
When the demand for injection control pressure
psi). An electrical signal from the ECM to the IPR
decreases, the ECM decreases the pulse width (duty
solenoid creates a magnetic field, which applies a
cycle %) to the IPR valve coil windings, allowing oil
variable force on the poppet valve to control pressure.
to drain out of the main dump ports. This action is
Injection control pressure is governed by the ECM,
accomplished by relieving the pressure behind the
depending upon ICP sensor input and the driver’s
poppet valve, which allows it to partially open the
demand for power.
relief port, decreasing ICP pressure.
The IPR valve is a pulse width (duty cycle %)
The described operation allows the IPR to
modulated valve operating at 200 Hz. The pulse
continuously adjust injection control pressure
width is modulated between 6 to 65% to control ICP
commanded by the ECM.
pressure in the range of 3 to 20 MPa (500 to 3,000
psi). The IPR valve is mounted in the hydraulic pump
EGES235-2
ENGINE SYSTEMS 27
Fuel Supply System

Overview
Figure 18 Fuel supply system

1. Fuel tube mounting bracket 7. 12 mm banjo bolt with check 13. Fuel rail plug assembly, (2)
2. Fuel supply tube from tank valve (2) 14. Cylinder head, left
3. Fuel supply and return tube 8. Fuel supply line, left cylinder 15. Fuel filter regulator valve
assembly head assembly
4. Filter strainer assembly 9. Fuel supply line, right cylinder
5. Fuel and power steering pump head
assembly (gear driven) 10. Fuel filter housing assembly
6. Fuel filter water drain tube 11. Fuel injector assembly (8)
assembly 12. Cylinder head, right
EGES235-2
28 ENGINE SYSTEMS
The function of the fuel supply system is to deliver fuel

from the fuel tank(s) through a filter to the fuel injectors
at a regulated pressure.
The Fuel System Consists of the Following
Components:
• Fuel tank(s)
• Fuel supply lines
• Banjo bolts with check valves
• Fuel filter and housing
• Fuel transfer pump (supply)
• Fuel passages within the cylinder head which
supply the fuel injectors
• Fuel pressure regulator and fuel return lines
Figure 19 Fuel system schematic
EGES235-2
ENGINE SYSTEMS 29
Fuel Pump This helps prevent fuel from waxing during cold
weather operation. An optional Water In Fuel (WIF)
The power steering and fuel pump assembly draws
sensor, in the base of the housing, detects water in
fuel from the tank(s) through an 80 micron fuel
the fuel. When water accumulates in the bottom of
prescreen element and transfers pressurized fuel
the fuel filter housing, the WIF sensor sends a signal
to the fuel filter housing. The fuel pump raises fuel
to illuminate an amber colored WATER IN FUEL lamp
pressure to insure proper filling of the fuel injectors.
in the instrument panel.
Fuel Filter Housing

Pressure Regulator
Fuel in the filter housing passes through a 10 micron
The pressure regulator contains a spring loaded valve
fuel filter cartridge to a standpipe in the center of the
to control pressure in the fuel galleries. Return fuel
filter assembly, and then clean fuel passes through
flows through the regulator and is routed to the fuel
fuel supply lines to a machined gallery in each cylinder
tank(s).
head.
The base of the fuel filter housing contains an electric
heating element (optional) used to warm the fuel.
EGES235-2
30 ENGINE SYSTEMS
Lubrication System (Low Pressure)
Figure 20 Engine oil flow (low pressure)

1. Oil cooler cover with oil filter 7. High-pressure oil pump 13. Oil pick up tube
base assembly 14. Front cover assembly
2. VGT oil supply line 8. Camshaft gear 15. Gerotor assembly
3. VGT 9. Piston cooling tube (8) 16. Gerotor housing cover
4. Push rod (16) 10. Main bearing insert (10) 17. Camshaft bushing
5. Valve lifter (16) 11. Cylinder head (2) 18. Oil pressure regulator
6. Main lube oil gallery (2) 12. Lower oil pan 19. Upper oil pan
EGES235-2
ENGINE SYSTEMS 31
Figure 21 Engine oil flow (oil cooler cover and oil filter base)
1. VGT oil supply tube assembly 3. Oil filter base assembly
2. Oil filter housing 4. Oil cooler cover
The lubrication system is pressure regulated, cooled, Table 2 Standard Engine Oil Pan Capacities
and full flow filtered. In addition to providing engine
With oil filter change 18 L (19 qts.)
lubrication, it supplies oil to the high pressure oil
system to control fuel delivery in the fuel injectors Without oil filter change 17 L (18 qts.)
(Injection Control Pressure (ICP) System, page 24). Overhaul only 21.8 L (23 qts.)
The following sequence describes lube oil flow
through the major oil system components: 2. Oil pick-up tube and screen
1. Oil pan (sump) approximate capacities.
EGES235-2
32 ENGINE SYSTEMS
3. The low pressure oil pump is a gerotor type 7. Main galleries

contained in the front cover. The gerotor
Cooled and filtered oil supplied from the oil cooler
assembly consists of an outer and an inner
base fills the main galleries to distribute oil to the
gear. The inner gear is driven by the crankshaft.
following components via passages machined
The pump inlet and outlet passages are through
within the crankcase:
ports in the front cover.
A. Hydraulic cam followers
Oil Pressure Regulator (bypass) controls lube oil
pressure via a spring loaded plunger relieving B. Camshaft main journals
oil back to the inlet of the pump once operating
C. Crankshaft main journals
pressure has exceeded 517 kPa (75 psi).
D. Connecting rod bearings receive
4. Oil cooler cover receives oil from the oil pump
pressurized oil from the main bearings via
and cools it in the oil cooler, which is located
drilled passages within the crankshaft.
underneath the oil cooler housing.
E. Rocker arms receive their lube oil from
Cooler bypass valve opens in the event that the
the hydraulic cam followers via the push
oil cooler base and/or cooler become restricted.
rods. Oil drains back to the sump through
5. Oil filter housing contains a paper type element. holes located in the cylinder head.
Unfiltered oil flows up and around the outside
F. Piston cooling tubes
of the filter and then down through the center
standpipe. 8. High pressure hydraulic pump oil reservoir
Oil filter bypass allows oil to pass directly to the This reservoir (below oil cooler) has a constant
main oil gallery should the filter become restricted. supply of oil for the high pressure hydraulic oil
pump. It has an approximate capacity of 0.9 L
6. Turbocharger and drive gears
(0.95 qt.).
Cooled and filtered oil supplied from the oil cooler
9. To air compressor (optional)
base lubricates the turbocharger bearings and
provides hydraulic pressure for the VGT control A port is provided for vehicles equipped with air
valve. Oil drains from the turbocharger through compressors.
a drain tube back to the high pressure hydraulic
pump cover.
EGES235-2
ENGINE SYSTEMS 33
Cooling System
Description
Figure 22 Engine coolant flow diagram and system components

1. Intake manifold 5. Oil cooler 9. Water pump assembly
2. EGR cooler 6. Crankcase 10. Thermostat assembly
3. Coolant outlet cap 7. Cylinder head 11. Coolant deaeration fitting
4. Oil cooler cover 8. Front cover housing
EGES235-2
34 ENGINE SYSTEMS
The function of the cooling system is to keep the is pushed by the water pump, through the front cover
engine within a designated temperature range. Major and into the crankcase. Crankcase coolant flows from
components include a thermostat, EGR cooler, oil the front to the rear, and is evenly distributed around
cooler, radiator and fan combination with a coolant the cylinders and through the cylinder heads. Cylinder
(water) pump. The water pump is a belt-driven head coolant flows up from the rear to the front of
centrifugal type, which is contained in the front cover. the heads. Coolant returns to the front cover through
passages in the crankcase.
The front cover incorporates several separate
passages. Two passages channel coolant to Thermostat Operation
the crankcase and heads from the water pump,
When the engine coolant temperature is below the
two passages channel returning coolant from the
specified start-to-open temperature (see Appendix
crankcase and heads, and a bypass to route coolant
A), the coolant flows through the bypass passage
back into the water pump when the thermostat is
to the water pump because the radiator outlet
closed. See Appendix A for thermostat start-to-open
port is blocked. As the engine reaches operating
temperature and fully open temperature.
temperature, the thermostat opens, directing coolant
Coolant flows from the radiator into the inlet tube of through the radiator, and restricts the bypass opening.
the front cover and into the water pump. The coolant
EGES235-2
ENGINE SYSTEMS 35
Electronic Control System

Electronic Control System Components
Figure 23
Operation and function The ECM supplies two independent circuits for VREF:
The Electronic Control Module (ECM) monitors and • VREF A supplies 5 volts to engine sensors
controls engine performance to ensure maximum
• VREF B supplies 5 volts to vehicle sensors
performance and adherence to emissions standards.
The ECM has four primary functions:
2. Signal conditioner
• Provides Reference Voltage (VREF)
The signal conditioner in the internal microprocessor
• Conditions input signals converts analog signals to digital signals, squares up
sine wave signals, or amplifies low intensity signals to
• Processes and stores control strategies
a level that the ECM microprocessor can process.
• Controls actuators
3. Microprocessor
1. Reference voltage (VREF)
The ECM microprocessor stores operating
The ECM supplies a 5 volt VREF signal to input sensors instructions (control strategies) and value tables
in the electronic control system. By comparing (calibration parameters). The ECM compares stored
the 5 volt VREF signal sent to the sensors with their instructions and values with conditioned input values
respective returned signals, the ECM determines to determine the correct operating strategy for all
pressures, positions, and other variables important to engine operations.
engine and vehicle functions.
EGES235-2
36 ENGINE SYSTEMS
Continuous calculations in the ECM occur at 4. Actuator control

two different levels or speeds: Foreground and
The ECM controls the actuators by applying a low
Background.
level signal (low side driver) or a high level signal
• Foreground calculations are much faster than (high side driver). When switched on, these drivers
background calculations and are normally more complete a ground or power circuit to an actuator.
critical for engine operation. Engine speed control
Actuators are controlled in three ways (determined by
is an example.
the kind of actuator):
• Background calculations are normally variables
• A duty cycle (percent time on/off)
that change at a slower rates. Engine
temperature is an example. • A controlled pulse width
Diagnostic Trouble Codes (DTCs) are generated by • Switched on or off
the microprocessor, if inputs or conditions do not
comply with expected values. ECM Control of Engine Operation
Diagnostic strategies are also programmed into the The ECM controls engine operation with the following:
ECM. Some strategies monitor inputs continuously
• VGT control valve
and command the necessary outputs to achieve the
correct performance of the engine. • EGR valve
• IPR valve
Microprocessor memory
• Glow plug relay
The ECM microprocessor includes Read Only
Memory (ROM) and Random Access Memory (RAM).
VGT control valve
ROM The VGT control valve is an actuator mounted on
the top right side of the VGT. The VGT control valve,
ROM stores permanent information for calibration
a variable position valve, controls vane position in
tables and operating strategies. Permanently stored
the turbine housing. Vane position is controlled by
information cannot be changed or lost by turning
a switching voltage source in the ECM. The ground
the ignition switch to OFF or when ECM power is
circuit is supplied directly from battery ground at all
interrupted. ROM includes the following:
times.
• Vehicle configuration, modes of operation, and
Actuator control is achieved by setting a pulse width
options
modulated signal in response to engine speed,
• Engine Family Rating Code (EFRC) desired fuel quantity, boost or exhaust back pressure
and altitude.
• Engine warning and protection modes
Exhaust Gas Recirculation (EGR) valve
RAM
The EGR valve controls the flow of exhaust gases
RAM stores temporary information for current
into the intake manifold. The EGR valve actuator
conditions. Temporary information in RAM is lost
controls the valve position and a position sensor to
when the ignition switch is turned OFF or when ECM
provide a feedback signal to the ECM. Valve position
power is interrupted. RAM information includes the
is controlled by switching the ground circuit in the
following:
ECM. The voltage source is supplied by the ECM
• Engine temperature power relay. Actuator control is achieved by setting a
pulse width modulated signal in response to engine
• Engine rpm
speed, desired fuel quantity, boost or exhaust back
• Accelerator pedal position pressure and altitude.
EGES235-2
ENGINE SYSTEMS 37
Injection Pressure Regulator (IPR) Electronic distributor for injectors

The IPR valve controls pressure in the Injection The IDM distributes current to the injectors. The IDM
Control Pressure (ICP) system. The IPR valve is a controls fueling to the engine by sending high voltage
variable position valve controlled by the ECM. This pulses to the OPEN and CLOSE coils of the injector.
regulated pressure actuates the fuel injectors. The The IDM uses information from the ECM to determine
valve position is controlled by switching the ground the timing and quantity of fuel for each injector.
circuit in the ECM. The voltage source is supplied by
The ECM uses CMP and CKP input signals to
the ignition switch.
calculate engine speed and position. The ECM
conditions both input signals and supplies the IDM
Glow plug relay
with CMP and CKP output signals. The IDM uses
The ECM activates the glow plug relay. The relay CMP and CKP output signals to determine the correct
delivers VBAT to the glow plugs for up to 120 seconds, sequence for injector firing.
depending on ambient temperature and altitude. The
The ECM sends information (fuel volume, EOT, and
ground circuit is supplied directly from the battery
ICP) through the CAN 2 link to the IDM; the IDM uses
ground at all times. The relay is controlled by
this information to calculate the injection cycle.
switching on a voltage source from the ECM.
Injector Power Source
Injection Drive Module (IDM) The IDM creates a constant 48 volt (DC) supply to
all injectors by making and breaking a 12 volt source
across a coil in the IDM. The 48 volts created by the
collapsed field is stored in capacitors until used by the
injectors.
The IDM controls when the injector is turned on and
how long the injector is active. The IDM first energizes
the OPEN coil, then the CLOSE coil. The low side
driver supplies a return circuit to the IDM for each
injector coil (open and close). The high side driver
controls the power supply to the injector. During each
injection event, the low and high side drivers are
switched on and off for each coil.
IDM and injector diagnostics

The IDM determines if an injector is drawing enough
current. The IDM sends a fault to the ECM, indicating
potential problems in the wiring harness or injector,
and the ECM will set a DTC. The IDM also does self
Figure 24 Injection Drive Module (IDM) diagnostic checks and sets a DTC to indicate failure
of the IDM.
On demand tests can be done using the Electronic
The IDM has three functions:
Service Tool (EST). The EST sends a request to the
• Electronic distributor for injectors ECM, the ECM sends a request to the IDM to do a
test. Some tests generate a DTC when a problem
• Power source for injectors
exists. Other tests require the technician to evaluate
• IDM and injector diagnostics parameters, if a problem exists.
EGES235-2
38 ENGINE SYSTEMS
Engine and Vehicle Sensors
Figure 25 Engine and Vehicle Sensors

1. Electronic Control Module 8. Engine Oil Pressure (EOP) 14. Driveline Disengagement Switch
(ECM) 9. Manifold Absolute Pressure (DDS)
2. Engine Oil Temperature (EOT) (MAP) 15. Engine Coolant Level (ECL)
3. Engine Coolant Temperature 10. Camshaft Position (CMP) 16. EGR drive module
(ECT) 11. Crankshaft Position (CKP) 17. Accelerator Position Sensor
4. Manifold Air Temperature (MAT) 12. Vehicle Speed Sensor (VSS) (APS)
5. Intake Air Temperature (IAT) 13. Barometric Absolute Pressure 18. Exhaust Gas Recirculation valve
6. Injection Control Pressure (ICP) (BAP) Position (EGRP)
7. Exhaust Back Pressure (EBP)
EGES235-2
ENGINE SYSTEMS 39
The ECT signal is monitored by the ECM for operation

of the instrument panel temperature gauge, coolant
temperature compensation, optional Engine Warning
Protection System (EWPS), glow plugs, and the wait
to start lamp. The ECM will use ECT sensor input as
a backup, if EOT sensor values are out of range.
The ECT sensor is installed in the left side of the front
cover.
Engine Oil Temperature (EOT)

The EOT sensor detects engine oil temperature.
The EOT signal is monitored by the ECM to control
Figure 26 Thermistor
EGR, VGT, and for engine fueling calculations
throughout the operating range of the engine. The
EOT signal allows the ECM and IDM to compensate
Thermistors
for differences in oil viscosity, due to temperature
• ECT changes.
• EOT The EOT sensor is installed in the oil filter base.
• IAT
Intake Air Temperature (IAT)
• MAT
The IAT sensor measures induction air temperature.
A thermistor sensor changes electrical resistance as
The IAT sensor provides feedback to the ECM for fuel
temperature changes. Resistance in the thermistor
injection quantity and duration calculations.
decreases as temperature increases, and increases
as temperature decreases. Thermistors work with a The IAT sensor is installed in the air filter assembly.
resistor that limits current in the ECM to form a voltage
signal matched with a temperature value. Manifold Air Temperature (MAT)
The top half of the voltage divider is the current limiting The MAT sensor detects intake manifold air
resistor that is internal to the ECM. A thermistor sensor temperature.
has two electrical contacts: signal return and ground.
The MAT signal is monitored by the ECM for EGR
The output of a thermistor sensor is a non-linear
operation.
analog signal.
The MAT sensor is installed in the right front of the
Engine Coolant Temperature (ECT) intake manifold.
The ECT sensor detects engine coolant temperature.
EGES235-2
40 ENGINE SYSTEMS
The BAP signal is monitored by the ECM for control

of fuel quantity, fuel timing, glow plug operation, and
adjustment of the VGT to compensate for density
changes.
The BAP sensor is installed behind the instrument
panel.
Engine Oil Pressure (EOP)

The EOP sensor detects engine oil pressure.
The EOP signal is monitored by the ECM for operation
Figure 27 Variable capacitance sensor of the instrument panel pressure gauge and optional
EWPS.
Variable capacitance sensors The EOP sensor is installed in the oil filter base.
• BAP Exhaust Back Pressure (EBP)

• EBP The EBP sensor measures exhaust back pressure
• EOP before the turbocharger.
• ICP The EBP sensor provides feedback to the ECM for

closed loop control of the VGT and for EGR position
• MAP calculations.
Variable capacitance sensors measure pressure. The The EBP sensor is installed on a bracket on the left
pressure measured is applied to a ceramic material. side of the engine below the ECM.
The pressure forces the ceramic material closer to a
thin metal disk. This action changes the capacitance Injection Control Pressure (ICP)
of the sensor.
The ICP sensor, a micro-strain gauge sensor,
The sensor is connected to the ECM by three wires: measures injection control pressure.
• VREF The ICP signal is monitored by the ECM for closed
• Signal return loop control of the IPR valve. The ICP signal is also
used by the IDM for engine fueling calculations.
• Signal ground
The ICP sensor is installed in the high-pressure oil
The sensor receives the VREF and returns an analog pump.
signal voltage to the ECM. The ECM compares the
voltage with pre-programmed values to determine Manifold Absolute Pressure (MAP)
pressure.
The MAP sensor detects intake manifold boost
The operational range of a variable capacitance pressure.
sensor is linked to the thickness of the ceramic disk.
The thicker the ceramic disk the more pressure the The MAP signal is monitored by the ECM for EGR
sensor can measure. position and engine fueling calculations.
The MAP sensor is installed in the top front of the
Barometric Absolute Pressure (BAP) intake manifold.
The BAP sensor detects altitude.
EGES235-2
ENGINE SYSTEMS 41
crankshaft turns the CKP sensor detects a 60 tooth

timing disk on the crankshaft. Teeth 59 and 60 are
missing. By comparing the CKP signal with the CMP
signal, the ECM calculates engine rpm and timing
requirements.
The CKP is installed in the front right side of the lower
crankcase.
NOTE: This short sensor measures crankshaft speed
and position for INTERNATIONAL® VT 365 and VT
275 diesel engines; However, for INTERNATIONAL®
DT 466, DT 570, and HT 570 diesel engines, this
sensor measures camshaft speed and position, not
crankshaft speed and position.
Camshaft Position (CMP)

The CMP sensor indicates camshaft speed and
position.
The CMP sensor sends a pulsed signal to the ECM
when a single peg on the camshaft rotates past
the CMP sensor once during each revolution of the
Figure 28 Magnetic pickups
camshaft. The ECM calculates camshaft speed and
position from CMP signal frequency.
Magnetic pickup sensors The CMP sensor is installed in the front left side of the
crankcase.
• CKP
NOTE: This long sensor measures camshaft speed
• CMP
and position for INTERNATIONAL® VT 365 and VT
• VSS 275 diesel engines; However, for INTERNATIONAL®
DT 466, DT 570, and HT 570 diesel engines, this
A magnetic pickup sensor generates an alternating
sensor measures crankshaft speed and position, not
frequency that indicates rotational speed. Magnetic
camshaft speed and position.
pickup sensors have a two wire connection for signal
and ground. The sensor has a permanent magnet
Vehicle Speed Sensor (VSS)
core surrounded by a wire coil. The signal frequency
is generated by the rotation of gear teeth that disturb The VSS sensor indicates vehicle speed.
the magnetic field.
The VSS sensor sends a variable frequency pulsed
signal to the ECM as a 16 tooth gear on the
Crankshaft Position (CKP) sensor
transmission tail shaft rotates. The ECM uses
The CKP sensor reads a timing disk on the crankshaft. tire size, axle ratio, and the VSS signal to calculate
vehicle speed.
The CKP sensor provides the ECM with a signal
that indicates crankshaft speed and position. As the The VSS is installed in the left side of the transmission.
EGES235-2
42 ENGINE SYSTEMS
Figure 30 Switch
Figure 29 Potentiometer
Switches
Potentiometers • DDS
• APS • ECL
• EGRP • IVS
A potentiometer is a variable voltage divider that Switch sensors indicate position. They operate open
senses the position of a mechanical component. or closed, allowing or preventing the flow of current.
A reference voltage is applied to one end of the A switch sensor can be a voltage input switch or a
potentiometer. Mechanical rotary or linear motion grounding switch. A voltage input switch supplies the
moves the wiper along the resistance material, ECM with a voltage when it is closed. A grounding
changing voltage at each point along the resistive switch grounds the circuit closed, causing a zero
material. Voltage is proportional to the amount of voltage signal. Grounding switches are usually
mechanical movement. installed in series with a current limiting resistor.
Accelerator Position Sensor (APS) Driveline Disengagement Switch (DDS)
The APS provides the ECM with a feedback signal The DDS determines if a vehicle is in gear. For
(linear analog voltage) that indicates the operator’s manual transmissions, the clutch switch serves as the
demand for power. The APS is mounted in the DDS. For automatic transmissions, the neutral switch
accelerator pedal. In the same application, a remote functions as the DDS.
accelerator or throttle device can be used in addition
to the accelerator pedal. Engine Coolant Level (ECL)
The ECL switch is used in plastic deaeration tanks.
Exhaust Gas Recirculation valve Position (EGRP) When the magnetic switch is open, the tank is full.
sensor
The ECL lamp on the instrument panel signals the
The ECM monitors the EGRP sensor signal to operator if engine coolant is low. ECL is part of the
determine the EGR valve position. EGRP sensor Engine Warning Protection System (EWPS)
provides feedback to the ECM for closed loop control
of EGR. The EGRP sensor is part of the EGR valve, Idle Validation Switch (IVS)
mounted on the top front of the intake manifold.
The IVS is a redundant switch that provides the ECM
with a signal that verifies when the APS is in the idle
position.
EGES235-2
ENGINE SYSTEMS 43
Glow Plug Controller System altitude). Battery voltage is monitored to extend glow
plug life. If the battery voltage is high, power to the
The glow plug system warms engine cylinders to
glow plugs is modulated by turning the glow plug relay
improve cold engine starting. It also aids in reducing
ON/OFF at programmed intervals.
smoke and exhaust emissions during engine warm
up. The engine is ready to start when the WAIT light
goes out. Glow plugs can remain ’ON’ for up to
The ECM is programmed to energize the glow plugs
120 seconds while the engine is running to reduce
(through the glow plug relay) while monitoring Engine
exhaust emissions and white smoke during engine
Coolant Temperature (ECT) and Barometric Absolute
warm up.
Pressure (BAP).
The glow plugs are activated longer when the engine
is colder and if the barometric pressure is low (high
EGES235-2
44 ENGINE SYSTEMS
EGES235-2
MOUNTING ENGINE ON STAND 45
Table of Contents
Mounting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
EGES235-2
46 MOUNTING ENGINE ON STAND
EGES235-2
Mounting Engine
WARNING: To prevent personal injury or

death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or dispose of clothing
and rags contaminated with engine fluids.

death, make sure engine has cooled before
removing components.
NOTE: Engine fluids (oil, fuel, and coolant) are a
threat to the environment. Recycle or dispose of
engine fluids according to local regulations. Never
put engine fluids in the trash, on the ground, in sewers
or bodies of water.
Figure 32 Right side coolant drain plug
NOTE: Before mounting engine on engine stand, do
steps 1 through 5. 1. Exhaust manifold
2. Coolant drain plug
1. Remove fuel and power steering lines from the
pump assembly.
2. Remove two coolant drain plugs and drain
coolant from crankcase into a suitable container.
The coolant drain plugs are in the rear of the
crankcase, below the exhaust manifolds.
3. Remove oil pan drain plug and drain oil into a
suitable container.
4. After fluids are drained from the engine, reinstall
plugs.
5. Torque oil pan drain plugs to the special torque
(Table 3).

death, attach hoist hook lifting bracket to engine
lifting eyes before lifting the engine.
Figure 31 Left side coolant drain plug
6. Attach hoist hook lifting bracket to the engine
1. Exhaust manifold lifting eyes. Use safety catches on the hoist
2. Coolant drain plug hooks when lifting engine.
EGES235-2
Figure 34 Mounting bolts for Engine Stand

Figure 33 Engine Stand Mounting Bracket Mounting Bracket
1. Grade 10.9 mounting bolts (4) to engine block
2. Grade 8 or 10.9 mounting bolts (4) to engine lift stand
death, use only grade 8 or 10.9 bolts to secure
Engine Stand Mounting Bracket to engine and 7. Position Engine Stand Mounting Bracket (Table 4)
engine lift stand. on right side of engine. Secure bracket plate with
four grade 10.9 mounting bolts and washers.
NOTE: See manufacturer’s safety instructions
(included with engine lift stand and Engine Stand 8. Mount engine on engine lift stand using four grade
Mounting Bracket). 8 or 10.9 mounting bolts.
EGES235-2
Special Torque
Table 3 Oil Pan Drain Plug

Oil pan drain plug 25 ± 5 N·m (18 ± 4 lbf·ft)
Special Service Tools
Table 4 Mounting Engine on Stand

Description ToolL Number
Engine Stand Mounting Bracket ZTSE4507
EGES235-2
EGES235-2
ELECTRONICALLY CONTROLLED VARIABLE GEOMETRY 51
TURBOCHARGER (VGT)
Table of Contents
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Turbocharger Assembly and Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
VGT Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Related Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Disassembly Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Free Rotation and Housing Rub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Check Axial End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Control Valve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Turbocharger Assembly and Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
EGES235-2
52 ELECTRONICALLY CONTROLLED VARIABLE GEOMETRY
TURBOCHARGER (VGT)
EGES235-2
TURBOCHARGER (VGT)
Description
Figure 35 Turbocharger components

1. Air inlet 4. Exhaust inlet 7. Turbocharger mounting bracket
2. Exhaust outlet 5. VGT control valve
3. Compressor outlet 6. Oil supply tube
Operation conditions. An additional benefit is lower exhaust

emissions.
The key feature of the VGT is actuated vanes
in the turbine housing. The vanes modify flow The VGT is a closed loop system that uses the
characteristics of exhaust gases through the turbine Exhaust Back Pressure (EBP) sensor to provide
housing. The benefit is the ability to control boost feedback to the Electronic Control Module (ECM).
pressure needed for various engine speeds and load The ECM uses the EBP sensor to continuously
EGES235-2
TURBOCHARGER (VGT)
monitor EBP and adjust the duty cycle to the VGT to barometric pressure in order to adjust the duty cycle
match engine requirements. to match the requirements of the engine.
The solenoid receives a pulse width modulated signal The VGT increases power output by supplying
from the ECM that indicates the on / off time that the compressed air to the engine. The internal
control valve is energized. The control valve directs components are oil and air cooled. Engine oil is
lube oil flow to both sides of the piston in the actuator circulated through the housing, which acts as a
housing. Directing oil to different sides of the piston heat barrier between the “hot” turbine and the “cold”
increases or decreases exhaust back pressure. compressor. Sleeve Bearings are lubricated by
engine oil. Oil is pumped directly from the oil filter
Actuated vanes are mounted around the inside
base, circulates to the VGT housing, and returns
circumference of the turbine housing. A unison ring
to the sump through an oil drain in the VGT center
links all the vanes. When the unison ring moves,
housing.
all vanes move to the same position. Unison ring
movement occurs when either side of the actuator Expanding exhaust gases drive the turbine shaft
piston is pressurized by engine oil. assembly to speeds over 100,000 rpm. Filtered
air entering the compressor side of the VGT is
Exhaust gas flow can be regulated depending on
compressed and delivered through a charge air
required exhaust back pressure for engine speed and
cooler. Hot compressed air is cooled, filling the intake
load.
manifold at a pressure higher than atmospheric
The VGT is an exhaust driven centrifugal air pressure. Because considerably more air is forced
compressor that uses signals from the ECM to control into the intake manifold, the results are increased
intake manifold pressure. The VGT uses a set of power, fuel efficiency and the ability to maintain
moveable vanes in the turbine housing to change the power at higher altitudes.
flow of exhaust gases through the VGT. These vanes
can be positioned to change the angle or direction
of flow to the turbine wheel depending on engine Removal
operating conditions. As power demands increase,
Turbocharger Assembly and Components
exhaust gas velocity increases in direct relation, as
does intake manifold boost pressure. Conversely, as
the flow of exhaust gas diminishes, intake manifold WARNING: To prevent personal injury or
boost pressure is also reduced at the same rate. death, read all safety instructions in the “Safety
Information” section of this manual.
Vanes mounted around the internal circumference
of the turbine housing are connected to a unison
ring. When the unison ring moves, all vanes move WARNING: To prevent personal injury or
to the same position. The unison ring moves, when death, shift transmission to park or neutral, set
either side of the actuator piston receives pressurized parking brake, and block wheels before doing
engine oil, regulated by the control valve, part of diagnostic or service procedures.
a Pulse Width Modulated (PWM) circuit regulated
by the ECM. An increase in duty cycle of the PWM WARNING: To prevent personal injury or
circuit routes oil through the control valve in a way death, make sure engine has cooled before
that will cause piston movement that increases removing components.
manifold pressure. Decreasing the pulse width will
direct oil such that the manifold pressure will be
decreased. The VGT control is a closed loop system
possible death, disconnect the main battery
using the EBP sensor to provide feedback to the
negative terminal before disconnecting or
ECM. The ECM provides a duty cycle in response to
connecting electrical components.
engine speed, engine load, manifold pressure, and
EGES235-2
TURBOCHARGER (VGT)

death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing
and rags contaminated with engine fluids.
or bodies of water.
Figure 37 Turbocharger oil supply tube

1. Turbocharger oil supply tube
2. Mounting bolts
2. Remove the two M8 x 20 bolts from the oil supply

tube on the top of turbocharger assembly. Swing
the oil supply tube out of the way.
3. Remove the oil supply tube gasket and discard.
Figure 36 Rotation of air inlet duct and breather

hose assembly with pitot tube
1. Air inlet duct
2. Breather hose assembly with pitot tube
1. Remove the turbocharger air inlet ducting as

follows:
a. Loosen the air inlet duct clamp.
b. Remove oil fill extension tube and place a cap
in the oil fill hole of the valve cover to prevent
foreign material from entering.
Figure 38 Removal of turbocharger oil supply
c. Remove air inlet duct by turning breather
tube
hose and pitot tube approximately 90° from
the valve cover as shown.
4. Using the #8 Quick Release Tool (Table 7),
carefully insert the tool under the free floating
washer until the oil supply tube releases.
5. Disconnect the VGT control valve harness
electrical connection.
EGES235-2
TURBOCHARGER (VGT)
7. Remove two M8 x 30 flange head bolts and

spacers securing the turbocharger to the rear of
its mounting bracket.
Figure 39 Turbocharger exhaust adapter

V-clamp
6. Remove the turbocharger exhaust adapter

V-clamp.
Figure 41 Turbocharger front mounting bolt and

spacer
8. Remove one M8 x 30 flange head bolt and

spacer securing the turbocharger to the front of
its mounting bracket.
NOTE: If removing the turbocharger only, cap off oil
drain to prevent foreign material from entering engine.
9. Lift the turbocharger assembly up and off the
engine. Cap all openings on turbocharger
assembly.
NOTE: Use Compressor Inlet Cap and Exhaust Outlet
Cap (Table 7). If plastic caps are not available, use
Figure 40 Turbocharger rear mounting bolts and tape to cover openings.
spacers
EGES235-2
TURBOCHARGER (VGT)
Figure 42 Removing turbocharger oil drain tube Figure 44 Removing turbocharger mounting
bracket
1. EGR cooler coolant inlet tube
10. Remove turbocharger oil drain tube by pulling it 2. Turbocharger mounting bracket
out of the hydraulic pump cover.
12. Lift up left side of the bracket first, so the right side
can clear the EGR cooler coolant inlet tube.
Cleaning
VGT Assembly

death, wear safety glasses with side shields to
protect eyes. Limit compressed air pressure to
207 kPa (30 psi).
NOTE: Do not use a caustic solution on the VGT and
related components.
Figure 43 Removing turbocharger bracket bolts Clean the turbocharger assembly and bracket with a
(4) suitable solvent and nylon brush. Dry with filtered
compressed air. See (page 3 ).
11. Remove four M8 x 20 turbocharger bracket bolts.

Related Components
1. Rinse out the inside of the oil supply tube if
removed from the oil filter base.
2. Clean turbocharger mounting bracket, exhaust
piping, and oil drain pipe.
EGES235-2
TURBOCHARGER (VGT)
Inspection
Disassembly Inspection
Make the following checks before disassembly. If
the turbocharger meets these requirements, it can
be considered satisfactory to install onto the engine.
If it does not meet these requirements, it must be
replaced.
Inspection
NOTE: Replace turbocharger if any bent blades are
found. Do not attempt to straighten bent wheel blades.
1. Inspect the compressor impeller and turbine
wheel for blade erosion, bending, breakage or
deposits. Replace turbocharger if problems are Figure 45 Free rotation of VGT shaft
found.
NOTE: Compressor impeller and turbine wheel
deposits can be caused by the following: 2. Shaft must spin freely when turned by hand.
Inspect the turbine and compressor housing for
• High air inlet restriction allows oil to transfer from signs of contact. Housing contact is not permitted.
the VGT center housing, resulting in oil deposits.
• Excessive oil consumption can result in turbine
wheel carbon deposits. Check Axial End Play
• Engine over fueling can result in excessive

operating temperatures which can cause
aluminum components to melt. Such deposits
may be found on the turbine wheel if such a
failure occurs.
• Oil from crankcase breather (mounted on top of
the left valve cover). Oil from the breather is
normal for this engine.
2. Inspect the turbine and compressor housings
for evidence of wheel rubbing. Replace the
turbocharger as required.
3. Inspect oil drain and supply lines for kinking,
clogging, restrictions and other signs of
deterioration. Discard both O-rings. Figure 46 Axial end play
1. Dial Indicator with Magnetic Base
Free Rotation and Housing Rub 2. Compressor housing
1. Place turbocharger on a bench with the shaft in a

horizontal position. 1. With turbocharger in a stable position, push the
impeller shaft towards the turbine housing as
far as it will go. Place tip of Dial Indicator with
Magnetic Base (Table 7) on end of the compressor
side of the shaft and zero the indicator.
EGES235-2
TURBOCHARGER (VGT)
2. Move shaft back towards the dial indicator and Installation

record measurement.
Control Valve
3. If measurement exceeds specifications (Table 5),
turbocharger must be replaced.
Control Valve Removal
Figure 49 Lubricating O-rings
1. For reassembly, always replace and lubricate

O-rings with clean engine oil. Make sure that
O-rings are seated in their correct locations and
are not twisted or distorted.
Figure 47 Retaining bolt for VGT control valve
1. Remove the control valve retaining bolt and

bracket.
Figure 50 VGT control valve
2. Install control valve carefully to prevent twisting or

cutting O-rings.
Figure 48 VGT control valve
NOTE: Do not use the retaining bolt to draw the control
valve into the housing. Push the control valve in by
2. Remove control valve from turbocharger center hand to seat securely before installing bracket and
housing. bolt.
EGES235-2
TURBOCHARGER (VGT)
coolant inlet tube. Then lower left side over bolt

holes.
Figure 51 Control valve retaining bolt

Figure 53 Turbocharger bracket bolts
3. Install control valve bracket and retaining bolt and

tighten bolt to standard torque (General Torque 2. Install four M8 x 20 mounting bolts to secure
Guidelines, page333). turbocharger bracket to crankcase. Tighten
bolts to the standard torque (General Torque
Guidelines, page333).
Turbocharger Assembly and Components
Figure 54 Turbocharger oil drain tube O-rings

Figure 52 Installing turbocharger bracket
1. EGR cooler coolant inlet tube 3. Install two new oil drain tube O-rings and lubricate
2. Turbocharger bracket with clean engine oil. Install drain pipe into the
hydraulic pump cover.
1. Place turbocharger bracket into engine valley by

placing right side of bracket under EGR cooler
EGES235-2
TURBOCHARGER (VGT)
Figure 55 Turbocharger alignment dowels and Figure 57 Turbocharger oil supply tube
bosses
1. Turbocharger oil supply tube
1. Alignment dowel
2. Alignment boss
8. Install turbocharger oil supply tube into oil supply
port by pushing in connector until latching
4. Use alignment dowels to locate turbocharger onto mechanism is engaged. Pull up on tube to
mounting bracket bosses. Lower turbocharger ensure latching mechanism is engaged. Tube
assembly onto mounting bracket and onto oil must not pull out of oil supply port.
drain tube.
5. Use three M8 x 30 flange head bolts to secure the
turbocharger to its mounting bracket. Coat all bolt
threads with antiseize compound and tighten bolts
to the special torque (Table 6).
Figure 58 Oil inlet hole
CAUTION: To prevent engine damage, prelubricate

Figure 56 Exhaust adapter V-clamp VGT bearings when installing the VGT.
9. Prelubricate the oil inlet hole of the turbocharger
assembly with clean engine oil and spin
6. Tighten turbocharger exhaust adapter V-clamp to
compressor wheel several times to coat bearings
the special torque (Table 6)
with oil. Refill the oil inlet hole up to oil supply
7. Connect the VGT control valve electrical harness. tube mounting surface.
EGES235-2
TURBOCHARGER (VGT)
Figure 59 Oil supply tube Figure 60 Securing air inlet duct to turbocharger
1. Turbocharger oil supply tube 1. Air inlet duct

2. Mounting bolts 2. Hose clamp
3. Breather hose with pitot tube
10. Position oil supply tube over a new gasket and

secure with two M8 x 20 bolts. Tighten to the 11. Press breather hose assembly into valve cover
standard torque (General Torque Guidelines, until it locks into place.
page333). Alternate tightening between both bolts 12. Align arrow on duct with feature on turbocharger
until the proper torque is reached. compressor housing.
13. Secure air inlet duct to turbocharger by tightening
hose clamp to the special torque.(Table 6).
EGES235-2
TURBOCHARGER (VGT)
Specifications
Table 5 Variable Geometry Turbocharger (VGT) Shaft

Maximum turbine shaft axial end play 0.091 mm (0.0036 in)
Maximum turbine shaft radial shaft movement (play) 0.5 mm (0.02 in)
Special Torque
Table 6 Variable Geometry Turbocharger (VGT)

Air inlet duct hose clamp 4 - 5 N·m (36 - 48 lbf·in)
Turbocharger to mounting bracket bolts 31 N·m (23 ± 3 lbf·ft)
Turbocharger exhaust adapter V-clamp 12 N·m (108 lbf·in)
Table 7
Tool Number Description
ZTSE4548 Intake Guard
ZTSE4581 Quick Release Tool
Obtain locally Dial Indicator with Magnetic Base
ZTSE4610 Cap Kit (All)
EGES235-2
TURBOCHARGER (VGT)
EGES235-2
MANIFOLDS AND EXHAUST GAS RECIRCULATION (EGR) 65
Table of Contents
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Exhaust Manifolds and Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Exhaust Gas Recirculation Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Intake Manifold and EGR Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Exhaust Gas Recirculation Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Intake and Exhaust Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Intake Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Intake Manifold/EGR Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Exhaust Manifolds and Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
EGES235-2
66 MANIFOLDS AND EXHAUST GAS RECIRCULATION (EGR)
EGES235-2
Description
A new one piece intake manifold includes an EGR
valve and EGR cooler.
Figure 61 Intake manifold and gaskets

1. Intake manifold 2. Intake manifold gasket (2)
EGES235-2
Figure 62 Exhaust gas recirculation components

1. Exhaust gas recirculation valve 3. Exhaust tube assembly (right 4. Shielded tube exhaust assembly
2. Exhaust gas recirculation cooler side) (left side)
5. Intake manifold assembly
NOTE: Flanged head bolts have special prevailing

torque threads. Use these bolts only for installation
of exhaust manifolds.
Figure 63 Exhaust manifolds

1. Exhaust manifold (right)
2. Exhaust manifold (left)
EGES235-2
Removal
WARNING: To prevent personal injury
Exhaust Manifolds and Tubing or death, do not let engine fluids stay on
your skin. Clean skin and nails using hand
WARNING: To prevent personal injury or cleaner and wash with soap and water. Wash
death, read all safety instructions in the “Safety or dispose of clothing and rags contaminated
Information” section of this manual. with engine fluids.

death, shift transmission to park or neutral, set
parking brake, and block wheels before doing
diagnostic or service procedures.

death, make sure the engine has cooled before
removing components.
or bodies of water.
Left Exhaust Manifold and Tubing Figure 65 Exhaust tube bolts (upper right)
2. Remove two M8 x 30 bolts securing the shielded

tube exhaust assembly (upper right side). Discard
exhaust tube gasket.
Figure 64 Mounting bolts for shielded tube

exhaust assembly to exhaust manifold
1. Remove two M8 x 1.25 x 60 bolts securing Figure 66 EBP sensor tube fitting
the shielded tube exhaust assembly at the left
exhaust manifold.
3. Remove the EBP sensor tube fitting and pull tube
away from exhaust manifold.
4. Before removal (engine cold), inspect exhaust
manifolds for warpage by inserting a feeler
EGES235-2
gauge between the manifold and cylinder head 6. Remove two M8 x 1.25 x 60 bolts connecting the
exhaust ports. Record values and compare right exhaust tube assembly to the right exhaust
with exhaust manifold specifications (Table 8). manifold.
Replace manifold as required.
7. Before removal (engine cold), inspect exhaust
manifolds for warpage by inserting a feeler
gauge between the manifold and cylinder head
exhaust ports. Record values and compare
with exhaust manifold specifications (Table 8).
Replace manifold as required.
Figure 67 Removal of left exhaust manifold

1. Exhaust manifold
2. Exhaust manifold mounting bolt and spacer (8)
Figure 69 Mounting bolt and spacer for right
exhaust manifold
5. Remove all eight M8 x 1.25 x 40 exhaust manifold
bolts and remove manifold. 1. Exhaust manifold mounting bolt and spacer (8)
Right Exhaust Manifold and Tubing

8. Remove eight M8 x 40 exhaust manifold bolts.
Exhaust Gas Recirculation Valve
Figure 68 Mounting bolts for right exhaust tube

assembly
Figure 70 EGR valve retaining bolts
EGES235-2
1. Remove two M6 x 16 EGR valve retaining bolts. CAUTION: To prevent engine damage, after removing
the EGR valve, vacuum loose carbon deposits and
2. Turn the EGR valve counter clockwise.
debris from inside the intake manifold.
Intake Manifold and EGR Cooler
NOTE: Before removing intake manifold, remove the
following components:
• Fuel filter housing and lines
• VGT
See “Fuel System” and “Electronically Controlled

VGT” sections for removal procedures.

protect eyes. Limit air pressure to 207 kPa (30
psi).
CAUTION: To prevent engine damage, blow out or
Figure 71 Removal of EGR valve vacuum dirt and debris under the intake manifold. This
prevents dirt and debris from entering intake ports
when the manifold is removed.
3. Install the EGR Valve Puller (Table 10). The
slotted arms slip around the EGR bolt mounting
tabs, while the other two are positioned over the
EGR bolt holes.
Figure 73 Intake heat shield mounting nuts

(right side)
Figure 72 EGR valve removed 1. Remove two M6 x 1 intake heat shield nuts
located on the right side of the intake manifold.
4. Thread shaft clockwise to remove EGR valve.
EGES235-2
Figure 74 Intake manifold bolts and studs

1. Bolt (M6 x 95 dog point) (13) 2. Bolt (M6 x 95) stud (3) 3. Bolt (M6 x 55 x 20) stud (2)
2. Remove 13 M6 x 95 bolts and three M6 x 95 studs 3. Do not remove two M6 x 55 x 20 studs (Figure 74).
securing the intake manifold. Do not remove two
M6 x 55 x 20 studs (Figure 74).
EGES235-2
5. Slide EGR coolant inlet coupling away from

coolant supply port.
Figure 75 EGR cooler coolant coupling

Figure 77 V-clamp
1. Flat edge
2. Dual index marks
3. Single index mark
6. Remove V-clamp at EGR cooler assembly.
4. Recess
4. To remove EGR coolant inlet coupling, align dual

index marks (if visible) or flat edge of coupling
(Figure 75) with index feature on coolant supply
port cover (Figure 76).
Figure 78 Removal of intake manifold and EGR

cooler assembly
7. To remove, lift intake manifold assembly straight

up.
Figure 76 Removal of EGR coolant inlet NOTE: The EGR cooler should remain attached
coupling from coolant supply port to the intake manifold.
1. Index feature on EGR coolant supply cover 8. Place Intake Port Covers over cylinder head
2. Coolant supply port intake ports (Table 10).
3. EGR coolant inlet coupling
EGES235-2
Exhaust Gas Recirculation Cooler

1. Put intake manifold on workbench
Figure 80 EGR cooler assembly removed

1. EGR cooler to intake manifold gasket
2. EGR cooler O-ring
Figure 79 EGR cooler retaining bolts
3. Remove cooler assembly, gasket, and O-ring

2. Remove two M6 x 55 x 20 stud bolts and one M8 from intake manifold and discard.
x 16 bolt securing the EGR cooler to the intake
manifold.
Cleaning
Intake and Exhaust Manifolds
Intake and exhaust manifolds are one piece castings
and may be cleaned with steam or suitable noncaustic
solvents.
Clean contact areas of EGR O-ring in the intake
manifold, using Injector Sleeve Brush (Table 10).
Make sure carbon above and below contact areas
can be vacuumed from the intake manifold. Vacuum
loose carbon debris.
EGES235-2
Inspection Intake Manifold

Exhaust Gas Recirculation Valve
Figure 82 Intake Manifold Pressure Test Plates
1. Install Intake Manifold Pressure Test Plates (Table

10) onto intake manifold assembly.
2. Install Intake Manifold Pressure Test Plug (EGR
Valve) (Table 10) into EGR orifice.
Figure 81 EGR valve assembly

1. EGR Gasket
2. O-ring (2)
3. Common pintle shaft
4. Pintle shaft frame
Figure 83 Intake manifold pressure test
assembly
1. Check the pintle shaft and frame for misalignment. 1. Air supply pressure regulator
2. Remove both O-rings and EGR gasket and 2. Pressure Test Adapter (intake)
discard. See EGES-240, VT 365 Engine 3. Intake Manifold Pressure Test Plug (EGR Valve)
Diagnostic Manual for electrical inspection. 4. Intake Manifold Pressure Test Plates
3. Install Pressure Test Adapter (Table 10) onto air

intake.
EGES235-2

protect eyes. Limit compressed air pressure to
207 kPa (30 psi).
Figure 85 EGR cooler with pressure test plates

installed
1. EGR Cooler Test Plate (2)
2. EGR cooler assembly
Figure 84 Testing intake manifold for leaks 3. Air pressure regulator
4. Submerge the intake manifold assembly into 1. Install an EGR Cooler Test Plate (Table 10) to
water. Pressurize at 172-207 kPa (25-30 psi) each end of the EGR cooler assembly.
using a regulated filtered air supply. Inspect for
leaks in the intake plenum, EGR and coolant
passages. Replace if necessary. WARNING: To prevent personal injury or
5. Inspect intake manifold gasket seal beads for protect eyes. Limit compressed air pressure to
defects. Replace if necessary. 207 kPa (30 psi).
2. Attach an air pressure regulator to the EGR
cooler. Connect to shop air supply and adjust air
pressure to approximately 413 kPa (60 psi).
3. Completely submerge EGR cooler in sink or large
container of water. Inspect for air bubbles coming
from coolant passages. Replace if necessary.
4. Return EGR cooler assembly to service if no leaks
are detected. If leaks are detected, replace entire
cooler assembly.
EGES235-2
Installation
Figure 88 EGR cooler retaining bolts
Figure 86 EGR cooler O-ring

3. Insert an M8 x 16 bolt through rear mounting tab
of intake manifold.
1. Place a new O-ring on the EGR cooler and
4. Tighten all three bolts to the standard torque
lubricate with clean engine oil before assembly.
(General Torque Guidelines, page333).
Intake Manifold/EGR Cooler
Figure 87 Installing EGR cooler to intake

manifold
1. Stud bolt (M6 x 55 x 20) (2)
2. EGR cooler to manifold gasket
3. EGR cooler
Figure 89 Front module seal
2. Install a new EGR cooler gasket and hand tighten 1. Install a new front module seal between the intake
nuts onto two M6 x 55 x 20 stud bolts. manifold and front cover module.
EGES235-2
3. Remove Intake Port Covers (Table 10) from

cylinder head intake ports.
Figure 90 Intake manifold gasket with centering

tab
2. Place intake manifold gasket onto each side of Figure 91 Installation of intake manifold and
intake manifold and run a few bolts through to EGR cooler assembly
hold gasket in place. Make sure centering tabs
are facing up into the manifold, while positioned
inboard towards the engine valley. 4. Position intake manifold on cylinder heads.
EGES235-2
Figure 92 Torque sequence for intake manifold mounting bolts
5. Install the 16 intake manifold bolts in their correct

locations (Figure 74). Use the following bolt
torque sequence (Figure 92).
A. Loosely assemble bolts numbers 1 - 8.
B. Torque bolts numbers 9 -16 to the special
torque value (Table 9).
C. Torque all M6 x 95 bolts to the special
torque value (Table 9).
Figure 93 Heat shield mounting nuts (right side)
6. Install intake heat shield and two M6 x 1 nuts onto

the right side of the intake manifold and tighten to
the special torque (Table 9).
EGES235-2
7. Connect the EGR coolant inlet coupling by

aligning the dual index marks (if visible) or flat
edge of coupling with index feature on EGR
coolant supply cover.
8. Slide EGR coolant inlet coupling onto coolant
supply port and rotate coupling either way until
single index mark (if visible) or recess (Figure 94)
aligns with index feature on EGR coolant supply
cover (Figure 95). Attempt to slide EGR coolant
inlet coupling off coolant supply port to verify
locked position.
Exhaust Manifolds and Tubing

NOTE: When installing the exhaust manifolds, only
Figure 94 EGR cooler coolant coupling use prevailing torque flange head bolts with an
interference thread.
1. Flat edge
2. Dual index marks Right Exhaust Manifold
3. Single index mark
4. Recess
Figure 96 Right exhaust manifold bolt and

spacer
Figure 95 Connecting EGR coolant inlet 1. Anti-seize compound
coupling to coolant supply port
1. Index feature on EGR coolant supply cover
1. Apply antiseize compound to all bolt threads.
2. Coolant supply port
3. EGR coolant inlet coupling
EGES235-2
Figure 97 Torque sequence for exhaust manifold Figure 99 EGR cooler V-clamp
bolts
1. Right exhaust manifold 4. Attach right exhaust tube assembly to EGR cooler
2. Left exhaust manifold assembly with V-clamp. Do not tighten V-clamp.
Left Exhaust Manifold
2. Install the right exhaust manifold and eight M8 x
1.25 x 40 prevailing torque flange head bolts and
spacers. Start with the second bolt from the rear
on top. The hole diameter is smaller, therefore
allowing alignment of the remaining bolts. Tighten
bolts to the special torque (Table 9) and in the
specified sequence (Figure 97).
Figure 100 Bolt and spacer for left exhaust

manifold
1. Anti-seize compound
5. Apply antiseize compound to all bolt threads.

Figure 98 Mounting bolts for right exhaust tube 6. Install left exhaust manifold using eight M8 x 1.25
x 40 prevailing torque flanged-head bolts and
spacers. Start with the second bolt from the rear
3. Apply antiseize compound to two M8 x 60 bolts on top. The hole diameter is smaller to allow
securing the right exhaust tube assembly to the alignment of the remaining bolts. Tighten bolts to
exhaust manifold flange with two prevailing torque specified torque (Table 9) and sequence (Figure
nuts. Leave bolts hand tight. 97).
EGES235-2
Figure 101 EBP sensor tube fitting

Figure 103 Mounting bolts for shielded tube
exhaust assembly on left exhaust manifold
7. Apply antiseize compound to threads of the EBP
sensor tube fitting. Install EBP sensor tube to
exhaust manifold and tighten fitting to the special 9. Apply antiseize compound to two M8 x 60 bolts
torque (Table 9). securing the shielded tube exhaust assembly to
the exhaust manifold flange. Leave bolts hand
tight.
10. For turbocharger installation procedure,
(Turbocharger Assembly and Components, page
60).
11. After turbocharger installation, torque all related
turbocharger tubing in the following order:
a. Shielded exhaust tube assembly at right
exhaust tube (upper flange)
b. Turbocharger exhaust adapter V-clamp
c. EGR cooler V-clamp
d. Shielded exhaust tube assembly at left
manifold
Figure 102 Exhaust tube bolts (upper right) e. Exhaust tube assembly at right manifold
(Table 9) for special torque specifications.
8. Apply antiseize compound to the threads of two
M8 x 30 bolts and prevailing torque nuts. Install a
new exhaust tube gasket and secure the shielded Exhaust Gas Recirculation Valve
tube exhaust assembly (upper right side) to the 1. Install a new gasket onto the EGR valve.
right exhaust tube assembly. Leave nuts and bolts
hand tight. 2. Lubricate two new O-rings with an approximate
50/50 solution of dish washing soap and water
and place onto EGR valve.
EGES235-2
3. When installing the EGR valve into the intake

manifold, seat EGR valve by hand before
installing bolts.
NOTE: Failing to completely seat the EGR valve
into the intake manifold, before inserting the
mounting bolts, may cause damage to the EGR
valve.
4. Thread two M6 x 16 bolts by hand and tighten,
alternating between both bolts to the standard
torque (General Torque Guidelines, page333).
Figure 104 Seat EGR valve
EGES235-2
Specifications
Table 8
Exhaust Manifold
Maximum allowable clearance (cold) 0.0762 mm (0.003 in)
Intake Manifold
Between ports: 0.13 mm (0.005 in)
Maximum allowable warpage
Total: 0.25 mm (0.010 in)
Special Torque
Table 9
Intake manifold, M6 x 95 flange bolts 11 ± 1 N·m (96 ± 10 lbf·in) (Figure 92)
Intake heat shield, M6 nut 11 ± 3 N·m (96 ± 24 lbf·in)
Exhaust manifold flange bolts* 38 ± 4 N·m (28 ± 3 lbf·ft) (Figure 97)
EBP tube assembly* 30 ± 1 N·m (22 ± 1 lbf·ft)
EBP sensor tube fitting* 14 - 15 N·m (120 - 132 lbf·in)
Shielded exhaust tube to exhaust manifold (left side)* 27 ± 4 N·m (20 ± 3 lbf·ft)
Shielded tube exhaust to right side exhaust tube* 27 ± 4 N·m (20 ± 3 lbf·ft)
Exhaust tube to exhaust manifold (right side)* 27 ± 4 N·m (20 ± 3 lbf·ft)
Turbocharger exhaust adapter V-clamp 12 N·m (108 lbf·in)
EGR cooler V-band clamp 6 N·m (48 lbf·in)
*Apply antiseize compound to bolt threads before assembly.
Table 10
Tool Number Description
ZTSE4527 Intake Manifold Pressure Test Plates
ZTSE4543 EGR Valve Puller
ZTSE4544 Intake Manifold Pressure Test Plug (EGR Valve)
ZTSE4545 EGR Cooler Pressure Test Plates
ZTSE4554 Pressure Test Adaptor (intake)
ZTSE4559 Intake Port Covers (cylinder head)
ZTSE4610 Cap Kit (All)
Obtain locally Straightedge
EGES235-2

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SERVICE MANUAL

2002 and 2003 Model Years

© 2006 International Truck and Engine Corporation

MOUNTING ENGINE ON STAND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

ELECTRONICALLY CONTROLLED VARIABLE GEOMETRY TURBOCHARGER (VGT). . . . . . . . . . . . . . . . . . . . . .51

MANIFOLDS AND EXHAUST GAS RECIRCULATION (EGR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

CYLINDER HEAD AND VALVE TRAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

FRONT COVER, VIBRATION DAMPER, and GEROTOR OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 .

POWER CYLINDERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161 .

CRANKCASE, CRANKSHAFT and BEARINGS, CAMSHAFT and BUSHINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179 .

Component Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192

OIL COOLER and FILTER HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201 .

ENGINE ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213 .

HIGH-PRESSURE OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241 .

FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255

REAR COVER, FLYWHEEL, and POWER STEERING GEAR DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267 .

IN-CHASSIS PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287 .

Appendix A – Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .319

Appendix B – Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .331

Appendix C – Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .347

Foreword Technical Service Literature

Technical Service Literature is revised periodically

Service Diagnosis • Knowledge of the principles of operation for

Safety Information Protective measures

Warning: A warning describes actions necessary to 3. Type C — Electrical equipment

Safety equipment • Wear hearing protection.

• Use safety blocks and stands.

Engine Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Figure 2 50 – State Exhaust Emissions Label

NOTE: The 50 – State Exhaust Emissions Label

The engine serial number is stamped on the

Engine serial number examples

International® VT 365 engine features and specifications

Engine Diesel, 4 cycle

Major features The firing order is 1-2-7-3-4-5-6-8. When viewing the

Engine Component Locations

Figure 5 Engine components – Front

Figure 6 Engine components – Left

Figure 7 Engine components – Rear

Figure 8 Engine components – Right

Figure 9 Engine components – Top

Air Management System (AMS)

Figure 11 Air management system

The Air Management system includes the

Figure 12 Air flow diagram

Air Induction System when it needs servicing. As filtered air approaches

Variable Geometry Turbocharger (VGT)

The key feature of the Variable Geometry Exhaust

The EGR valve uses a position feedback sensor to 1. Actuator coil

Injection Control Pressure (ICP) System

Figure 16 High-pressure oil system

Fuel Supply System

Figure 18 Fuel supply system

The function of the fuel supply system is to deliver fuel

Figure 19 Fuel system schematic

Fuel Filter Housing

Lubrication System (Low Pressure)

Figure 20 Engine oil flow (low pressure)

1. Oil pan (sump) approximate capacities.

3. The low pressure oil pump is a gerotor type 7. Main galleries

Figure 22 Engine coolant flow diagram and system components

Electronic Control System

Continuous calculations in the ECM occur at 4. Actuator control