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Service Manual 04-06 Part 4 (Fuel System).

1. ne 391 Mounting Engine on Stand sssssssessseeeeeeeee esee meme e eme nnn n n n n n nnn 391 Variable Geometry Turbocharger VGT eeeeeee eee eeee eee eee ee eee eee e ee snnm nnn 391 Manifolds and Exhaust Gas Recirculation EGR 00cceeeeeee eens eeeeeee eee ee eee neeeeeeeeeeeees 391 Cylinder Head and Valve Train eere iiie ehe tret tnter rr ERRERERETRM ERU 392 Front Cover Vibration Damper and Gerotor Oil Pump eere nnne 393 Connecting Rods and PiStons ccccee cece eee cece e cece cece eee nme 393 Crankcase Crankshaft and Bearings Camshaft and Bushings 394 Oil Cooler and Oll Filter a tegen wah ate oe sae bitextnsi n en Reese EE E RE ENSE METER eee 394 Engine Electrical ccena hh mere ada RR RR ERARRGAPRR RR RR ER ERR RRRRARRRER rra 394 High pressure Oil Pump ie annaa teri iiir RE E RDUN EANRRRAREXENREMEE EIU aaa aA ETE 395 laE3ucu mm 395 Flywheel Rear Cover and Power Steering and Fuel Pump eee 395 In chasiss Proced res 1 ccieliiie ue Ie aspe rer e rh rh hn Ran war iade eee ierra 395 Special Tools i nniduioceiiibg ee n RE IUERUIALERRR RR RR RA ki a it eni abadiai 397 Essential orc Umm 397 Photos of Essential Tools from T 444E Essential Tool Kit ZTSE4350 404 EGES295 2 Read all safety instructions in the Safety Informatio
2. D31400 Figure 663 Oil Cooler Reservoir High pressure Pump Magnetic Covers ZTSE4557 Figure 664 Magnetic Covers for Cylinder Head Intake Ports ZTSE4559 D31402 Figure 665 Quick Release Tool No 8 and No 10 ZTSE4581 eek x D31403 Figure 666 Fan Wrench pulley bolts ZTSE4587 EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX C SPECIAL SERVICE TOOLS 403 D31404 D31458 Figure 667 Injector Connector Remover Figure 669 Crankcase to head Removal Tool ZTSE4650 ZTSE4694 D31550 Figure 670 On engine Valve Spring Compressor Tool ZTSE4697 D31291 Figure 668 EGR Valve Puller ZTSE4669 EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 404 D31551 Figure 671 Idler Shaft Installation Tool ZTSE4719 D06137 Figure 672 Secondary Flange Installation Tool ZTSE4720 APPENDIX C SPECIAL SERVICE TOOLS Photos of Essential Tools from T 444E Essential Tool Kit ZTSE4350 D31405 Figure 673 ZTSE4301 Injector Tip Cleaning Brush D31406 Figure 674 Injector Sleeve Brush ZTSE43041
3. 02 0 A A ea c a EU ELELEE a eee ree M EE E UE 330 EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 310 REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE 311 Removal M wai To prevent personal injury or death read all safety instructions in the Safety Information section of this manual A warnine To prevent personal injury or death shift transmission to park or neutral set parking brake and block wheels before doing diagnostic or service procedures Preliminary Checks Flexplate Automatic Transmission 1 Inspect flexplate for cracks around webbing and ring gear weldments 2 Inspect all ring gear teeth for starter pinion damage 3 Replace flexplate if necessary Flywheel Manual Transmission 1 Inspect flywheel for cracks around webbing and bolt holes 2 Inspect flywheel for heat checks and extensive scoring 3 Check for ring gear damage associated with the starter pinion 4 Replace flywheel if necessary Flywheel Surface Runout CAUTION To prevent engine damag
4. D31407 Figure 675 Injector Sleeve Flat Bottom Brush ZTSE43042 EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX C SPECIAL SERVICE TOOLS 405 D31408 Figure 676 Fan Hub Wrench 2 inch ZTSE43972 EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 406 APPENDIX C SPECIAL SERVICE TOOLS EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation Printed in the United States of America
5. Lubricity Lubricity is the ability of a substance to reduce friction between solid surfaces in relative motion under loaded conditions Lug engine A condition when the engine is operating at or below maximum torque speed Manometer A double leg liquid column gauge or a single inclined gauge used to measure the difference between two fluid pressures Typically a manometer records in inches of water MasterDiagnostics MD The diagnostics software for engine related components and systems Microprocessor An integrated circuit in a microcomputer that controls information flow Nitrogen Oxides NO Nitrogen oxides form by a reaction between nitrogen and oxygen at high temperatures and pressures in the combustion chamber Normally closed Refers to a switch that remains closed when no control force is acting on it Normally open Refers to a switch that remains open when no control force is acting on it Ohm Q The unit of resistance One ohm is the value of resistance through which a potential of one volt will maintain a current of one ampere SAE J1213 NOV82 On demand test A self test that the technician initiates using the EST and is run from a program in the processor Output Circuit Check OCC An On demand test done during an Engine OFF self test to check the continuity of selected actuators EGES295 2 Read all safety instructions in the Safety Information section of t
6. Rated horsepower Maximum brake horsepower output of an engine as certified by the engine manufacturer The power of an engine when configured as a basic engine SAE J1995 JUN90 Rated net horsepower Engine net horsepower at rated speed as declared by the manufacturer SAE J1349 JUN90 Rated speed The speed as determined by the manufacturer at which the engine is rated SAE J1995 JUN90 Rated torque Maximum torque produced by an engine as certified by the manufacturer Ratiometric Voltage In a Micro Strain Gauge MSG sensor pressure to be measured exerts force TERMINOLOGY on a pressure vessel that stretches and compresses to change resistance of strain gauges bonded to the surface of the pressure vessel Internal sensor electronics convert the changes in resistance to a ratiometric voltage output Read Only Memory ROM Computer memory that stores permanent information for calibration tables and operating strategies Permanently stored information in ROM cannot be changed or lost by turning the engine off or when ECM power is interrupted Reference voltage V A 5 volt reference supplied by the ECM to operate the engine sensors Reserve capacity Time in minutes that a fully charged battery can be discharged to 10 5 volts at 25 amperes Signal ground The common ground wire to the ECM for the sensors Speed Control Command Switches SCCS A set of switches used for cruise contr
7. EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX B TORQUES NOTE All M14 x 193 cylinder head mounting bolts must be torqued first before torquing M8 x 70 bolts M14 x 193 Cylinder Head Mounting Bolts A Lightly lubricate all bolts and torque in the sequence numbered 1 through 10 to 88 N m 65 Ibf ft B Torque bolts 1 3 5 7 and 9 in sequence to 116 N m 85 Ibf ft C Torque all bolts in sequence numbered 1 through 10 clockwise 90 D Torque all bolts in sequence numbered 1 through 10 a second time clockwise 90 E Torque all bolts in sequence numbered 1 through 10 a third time clockwise 90 F M14 x 193 torque sequence complete M8 x 70 Cylinder Head Mounting Bolts A Install all M8 bolts and torque in the sequence numbered 11 through 15 to 24 N m 18 Ibf ft B Torque all M8 bolts in the sequence numbered 11 through 15 to 31 N m 23 Ibf ft C M8 x 70 torque sequence complete Table 59 Cylinder Head and Valve Train Lifting eye front M10 x 30 Lifting eye rear flat socket head M10 x 35 Crankcase breather nuts Cylinder head bolt torque and sequence Fuel injector hold down bolt Rocker arm fulcrum plate M8 x 65 Glow plugs Injection Control Pressure ICP sensor Oil rail assembly mounting bolts M6 x 25 Crankcase to head
8. Special Torque Table 36 Flywheel Flexplate and Power Steering Assembly Flywheel mounting bolts new bolts only Flexplate mounting bolts new bolts only Power steering pump outlet pipe fitting Power steering pump inlet pipe fitting EGES295 2 0 25 mm 0 010 in 1 27 mm 0 050 in 36 4 0 15 mm 1 4 0 01 in 8 0 0 25 mm 0 315 0 01 in 0 51 mm 0 020 in 0 173 to 0 288 mm 0 0068 to 0 0113 in 0 173 to 0 288 mm 0 0068 to 0 0113 in 17 5 MPa 2 538 psi 94 N m 69 Ibf ft Figure 590 94 N m 69 Ibf ft Figure 590 45 5 N m 33 4 lbf ft 90 10 N m 66 7 Ibf ft lt Te Tr hl Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 330 REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE Special Service Tools Table 37 Flywheel Rear Cover and Power Steering and Fuel Pump Description Cap Kit All Dial Indicator with Magnetic Base Liquid Gasket RTV 6 oz tube Rear Wear Sleeve Installer Rear Wear Sleeve Removal Tool Power Steering Idler Shaft Installation Tool Crankshaft Secondary Flange Installation Studs Loctite amp 290 Sealant Loctite amp Hydraulic Sealant EGES295 2 Tool Number ZTSE4610 Obtain locally 1830858C1 ZTSE4515 ZTSE4518 ZTSE4719 ZTSE4720 1847432C1 Obtain locally Read all safety instructions in the Safety Information secti
9. 0 10 mm 0 004 in Valve seat width intake 1 80 to 2 56 mm 0 071 to 0 101 in Valve seat width exhaust 1 48 to 2 24 mm 0 058 to 0 088 in Valve seat angle intake 30 0 Valve seat angle exhaust 37 5 Valve seat runout T I R max 0 035 mm 0 0014 in 0 05 mm 0 002 in per 51 mm 2 in 0 10 mm 0 004 in per total surface area Gasket surface flatness Overall thickness of cylinder head deck to deck Valve head recession relative to deck surface of cylinder head 95 mm 3 74 in 0 32 to 0 68 mm 0 0126 to 0 0268 in Valve Spring Free length 51 96 mm 2 045 in Solid height 36 1 mm 1 42 in Compressed 46 3 mm 340 17 N 1 82 in 76 5 3 8 Ibf Compressed 38 3 mm 850 43 N 1 51 in 191 9 7 Ibf Spring must be compressed to a solid height before checking test loads Push Rods Runout maximum 0 25 mm 0 01 in EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX A SPECIFICATIONS 367 Front Cover Vibration Damper and Gerotor Oil Pump Table 44 Vibration Damper Lubricating Oil Pump and Thermostat Vibration Damper Face runout maximum Rubber bulging maximum Lubricating Oil Pump Type Drive Location Pressure Regulating Valve Pressure low idle minimum 110 C 230 F oil temperature Pressure high idle
10. 2006 International Truck and Engine Corporation 346 Rocker Arm Removal A warnine To prevent personal injury or death read all safety instructions in the Safety Information section of this manual A warnine To prevent personal injury or death shift transmission to park or neutral set parking brake and block wheels before doing diagnostic or service procedures A warnine To prevent personal injury or death make sure the engine has cooled before removing components A 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 discard clothing and rags contaminated with engine fluids 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 A warnine To prevent personal injury or death always disconnect main negative battery cable first Always connect the main negative battery cable last NOTE Before doing the rocker arm removal procedure below remove the following components Turbocharger inlet air ducting See Electronically Controlled Variable Geometry Turbocharger VGT Valve covers See Oylinder Head And Valve Train e High pressure oil rails See Oylinder Head And Valve Train IN CHASSIS PROCEDURES C
11. 352 Figure 627 Fuel injector external O rings 1 O ring lower white Teflon coating smaller diameter Fuel inlet screen 3 O ring upper black Teflon coating larger diameter Clamp alignment slot O ring harness connector dark blue c ovg 9 Use a nonmetallic hand tool to remove upper and lower O rings from fuel injector Discard O rings 10 Install a new Teflon coated white O ring smaller diameter in the lower recess just below the fuel screens Avoid contact with sharp machined surfaces 11 Install a new Teflon coated black O ring larger diameter in the recess just above the fuel inlet screens Avoid contact with sharp machined surfaces IN CHASSIS PROCEDURES AS D0893 Figure 628 Lubrication of fuel injector O rings 12 Lubricate upper and lower O rings with clean engine oil 13 Remove paper towels from injector bores and install injectors injector hold down clamp as outlined in the Engine Service Manual 14 Check for small broken particles using a magnet before removing shop towels or rubber hose from oil drain holes 15 Install the following components e Crankcase to head tube assembly See Cylinder Head And Valve Train High pressure oil rail See Cylinder Head And Valve Train Valve covers See Cylinder Head And Valve Train Turbocharger inlet air ducting See Electronically Controlled Variable Geometry Turbocharger VGT EGES295 2
12. Flexplate Automatic Transmission sssss nennen mem nn nn nn 312 Flywheel Manual Transmission seeen nnne nn n n nnn 313 Rear Main Seal and Wear Sleeve ccccccceee cece teen eee e eee e eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeennns 314 Secondary Flanges cccceciscccctaaceceeseeeeeeeeeiseeeeeevdee a ia a a n RII I EPPAPPI iD GP GG Gudinis 315 Power Steering and Fuel Pump Assembly ssssssnnn mmn 316 Rear Cover and Power Steering Idler Shaft cccceeeeeee eee e eee eeeeeeeeeeee eee nm 317 SLT DIDIT PE 318 All Components ea ex exu bu diea e eite urbe Eu xa deeHe dee cue RE ex Ma epe Dau 318 Installation IIR IIiiiiiiilllll cti in 4 ok x M Mei Psggg E E SLE RRNNNNMS 319 Rear Cover and Power Steering Idler Shaft esee m 319 Secondary Flanges eis sc cise 321 Rear Main Oil Seal and Wear Sleeve cccce eee e cece cere e eee e ene e eee e eee eeeeeeeeeeeeeeeeees 324 Power Steering and Fuel Pump Assembly sssssnnn Innen 326 Flexplat 2 2 0 222 244m rr RPRARRRa veces stten cee RR oa RATE iiiki Aaa Aadan 326 xA IAM IS 327 Specifications Iilllll ii llliiil ku kadg e Ra ECE E be E RT E greg aaa pre ee MR DINI 329 Special Torque e eerte RR we eccentrics Law Ne Ru MEN UE Xx on RE UUAEUNN RIDERE Ee EE A RE E Ru a a a aei ien 329 Special Service ToolsS
13. Fuel filter water separator with heater and WIF probe 10 micron Fuel pressure in filter Pressure test port clean side not to exceed 448 kPa 132 I hr 65 psi 35 gal h Fuel regulator valve 345 34 kPa 50 5 psi cracking pressure Pressure test port dirty side Fuel filter water drain Fuel and power Valve Right 3 Left steering pump cylinder cylinder 57 assembly 9 head Fr head we 620 896 kPa 1 i rater vale Fuel strainer 80 micron 65 mn 02 in Fuel tank D31168 Figure 529 Fuel system schematic EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation FUEL SYSTEM 301 Removal Fuel Prescreen Element A warning To prevent personal injury or death read all safety instructions in the Safety Information section of this manual P warns To prevent personal injury or death shift transmission to park or neutral set parking brake and block wheels before doing diagnostic or service procedures A 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 discard clothing and rags contaminated with engine fluids CAUTION Using
14. Position 3 8 ball and rocker arm underneath fulcrum and rotate rocker arm into place making sure push rod is seated within rocker arm D08161 Figure 625 Retaining clip in correct position 1 Rocker arm retaining clip 2 Fulcrum plate 3 Install new plastic rocker arm retaining clip by positioning top of clip to top of rocker arm opening and rotating clip snapping into position around fulcrum plate 4 Remove valve spring compressor bolt Make sure the rocker arm and 3 8 ball are in place CAUTION To prevent engine damage do not use air tools when installing fuel injectors Do not scratch injector surfaces CAUTION To prevent engine damage replace external O rings and copper gasket each time a fuel injector is removed 5 Remove the old copper gasket with a small hand tool Wipe injector nozzle with a lint free cloth Figure 626 Seating copper gasket 1 Injector nozzle end 2 Gasket copper 3 Deep socket 6 Install a new copper gasket injector onto injector tip NOTE The copper gasket may be installed in either direction 7 To seat gasket push on gasket with a deep Socket 8 Usea nonmetallic hand tool to remove upper and lower O rings from fuel injector Discard O rings EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation
15. Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation IN CHASSIS PROCEDURES 353 Special Torque Table 38 Branch Tube Assembly Bolts for branch tube mounting blocks 13 N m 115 Ibf in Bolts for branch tube adapter 13 N m 115 Ibf in STC fitting 53 4 N m 39 3 Ibf ft Bolts for heat shield M10 x12 13 N m 115 Ibf in Bolt for heat shield and M10 x 16 62 N m 45 Ibf ft V clamp for shielded exhaust tube 12 N m 106 Ibf in Bolts for right exhaust tube shielded exhaust tube connected to right exhaust manifold M8 Bolts for rear engine mounts M12 x 40 107 N m 79 Ibf ft Nut for bolt through rear engine mounts and chassis mounts M16 Bolts for starter motor M12 x 40 47 58 N m 35 43 Ibf ft Turbocharger exhaust clamp for turbocharger down pipe Bolts for alternator and air conditioning compressor bracket M10 Bolts for air compressor bracket M10 x 100 72 N m 53 Ibf ft 27 4 Nm 20 3 Ibf ft 294 325 N m 216 239 Ibf ft 25 10 N m 4 6 Ibf ft 72 Nem 53 Ibf ft Special Service Tools Table 39 Branch Tube Assembly Description TOOL NUMBER No 10 Quick Release Tool ZTSE4581 Table 40 Rocker Arm Description TOOL NUMBER Injector Connector Release Tool ZTSE4650 Fuel Injector Hold Down Wrench ZTSE4524 On engine Valve Spring Compr
16. assembly 1 Bolt M8 X 45 2 Retainer 3 Clamp alignment index EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation IN CHASSIS PROCEDURES 349 bii PREPRESS AUD D31368 Figure 619 Hold down clamp and valve spring compressor base 1 2 3 9 Injector hold down clamp Valve spring compressor base Clamp alignment index Install On engine Valve Spring Compressor Tool Table 40 Insert valve spring compressor base into a new injector hold down clamp Make sure the notch in the valve spring compressor base aligns with the alignment index tab on hold down clamp Figure 620 gut D31367 1 Valve bridge 2 Valve spring compressor base and hold down clamp 3 Hold down bolt 10 Install new hold down clamp and valve spring compressor base between valve bridges NOTE While centering base between the two valve bridges lightly tighten hold down bolt but do not torque Figure 621 Clearance between rocker arm and valve bridge 1 Valve spring compressor plate 2 Valve bridge 3 Small pry bar EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 350 11 Install valve spring compress
17. cautions and notes 2006 International Truck and Engine Corporation IN CHASSIS PROCEDURES CAUTION To prevent engine damage do not drop mounting bolts into crankcase 45 Carefully loosen torx bolt to allow removal 46 Remove extension from pushrod hole 47 Look through back of crankcase and use a magnet to carefully remove torx bolt in one of three ways Magnet inserted through pushrod hole e Magnet inserted through hole for crankcase to head tube e Magnet inserted through back of crankcase 48 Insert extension through exhaust pushrod hole for cylinder 7 and push torx bit into M6 x 40 torx bolt in block of branch tube assembly 49 Repeat steps 45 through 47 Figure 598 Removal of bolts from branch tube adaptor 1 Branch tube adaptor 2 Branch tube assembly 50 Remove two M6 x 30 bolts connecting branch tube adapter to branch tube assembly 339 Figure 599 Removal of branch tube adapter 1 No 10 quick release tool 2 Branch tube adapter 3 Branch tube assembly 51 Remove branch tube adapter using a No 10 Quick Release Tool Table 39 Figure 600 Removal of O ring 52 Remove O ring from recess in branch tube assembly EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 340 IN CHASSIS PROCEDURES Figure 601 High pr
18. horsepower is less than the indicated horsepower by 357 the amount of friction horsepower consumed in the engine Brake Horsepower bhp net Net brake horsepower is measured with all engine components The power of an engine when configured as a fully equipped engine SAE J1349 JUN90 Calibration The data values used by the strategy to solve equations and make decisions Calibration values are stored in ROM and put into the processor during programming to allow the engine to operate within certain parameters Catalyst A substance that produces a chemical reaction without undergoing a chemical change itself Catalytic converter An antipollution device in the exhaust system that contains a catalyst for chemically converting some pollutants in the exhaust gases carbon monoxide unburned hydrocarbons and oxides of nitrogen into harmless compounds Cavitation A dynamic condition in a fluid system that forms gas filled bubbles cavities in the fluid Cetane number 1 diesel fuel The auto ignition quality of 2 A rating applied to diesel fuel similar to octane rating for gasoline 3 A measure of how readily diesel fuel starts to burn autoignites at high compression temperature Diesel fuel with a high cetane number autoignites shortly after injection into the combustion chamber Therefore it has a short ignition delay time Diesel fuel with a low cetane number resists autoignition Therefore
19. 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation Dust seal lip Rear main oil seal Crankshaft side forward Wear sleeve internal bevel REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE 325 2 Position seal Figure 581 and slide onto Rear Wear Sleeve Installer NOTE Before assembly lubricate the outer diameter of rubber seal with a solution of dish washing soap and water approximately 50 50 mix Do not use other lubricants Figure 583 Rear Wear Sleeve Installer 1 Base 2 Rear main oil seal and wear sleeve 3 Rear wear sleeve installer 4 Position rear main oil seal and wear sleeve onto Figure 582 Sealant application to secondary the rear wear sleeve installer crankshaft flange 3 Before installing wear sleeve and rear main seal oil apply a 360 bead of Loctite amp Hydraulic Sealant Table 37 onto the rear edge of the secondary crankshaft flange Figure 584 Rear main oil seal and wear sleeve combination on crankshaft 1 2 3 4 Rear wear sleeve installer Rear main oil seal Drive nut Thrust bearing 5 Place thrust bearing and drive nut on threaded shaft Tighten nut until rear main oil seal bottoms out in rear oil seal carrier EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing
20. Bolts for branch tube mounting blocks 13 N m 115 Ibf in Bolts for branch tube adapter 13 N m 115 Ibf in STC fitting 53 4 Nm 39 3 Ibf ft Bolts for heat shield M10 x12 13 N m 115 Ibf in Bolt for heat shield and M10 x 16 62 N m 45 Ibf ft V clamp for shielded exhaust tube 12 N m 106 Ibf in Bolts for right exhaust tube shielded exhaust tube connected to right exhaust manifold M8 Bolts for rear engine mounts M12 x 40 107 N m 79 Ibf ft Nut for bolt through rear engine mounts and chassis mounts M16 Bolts for starter motor M12 x 40 47 58 N m 35 43 Ibf ft Turbocharger exhaust clamp for turbocharger down pipe Bolts for alternator and air conditioning compressor bracket M10 Bolts for air compressor bracket M10 x 100 72 N m 53 Ibf ft 27 4 Nm 20 3 Ibf ft 294 325 N m 216 239 Ibf ft 25 10 N m 4 6 lbf ft 72 N m 53 Ibf ft EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 388 APPENDIX B TORQUES EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX C SPECIAL SERVICE TOOLS 389 Table of Contents EhrIdrigrelre c
21. Ibf ft 14 mm 2 172 N m 127 Ibf ft 15 mm 2 216 N m 159 Ibf ft 16 mm 2 266 N m 196 Ibf ft 18 mm 2 5 368 N m 272 Ibf ft 20 mm 2 5 520 N m 384 Ibf ft Tolerances are 10 of nominal value Table 55 Standard Torques Class 12 9 Metric Bolts and Studs Thread Thread Pitch Torque Diameter mm thread 6 mm 1 15 N m 132 Ibf in 8 mm 1 25 36 N m 27 lbf ft 10 mm 1 5 72 N m 53 Ibf ft 12 mm 1 75 126 N m 93 Ibf ft 14 mm 2 201 N m 148 Ibf ft 15 mm 2 252 N m 186 lbf ft 16 mm 2 311 N m 230 Ibf ft 18 mm 2 5 430 N m 317 Ibf ft 20 mm 2 5 608 N m 448 Ibf ft 1 Tolerances are 10 of nominal value EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 376 APPENDIX B TORQUES Alloy steel or low INTERNATIONAL ISO MATERIAL THERMAL HEAD MARKING Class R 898 TREATMENT Preferred Optional p7 SY ae Pu Low or medium Non required 15 87 i Carbon steel gu iW co Medium carbon FS y 8 8 8 8 Medium carbon Quench and tempered lt L 8 8 Alloy steel or low 8 8 p Carbon boron steel Medium carbon T 9 8 i Medium carbon Quench and tempered 4 9 81 Alloy steel or low 98 H Carbon boron steel Medium carbon F PT 10 8 10 8 Medium carbon Quench and tempered Ga at YQ Carbon boron steel D31370 F
22. Manifolds and Exhaust Gas Recirculation EGR Intake manifold M6 x 95 flange bolts Intake heat shield M6 nut Exhaust manifold flange bolts EBP tube assembly EBP tube connector Shielded exhaust tube to exhaust manifold left side Shielded tube exhaust to right side exhaust tube Exhaust tube to exhaust manifold right side VGT exhaust adapter V clamp EGR cooler V clamp Apply anti seize compound to bolt threads before assembly EGES295 2 11 1 N m 96 10 Ibf in Figure 633 11 3 N m 96 24 Ibf in 38 4 N m 28 3 Ibf ft Figure 632 30 1 N m 22 1 Ibf ft 14 15 N m 120 132 Ibf in 27 4 N m 20 3 Ibf ft 27 4 N m 20 3 Ibf ft 27 4 N m 20 3 Ibfft 12 N m 108 Ibf in 6 N m 48 Ibf in Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 380 APPENDIX B TORQUES Cylinder Head and Valve Train a e 3 vil ec ZE b z x D08132 Figure 634 Torque sequence for oil rail bolts Torque Sequence for Oil Rail Bolts A Press rail down until seated Thread remaining bolts finger tight B Torque bolts to the special torque in the sequence above M8 X 70 Cylinder Rocker arm 11 through 15 head carrier M14 X 193 1 through 10 D08170 Figure 635 Tightening sequence for cylinder head mounting bolts
23. PROCEDURES 345 Figure 610 Parts for Installation Engine In chassis 4100 truck 1 2 3 4 36 37 38 39 40 Air intake duct 5 Air conditioning compressor 9 Air filter housing Air compressor 6 Serpentine drive belt 10 Exhaust down pipe Turbocharger air inlet duct 7 Belt tensioner 11 Turbocharger exhaust clamp Charge Air Cooler CAC pipe 8 Alternator assembly 12 Shielded tube exhaust assembly Install oil dipstick washer bottle and bracket if 41 removed 42 Install alternator and air conditioning compressor 43 mounting bracket and tighten M10 bolts to the d special torque Table 68 44 Install alternator and reconnect alternator wiring Mr 45 If removed install air conditioning compressor 46 If removed install air compressor and mounting bracket Tighten three M10 x 100 air compressor mounting bracket bolts to the special torque 47 Table 68 EGES295 2 Reconnect air compressor lines and hoses Install serpentine drive belts Install CAC pipe and tighten clamps Install air intake duct air filter housing and mounting bracket Install right inner fender well if removed Install inside engine cover in truck if equipped See Truck Service Manual Reconnect Electronic Control Module ECM ground and negative battery cable Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes
24. Remove reinforcement ring Figure 546 Flywheel guides Figure 547 Flywheel guide pins 1 Remove and discard two M10 x 77 flywheel mounting bolts at approximately 3 o clock and 9 5 Slide flywheel off guide pins and out of housing o clock Do not reuse these bolts 6 Remove guide pins from secondary flange Install two guide pins make locally Remove and discard remaining eight flywheel mounting bolts Do not reuse these bolts EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 314 REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE Rear Main Seal and Wear Sleeve Figure 548 Starter holes 1 Starter hole 2 Rear main seal A vine To prevent personal injury or death wear safety glasses with side shields to protect eyes 1 Use an awl or 1 8 inch drill bit to make two small starter holes 180 apart in rear main seal Figure 549 Hammer screw in starter hole 2 Thread slide hammer screw into one of the starter holes 3 Toremove seal evenly slide hammer on one side and then alternate to other side Figure 550 Rear main oil seal removal 4 Remove and discard rear main oil seal from rear oil seal carrier NOTE When replacing the rear main seal note that production engines will not have a wear sleeve Wear sleeves are
25. Steering Gear Drive to remove the following e Flywheel or flex plate Oil seal carrier Power steering idler gear Crankshaft secondary flange 29 Remove two M10 x 30 bolts from power steering and fuel pump assembly and support the power Steering and fuel pump assembly 30 Disconnect starter motor assembly wiring remove M10 bolts from starter motor and remove starter motor assembly 337 Figure 594 Removal of through bolt from rear engine mount in chassis mounting bracket 1 Rear engine mounting bracket 2 Chassis mounting bracket 3 Through bolt A WARNING To prevent personal injury or death use a chain hoist rated for the weight of the engine follow manufacturer s installation and safety instructions and attach safety latch lifting hooks to lifting eyes on the engine 31 Attach a hoist to support the engine 32 Remove two M16 through bolts and nuts from rear engine mounts 33 Raise engine with a hoist and support engine with a jack 34 Remove eight M12 bolts from rear engine mounting brackets and remove brackets from rear cover 35 Remove wiring retaining clips from rear cover assembly if installed EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation D06150 Figure 595 Rear cover mounting bolts 1 Bolts marked A M1
26. With rocker arms removed back out valve spring compressor bolt and remove valve spring compressor plate to access valve bridges Cleaning and Inspection r ETR To prevent personal injury or death wear safety glasses with side shields to protect eyes Limit compressed air pressure to 207 kPa 30 psi 1 Clean parts with a suitable solvent Use filtered compressed air to dry parts 2 Inspect each rocker arm pivot foot and corresponding valve bridge for pitting or scuffing Replace rocker arms and valve bridges if necessary 3 Inspect each rocker arm ball and socket for scuffing Replace rocker arm ball and socket if necessary 4 Inspect rocker arm post ball socket for excessive wear Inspect bolts for thread damage Replace worn components if necessary EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation IN CHASSIS PROCEDURES 351 5 Inspect the valve cover gasket for damage or misalignment under compression Under normal service conditions the gasket can be reused Installation 1 Following valve bridge replacement place a dab of wheel bearing grease onto new rocker arm socket to hold new 3 8 ball in place compress valves and install new rocker arms D08160 Figure 624 1 Rocker arm retaining clip 2 Fulcrum plate 3 3 8 ball 2
27. below to avoid pulling these gaskets out when removing the rear cover assembly Upper and lower crankcase e Rear cover assembly Crankcase e High pressure oil pump cover Rear cover assembly A WARNING To prevent personal injury or death get help when removing the rear cover 3 Remove rear cover NOTE If necessary use a slide hammer to remove power steering idler shaft EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 318 Cleaning All Components 1 Clean foreign material from gasket surfaces of crankcase and rear cover Use a scraper or wire brush to remove sealant from gasket surfaces 4 Gasket surfaces must oil free for good adhesion of liquid gasket during assembly Use a 5 commercially available non caustic brake cleaner to clean gasket surfaces of crankcase and rear cover Remove sealant under the hydraulic oil pump cover while it is still in place EGES295 2 REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE A warnine To prevent personal injury or death wear safety glasses with side shields to protect eyes Limit compressed air pressure to 207 kPa 30 psi Wash rear oil seal carrier flywheel flexplate and rear cover Dry all with filtered compressed air Wash secondary flange power steering idler gear and shaft wi
28. extension e Torque wrench 12 inches e Extension 6 inches T 88 N m 65 Ibf ft 12 in 12 in 6 in T 88 N m 65 Ibf ft 12 in 18 in T 88 N m 65 Ibf ft 0 666 T 58 9 N m 43 3 Ibf ft EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 378 APPENDIX B TORQUES Special Torques Mounting Engine On Stand Table 56 Oil Pan Drain Plug Oil pan drain plug 25 5 Nm 18 4 lbf ft Variable Geometry Turbocharger VGT Table 57 VGT Bolts and Clamps Air inlet duct hose clamp 4 5 N m 86 48 Ibf in VGT to mounting bracket bolts 31 4 N m 23 3 Ibf ft VGT exhaust adapter V clamp 12 N m 108 Ibf in Manifolds and Exhaust Gas Recirculation EGR Figure 632 Tightening sequence for exhaust manifold mounting bolts 1 Right side exhaust manifold 2 Leftside exhaust manifold EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX B TORQUES 379 9 11 12 13 9 ie 6 9 9 9 9 fle 7 go 9 2 8 7 6 5 D1423a Figure 633 Tightening sequence for intake manifold mounting bolts Table 58
29. gear must not move 4 Zero the dial indicator Move the secondary flange Verify reading with the specification in Table 35 Backlash Test for Power Steering Idler Gear NOTE Before doing this test remove the power steering and fuel pump assembly See Power Steering and Fuel Pump Assembly page 316 for procedure Figure 544 Idler gear backlash REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE 1 Attach dial indicator Table 37 to rear cover 2 Place indicator tip against power steering idler gear 3 Lock the power steering drive gear NOTE The power steering drive gear must be locked for an accurate measurement 4 Zero the dial indicator Move the power steering idler gear and record the dial indicator reading Verify reading with the specification in Table 35 Flexplate Automatic Transmission Figure 545 Flexplate hardware 1 Flexplate bolts 10 Reinforcement ring Flexplate adapter hub Transmission side stamp XMSN SIDE Tog 1 Remove and discard ten M10 x 77 flexplate mounting bolts Do not reuse these bolts 2 Remove the reinforcement ring flexplate and adapter hub EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE 313 Flywheel Manual Transmission 4
30. instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 400 APPENDIX C SPECIAL SERVICE TOOLS D31392 Figure 655 Glow Plug Sleeve Remover ZTSE4531 D31390 Figure 653 Injector Sleeve Remover ZTSE4528 D31393 re Figure 656 Glow Plug Sleeve Installer ZTSE4532 D31391 Figure 654 Injector Sleeve Installer ZTSE4529 MOOR OUR P D31394 Figure 657 Glow Plug Sleeve Brush nylon ZTSE4533 EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX C SPECIAL SERVICE TOOLS 401 D31395 Figure 658 Cylinder Head Pressure Test Plate ZTSE4534 D31397 Figure 660 Intake Manifold Pressure Test Plug EGR Valve ZTSE4544 D31396 Figure 659 Cylinder Head Lifting Bracket ZTSE4535 D31398 Figure 661 EGR Cooler Test Plates ZTSE4545 EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 402 APPENDIX C SPECIAL SERVICE TOOLS I l li jl umm D31399 D31401 Figure 662 Intake Manifold Pressure Test Cap ZTSE4554
31. of the branch tube assembly 8 9 10 11 12 Hy 13 gt A D13138 Figure 605 Installation of bolts for branch tube adapter 1 Branch tube adaptor 2 Branch tube assembly 6 Install and loosely tighten two M6 x 30 mounting bolts to connect new branch tube adapter to branch tube assembly T EGES295 2 Figure 606 Extension in pushrod hole Look through back of crankcase insert extension with No 27 torx bit attached through exhaust pushrod hole for cylinder 6 and install and loosely tighten M6 x 40 torx bolt Look through back of crankcase insert extension with No 27 torx bit attached through exhaust pushrod hole for cylinder 7 and install and loosely tighten M6 x 40 torx bolt Tighten both M6 x 40 torx bolts to the special torque Table 68 Torque both M6 x 30 mounting bolts to the special torquefor the branch tube adaptor Table 68 Install exhaust pushrod for cylinder 6 Install intake and exhaust pushrods for cylinders 7 and 8 See Engine Service Manual Cylinder Head and Valve Train to install the following Fuel injectors for cylinders 6 7 and 8 Case to head tube assemblies e High pressure oil rails e Rocker arm assembly exhaust for cylinder 6 e Rocker arm assemblies intake and exhaust for cylinders 7 and 8 e Valve covers Install high pressure oil pump cover See Engine Service Manual High pressure Oil Pump Read all safety instructions in
32. only available as a service item included with the replacement rear main oil seal Figure 551 Wear sleeve removal tool 5 Install wear sleeve removal tool NOTE Before applying force to threaded shaft make sure the half shells of the wear sleeve removal tool are secured behind wear sleeve EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE 315 Figure 554 Rear oil seal carrier Figure 552 Wear sleeve 1 Wear sleeve removal tool 2 Remove rear oil seal carrier and discard gasket SP Meg eyR NOTE Do the backlash test for the secondary flange and power steering idler gear See Backlash Test for Secondary Flange Crankshaft Gear page 312 6 Turn the threaded shaft clockwise until the wear before doing the following steps sleeve is free of the crankshaft flange A wane To prevent personal injury or Secondary Flange death wear safety glasses with side shields to protect eyes Figure 553 Rear cover and rear oil seal carrier 1 Rear oil seal carrier 2 Long bolts 3 Rear cover Figure 555 Snap ring on power steering idler gear 1 Remove eight M8 bolts from rear oil seal carrier 3 Remove snap ring from power steering idler gear EGES295 2 Read all safety instructions in the S
33. tensioner 11 Turbocharger exhaust clamp 4 Charge Air Cooler CAC pipe 8 Alternator assembly 12 Shielded tube exhaust assembly 5 Remove air intake duct air filter housing and mounting bracket Loosen CAC pipe clamps and remove CAC pipe 10 7 Rotate belt tensioner clockwise to release belt tension and remove serpentine drive belts 11 8 Remove alternator wiring and remove alternator assembly A warnine To prevent personal injury or death do not open pressurized air conditioning lines 9 If truck is equipped with air conditioning remove air conditioning compressor bolts from mounting bracket but do not remove or disconnect pressurized air conditioning lines Move EGES295 2 12 13 compressor out of the way and secure with a strap Remove mounting bracket for alternator and air conditioning compressor If truck is equipped with an air compressor remove coolant supply line and pinch off hose Remove two of three M10 air compressor mounting bracket bolts Loosen third bolt and pivot or reposition air compressor out of the way If required to remove valve covers remove oil dipstick washer bottle and bracket Loosen turbocharger exhaust clamp and remove exhaust down pipe from turbocharger exhaust flange Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corp
34. top of lobe Intake open Intake closed Exhaust open Exhaust closed Table 47 Crankcase and Main Bearings Crankcase Cylinder block top surface of crankcase firing deck flatness Crankcase main bearing bore diameter Crankcase cam bearing bore diameter Valve tappet bore diameter Valve tappet outside diameter Cylinder bore diameter Cylinder bore maximum out of round Cylinder stroke Rear oil seal face runout T I R maximum Front oil seal face runout T I R maximum Main Bearings Type Material Number of main bearings Thrust applied at Lower crankcase Coolant heater element rating 5 744 mm 0 2261 in 5 832 mm 0 2296 in 7 22 BTDC 34 66 ABDC 45 12 BBDC 6 24 ATDC Total 0 10 mm 0 004 in 150 mm x 150 mm 6 in x 6 in area 0 05 mm 0 02 in 25 mm x 25 mm 1 in x 1 in area 0 025 mm 0 001 in 85 99 to 86 01 mm 3 3854 to 3 3862 in 65 98 to 66 02 mm 2 597 to 2 599 in 23 439 to 23 477 mm 0 9228 to 0 9243 in 23 391 to 23 411 mm 0 9209 to 0 9217 in 94 999 to 95 001 mm 3 7401 to 3 7402 in 0 05 mm 0 002 in 105 mm 4 13 in 0 38 mm 0 015 in 0 25 mm 0 010 in Precision replaceable Steel backed copper lead 5 No 4 main upper Four bolts per main journal 1 000 watts 120 volts EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and E
35. tube assembly Valve cover bolts and studs Oil fill extension Rear heat shield M10 x 16 EGES295 2 381 41 N m 30 x 3 Ibf ft 41 N m 30 3 Ibf ft 7 N m 60 Ibf in Figure 635 33 N m 24 Ibf ft 31 N m 23 Ibf ft 19 N m 168 Ibf in 12 2 N m 108 18 Ibf in 13 N m 120 Ibf in Figure 634 82 N m 60 Ibf ft 9 1 2 N m 72 12 Ibf in 14 1 N m 120 132 Ibf in 49 5 Nm 36 x 4 Ibf ft Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 382 APPENDIX B TORQUES Front Cover Vibration Damper and Gerotor Oil Pump D0738 Figure 636 Torque sequence for vibration damper bolts Table 60 Front Cover Vibration Damper Water Pump and Oil Pan Drain Plug Oil pan drain plug Front cover module bolts Water pump mounting bolts Vibration damper mounting bolts Connecting Rods and Pistons Table 61 Connecting Rod Assembly Initial Connecting rod bearing bolts i Final EGES295 2 25 5 Nm 18 4 Ibf ft 24 N m 18 Ibf ft 23 1 Nem 17 amp 1 Ibf ft New bolts only 68 N m 50 Ibf ft 90 rotation Figure 636 45 N m 33 Ibf ft 68 N m 50 Ibf ft Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 Internat
36. 0 5 Nm 37 4 Ibf ft 12 2 Nm 108 x 12 Ibf in 18 2 3 N m 156 24 Ibf in 14 Nm 120 Ibf in 14 N m 120 Ibf in 50 5 Nm 37 4 Ibf ft 11 3 Nem 96 24 Ibf in 49 5 Nm 36 4 Ibf ft 41 4Nm 25 2Nm 25 2Nm 38 4 Nm 27 1Nm 90 10 Nm 45 4Nm 79 4Nm 30 3 Ibf ft 19 2 Ibf ft 18 2 Ibf ft 28 3 Ibf ft 20 1 Ibf ft 66 7 Ibf ft 33 3 Ibf ft 58 3 Ibf ft A RA A A Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 386 APPENDIX B TORQUES Flywheel Rear Cover and Power Steering and Fuel Pump D0739 Figure 639 Torque sequence for flywheel and flexplate typical Table 67 Flywheel Flexplate and Power Steering Assembly Flywheel mounting bolts M10 x 77 new bolts only 94 N m 69 Ibf ft Figure 639 Flexplate mounting bolts M10 x 77 new bolts only 94 N m 69 Ibf ft Figure 639 Power steering pump outlet pipe fitting 45 5 N m 33 4 Ibf ft Power steering pump inlet pipe fitting 90 10 N m 66 7 Ibf ft EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation Z Z DH APPENDIX B TORQUES 387 In chasiss Procedures Table 68 Branch Tube Assembly
37. 0 x 55 5 2 Bolts marked B M10 x 70 2 3 Bolts marked C M10 x 60 4 36 Remove rear cover mounting bolts marked A and C in figure A WARNING To prevent personal injury or death use a suitable lifting device or get help to lower rear cover 37 Loosen rear cover mounting bolts marked B but do not remove CAUTION To prevent engine damage when removing the rear cover avoid pulling out gasket between the upper and lower crankcase 38 Use a thin gasket scraper to separate sealant between the upper and lower crankcase and the rear cover assembly 39 Remove rear cover mounting bolts marked B and remove rear cover IN CHASSIS PROCEDURES Figure 596 Sealant at upper and lower crankcase CAUTION To prevent engine damage cut sealant at upper and lower crankcase 40 Remove remaining sealant from upper crankcase lower crankcase and rear cover using a sharp gasket scraper or putty knife 41 Remove intake and exhaust pushrods from cylinders 7 and 8 42 Remove exhaust pushrod from cylinder 6 43 Attach a No 27 torx bit to a 1 4 x 10 inch extension Figure 597 Extension in pushrod hole 44 Look through back of crankcase and insert extension through exhaust pushrod hole for cylinder 6 and push torx bit into M6 x 40 torx bolt in block of branch tube assembly EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings
38. AUTION To prevent engine damage insert clean shop towels see TSI 02 12 16 or piece of rubber hose into oil drain holes in rocker arm carrier before removing fuel injectors This will ensure that the following parts or pieces of these parts will not fall into the oil supply 93 8 rocker arm pivot balls e Rocker arm pivots and pivot retainers NOTE Account for all parts or pieces before removing shop towels or rubber hoses after rocker arms have been replaced 1 Find dowel hole in vibration damper between two of the four bolt heads Figure 611 Dowel hole in vibration damper 2 Rotate crankshaft to position dowel hole at 12 00 3 Wiggle both rocker arms for cylinder 1 If rocker arms feel free of valve train loading the valves are completely closed Rocker arms can be serviced for cylinders 1 2 7 and 8 Do steps 4 through 16 If rocker arms do not feel free rotate crankshaft 360 to put crankshaft in the correct position Rocker arms can be serviced for cylinders 1 2 7 and 8 Do steps 4 through 16 EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation IN CHASSIS PROCEDURES 347 D08202 Figure 612 Engine harness connector to injector connector 1 Engine harness connector 2 Spring loaded metal clip Figure 613 Injector connec
39. Assemblies cont Bearing bore maximum taper per 25 mm 1 in Connecting rod bearing inside diameter Connecting rod bearing running clearance diameter Connecting rod side clearance Weight complete rod without bearing Pistons Material Skirt diameter 0 013 mm 0 0005 in 69 027 to 69 077 mm 2 7176 to 2 7196 in 0 0203 to 0 0837 mm 0 0008 to 0 0033 in 0 3 to 0 6 mm 0 012 to 0 024 in 1201 5 to 1215 5 g 2 649 to 2 679 Ib Aluminum Alloy 94 9460 to 94 9186 mm 3 737 to 3 738 in Measure 14 68 mm 0 578 in from bottom at 90 to the piston pin Measure only at room temperature of 19 to 21 C 66 to 70 F Service Piston Standard size 0 254 mm 0 010 in oversize 0 508 mm 0 020 in oversize 0 762 mm 0 030 in oversize 94 9460 to 94 9186 mm 95 1738 to 95 1992 mm 95 4278 to 95 4532 mm 95 6818 to 95 7072 mm 3 737 to 3 738 in 3 747 to 3 748 in 3 757 to 3 758 in 3 767 to 3 768 in Top compression ring groove width measured over 2 08 mm 0 082 in gauge pins Upper limit Replacement limit Piston height above crankcase deck protrusion Piston skirt clearance 1 8 Piston Pins Length Diameter Pin fit at room temperature of 19 to 21 C 66 to 70 F Clearance in connecting rod piston pin bushing Clearance in piston End clearance Piston Rings Ring diameter standard Fit in groove side clearance in bore Top compression Intermediate compress
40. FUEL SYSTEM 297 Table of Contents CIERRE RETE 301 Fuel Prescreen Element 121 rite ue Ruidilliitawe este RRRRRRRRRR A epe EN ss 301 F el Filter Element e a essa iaaaas vacate EERRR RRRRREK M Mee Aaaa 302 Fuel Filter Assembly and Tubing eeeeeesssess messen nmm nn n n nn nn 302 Fuel Injectors ern EEE NEE PENAN EREKE ECEE EUR NAAN eee wes ESE EPPO PAUAR RR EE fa 303 Inspection iie oie cee ee el eee eee oo a AAA ER EERREE EE KE Qe as na CAE a TURA 303 Installation ea a a aa a aaa aa E thee eee ewe ea a a AAAA AEE E EEEa Eaa aaa 304 Fuel Prescreen Element 2 aah a add a aaa dees dele eee el eis 304 Fuel Filter Assembly and Tubing cccceee cece eee e mene e nn n n nn nn 304 Priming the Fuel System iiiiisuiuuino nl llllllidagaa ka v9 ARI IRR fA RR ern LRS AETA ii 305 Priming without Vacuum SOUMCE cece eee eee reer eee nnn nnns 305 Priming with Vacuum Source sseeeeesssseeen enne nnn nnn nnn 306 Fuel Filter Element a Aa a n EE E EEL Ur wwwage E E EDEN DDUDDMA 307 Fuel Injectors iiie e e dide kk Rum ttt eeen AARAA XR RR raerek baiia Aai 307 Specifications ior uec rau E ar Aa sa uerus eee ee eerie exiis 308 Special Torque 2 c c ninilimad ln 4 lilii aA Aa aai XdIO dde DD LRILAZ NR ahihi Aa didida 308 Special Service Tools leslie reri ssi AAA Rel i lebber anda nuu texere exem E e TERRA ad 308 EGES295 2 Read all safety instructions in the Saf
41. Manual Engine Electrical to remove the following ECM IDM and mounting bracket e Glow plug relay and bracket EGES295 2 Exhaust manifold right 6 V clamp Shielded tube exhaust 7 assembly to turbocharger 23 24 25 IN CHASSIS PROCEDURES Pump gasket heat shield Exhaust manifold left See Engine Service Manual Electronically Controlled Variable Geometry Turbocharger VGT to remove the following e Turbocharger air inlet duct e VGT assembly Remove the high pressure oil pump cover See Engine Service Manual High pressure Oil Pump See Engine Service Manual Cylinder Head and Valve Train to remove the following e Valve covers e High pressure oil rails e Case to head tube assemblies e Fuel injectors for cylinders 6 7 and 8 e Rocker arm assemblies intake and exhaust for cylinders 7 and 8 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation IN CHASSIS PROCEDURES e Rocker arm assembly exhaust for cylinder 6 A WARNING To prevent personal injury or death use a suitable lifting device to support and lower transmission assembly 26 Remove transmission assembly 27 Remove clutch assembly if equipped with a manual transmission 28 See Engine Service Manual Rear Cover Flywheel and Power
42. Slide Hammer Kit 5 8 in ZTSE4398 D31558 Figure 640 C Type Valve Spring Compressor ZTSE1846 D31549 Figure 643 Engine Stand Mounting Bracket ZTSE4507 D31559 Figure 641 Fuellnjector Rack Holder ZTSE4299B D31382 Figure 644 Piston Gauge Pins 0 082 in ZTSE4513 EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 398 APPENDIX C SPECIAL SERVICE TOOLS Qo D31383 Figure 645 Crankshaft Rear Seal Wear Sleeve Installer ZTSE4515 D31385 Figure 647 Front Wear Sleeve Remover ZTSE4517 OO D31384 D31386 Figure 646 Front Seal Installer Wear Sleeve Installer ZTSE4516 Figure 648 Crankshaft Rear Wear Sleeve Remover ZTSE4518 EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX C SPECIAL SERVICE TOOLS 399 D31388 Figure 651 Oil Cooler Test Plate Pressure Adapter ZTSE4525 D31387 Figure 649 Crankshaft Timing Tool ZTSE4519 ZTSE4527 hd ZTSE4527 Figure 652 Intake Manifold Test Plates ZTSE4527 D31554 Figure 650 Fuel Injector Hold down wrench ZTSE4524 EGES295 2 Read all safety
43. a aaa ERRRREUNNNERE ERR RR RE ENRE 375 Torque Wrench Extension and Adapters ssssssssssseeuellssse esses ene n nnne 377 Special Torq es eios re dese see aevs ndr xus m4 daaa aaa crise NR RRRRRRARRRAAALN NUN RN rena a RR ad 378 Mounting Engine On Stand ieece elle e ie IeeR RR e Rad gaaa aree reser een n 378 Variable Geometry Turbocharger VGT ceeeeee eee ee cere e eee nnm nnn 378 Manifolds and Exhaust Gas Recirculation EGR 0ccccceeeee tees seen essen eee eeeeeeeeeeeeees 378 Cylinder Head and Valve Train ccc cceeee cere e eee eeeeeee eee eeeeeeeeee eee e ete eeeeeeeeeeeeeaes 380 Front Cover Vibration Damper and Gerotor Oil Pump seen enne 382 Connecting Rods and PiStons ccccee cece eee cece cece ee eeee emen 382 Crankcase Crankshaft and Bearings Camshaft and Bushings 383 Oil Cooler and Oil Filter iiec a e Rr rea i d aaa dk ee eR Cece eevee E DDR RARE 384 Engine Electricals sss rire RR vets Sennen die wee REIR Re dll RR Rr DEN ER Er E rr ERR NAE 385 High pressure Oil Pump enr iau iu ttti ink Rr RR ERAR RR aaan aiaia 385 Fuel System eerte TA IV ER ipNUIRICR Re Reda aa nera ewee re REED RR 385 Flywheel Rear Cover and Power Steering and Fuel Pump Luuuueees 386 Irni chasiss Procedures ciel ke eu riri oa UR EA DR RR EEE REEE eth Cee ERE 387 EGES295 2 Read all safety
44. afety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 316 REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE cu Figure 558 Gear puller Figure 556 Power steering idler gear 5 Use a gear puller to remove the secondary flange 4 Remove power steering idler gear Power Steering and Fuel Pump Assembly Figure 557 Secondary flange Figure 559 Mounting bolts for power steering and fuel pump assembly 1 Remove two M10 x 30 mounting bolts from power steering and fuel pump assembly EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE 317 Rear Cover and Power Steering Idler Shaft oY d S 4 E J f Figure 560 Power steering and fuel pump assembly 1 O ring D06150 Figure 561 Rear cover mounting bolts 2 Remove power steering and fuel pump assembly 1 Bolts marked A M10 x 55 5 from rear cover and discard O ring 2 Bolts marked B M10 x 70 2 S 4 NOTE The power steering and fuel pump assembly Be SONS MAKSA TaM OBU is serviced only as a single unit 1 Remove eleven mounting bolts from rear cover 2 Use a thin gasket scraper to separate sealant between rear cover joints listed
45. all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 344 IN CHASSIS PROCEDURES Figure 609 Parts for Installation 1 Turbocharger air inlet duct 6 Pump gasket heat shield 10 EGR Drive Module 2 Glow plug relay 7 Rear cover 3 Turbocharger exhaust flange 8 V clamp Shielded tube exhaust 4 Rear engine mounting bracket assembly to turbocharger 2 9 Electronic Control Module 5 V clamp Right exhaust tube to ECM Injector Drive Module EGR cooler IDM 31 See Engine Service Manual Electronically 33 See Engine Service Manual Engine Electrical Controlled Variable Geometry Turbocharger to install the following VGT to install the following Glow plug relay and bracket E e Electronic Control Module ECM Injector e Turbocharger air inlet duct Driver Module IDM and mounting bracket 32 Install exhaust down pipe onto turbocharger 34 Plug in ECM and IDM electrical connectors exhaust flange and tighten exhaust clamp to the special torque Table 68 35 Install EGR drive module with mounting bracket and plug in electrical connector EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation IN CHASSIS
46. anual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 304 Installation Fuel Prescreen Element 1 Place cleaned prescreen element in the bowl or obtain a new precleaner assembly D06152 Figure 535 and bowl Installation of prescreen element 1 Power steering pump 2 Fuel pump 3 Prescreen bowl 2 Apply coating of diesel fuel on new strainer O ring and prescreen bowl Thread on fuel FUEL SYSTEM transfer pump until hand tight and snug O ring with 30 mm box end wrench Fuel Filter Assembly and Tubing Figure 536 Fuel filter assembly 1 Install fuel filter assembly on intake manifold Secure assembly with two M10 x 20 mounting bolts Tighten bolts to the standard torque Standard Torques page 375 2 Connect filter water drain tubing EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation FUEL SYSTEM Figure 537 Fuel supply and return O rings 1 Fuel return O ring 2 Fuel supply O ring 3 Replace all O rings in fuel return and supply fittings Replace all banjo fitting copper washers in cylinder heads Figure 538 Filter drain and tubing for cylinder head fuel supply 1 Water drain tube assembly 2 Filter to left cylinder head tube assembly 3 Filter to righ
47. any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 326 Power Steering and Fuel Pump Assembly 1 k N S g Check power steering and fuel pump assembly for cracks leaks or other damage Before installation put a new O ring on power steering and fuel pump assembly lif Figure 585 Power steering and fuel pump assembly 1 O ring 2 Install power steering and fuel pump assembly in 2 3 4 2 3 4 Figure 586 Mounting bolts for power steering and fuel pump assembly 5 EGES295 2 rear cover REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE 3 Install two M10 x 30 mounting bolts for power steering and fuel pump assembly Tighten bolts to the standard torque Flexplate CAUTION To prevent engine damage use new bolts to install flexplate CAUTION Do not use anti seize compounds grease or lubricants Each has an adverse effect on torque results Position flexplate on adapter hub and align hub over the crankshaft secondary flange dowel Make sure the XMSN SIDE stamp is facing the transmission Figure 587 Flexplate Flexplate bolts M10 x 77 10 Reinforcement ring Flexplate adapter hub Transmission side stamp XMSN SIDE Make sure lip on outer circumference of reinforcement ring faces the transmission and align bolt holes to position reinforcement ring Install two M10 x 77 bolts for flexplate 180 apart through r
48. aust tube to cover assembly and tighten eight M12 x 40 bolts EGR cooler and tighten V clamp to to the special the special torque Table 68 torque Table 68 20 Tighten M8 bolts securing shielded exhaust tube assembly right exhaust tube attached to the special torque Table 68 EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation IN CHASSIS PROCEDURES 343 Figure 608 Installation of through bolt into rear engine mount 1 Rear engine mounting bracket 2 Chassis mounting bracket 3 Through bolt A WARNING To prevent personal injury or death make sure the lifting hoist and hooks are secure before lowering the engine 24 Lower engine to set rear engine mounting brackets in chassis mounting brackets 25 Install two M16 through bolts and nuts to secure rear engine mounts to chassis mounting brackets Tighten nuts to the special torque Table 68 26 Remove chain hoist 27 Install starter motor assembly and tighten M10 x 40 starter bolts to the special torque Table 68 28 Reconnect starter wiring 29 Install clutch and pressure plate if equipped with a manual transmission A WARNING To prevent personal injury or death use a suitable lifting device to support and raise transmission assembly 30 Install transmission assembly EGES295 2 Read
49. c Cover Quick Release Tool Flywheel Rear Cover and Power Steering and Fuel Pump Table 80 Flywheel Rear Cover and Power Steering and Fuel Pump Description Cap Kit all Liquid Gasket RTV 6 oz tube Rear Wear Sleeve Installer Rear Wear Sleeve Removal Tool Loctite Hydraulic Sealant In chasiss Procedures Table 81 Branch Tube Assembly Description No 10 Quick Release Tool EGES295 2 395 Tool Number ZTSE4610 Obtain locally ZTSE4564 1830858C1 ZTSE4557 ZTSE4581 Tool Number ZTSE4610 Obtain locally ZTSE4564 1830858C1 ZTSE4557 ZTSE4581 Tool Number ZTSE4610 1830858C1 ZTSE4515 ZTSE4518 Obtain locally TOOL NUMBER ZTSE4581 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 396 APPENDIX C Table 82 Rocker Arm Description Injector Connector Release Tool Fuel Injector Hold Down Wrench On engine Valve Spring Compressor Tool SPECIAL SERVICE TOOLS TOOL NUMBER ZTSE4650 ZTSE4524 ZTSE4697 EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX C SPECIAL SERVICE TOOLS 397 Special Tools Essential Tools INTERNATIONAL ZTSE4398 D31381 Figure 642
50. ce EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 320 4 Align the idler shaft in the rear cover at the correct location Using the installation tool drive the idler shaftin the idler shaft bore in the transmission side of the rear cover until the installation tool bottoms out 34 6 0 15 mm 1 44 0 01 in Section A A Figure 566 Power steering idler shaft installation height 1 Retaining ring 2 Power steering idler shaft 3 Rear cover assembly 5 If installation tool is not available use brass drift to install the idler shaft in the rear cover to the correct height REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE Figure 567 Idler shaft height measurement 6 Measure idler shaft height using a dial caliper Idler shaft height should be 34 6 0 15 mm 1 362 0 006 in CAUTION To prevent engine damage replace dowel pins in crankcase if damaged or missing Figure 568 Application of sealant 1 Apply Liquid Gasket RTV Table 37 at the ends where the crankcase and the lower crankcase meet Apply liquid gasket to the hydraulic oil pump cover joint if the cover was not removed CAUTION To prevent engine damage do not allow the retaining ring to contact the rear cover Contact may distort the retaining ring adversely affecting it
51. cklash See Figure 578 14 Install new gasket on rear oil seal carrier EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 324 Figure 579 Rear cover and rear oil seal carrier 1 Rear oil seal carrier 2 Longer bolts M8 x 70 3 Rear cover 15 Install two M8 x 70 bolts in lower holes of rear oil seal carrier Figure 579 Tighten bolts to the standard torque Standard Torques page 375 16 Install six remaining x 285 bolts M8 to secure rear oil seal carrier to rear cover Figure 579 Tighten bolts to the standard torque Standard Torques page 375 Rear Main Oil Seal and Wear Sleeve CAUTION To prevent engine damage do not separate wear sleeve from oil seal this will damage the seal and engine NOTE When replacing the rear main oil seal note that production engines will not have a wear sleeve Wear sleeves are only available as a service item included with the replacement rear main oil seal REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE Figure 580 Rear Wear Sleeve Installer Bolt Rear Wear Sleeve Installer Table 37 on end of crankshaft Make sure crankshaft alignment dowel fits in dowel recess hole in the rear wear sleeve installer Figure 581 D0727 Orientation or rear main oil seal and wear sleeve BON EGES295
52. ctronic module that controls the ground to an actuator circuit Duty cycle A control signal that has a controlled on off time measurement from 0 to 100 Normally used to control solenoids Engine lamp An instrument panel lamp that comes on when DTCs are set DTCs can be read as flash codes red and amber instrument panel lamps Engine OFF tests Tests that are done with the ignition switch ON and the engine OFF Engine rating Engine rating includes Rated hp and Rated rpm Engine RUNNING tests Tests done with the engine running Exhaust brake A brake device using engine exhaust back pressure as a retarding medium Exhaust manifold Exhaust gases flow through the exhaust manifold to the turbocharger exhaust inlet and are directed to the EGR cooler Fault detection management An alternate control strategy that reduces adverse effects that can be caused by a system failure If a sensor fails the ECM substitutes a good sensor signal or assumed sensor value in its place A lit amber instrument panel lamp signals that the vehicle needs service Filter restriction A blockage usually from contaminants that prevents the flow of fluid through a filter Flash code See Diagnostic Trouble Code DTC Fuel inlet restriction A blockage usually from contaminants that prevents the flow of fluid through the fuel inlet line Fuel pressure The force that the fuel exerts on the fuel system a
53. e basic engine with air cleaner without fan and alternator and air compressor not charging Hall effect The development of a transverse electric potential gradient in a current carrying conductor or semiconductor when a magnetic field is applied Hall effect sensor Generates a digital on off signal that indicates speed and timing High speed digital inputs Inputs to the ECM from a sensor that generates varying frequencies engine speed and vehicle speed sensors Horsepower hp Horsepower is the unit of work done in a given period of time equal to 33 000 pounds multiplied by one foot per minute 1hp 33 000 Ib x 1 ft 1 min Hydrocarbons Unburned or partially burned fuel molecules Idle speed Low idle is minimum rpm at no load e High idle is maximum rpm at no load 359 Intake manifold A collection of tubes through which the fuel air mixture flows from the fuel injector to the intake valves of the cylinders International NGV Tool Utilized for Next Generation Electronics INTUNE The diagnostics software for chassis related components and systems Low speed digital inputs Switched sensor inputs that generate an on off high low signal to the ECM The input to the ECM from the sensor could be from a high input source switch usually 5 or 12 volts or from a grounding switch that grounds the signal from a current limiting resistor in the ECM that creates a low signal 0 volts
54. e check runout of flywheel surface to ensure correct alignment of engine to transmission Failure to ensure correct bore concentricity and face runout may reduce life of clutch or transmission NOTE Keep crankshaft end play at zero in the same direction for all measurements Figure 542 Flywheel surface runout 1 Attach dial indicator Table 37 to rear cover Place indicator tip against surface of flywheel Zero the dial indicator Rotate crankshaft slowly Table 35 Rear Cover Runout Figure 543 Rear cover runout 1 Attach dial indicator Table 37 to surface of flywheel Place indicator tip against rear cover NOTE Keep crankshaft end play at zero in the same direction for all measurements 2 Zero the dial indicator EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 312 3 Measure at four points 90 apart for total face variation with Table 35 Backlash Test for Secondary Flange Crankshaft Gear NOTE Before doing this test remove the power steering and fuel pump assembly See Secondary Flange page 315 for procedure 1 Attach dial indicator Table 37 to rear cover 2 Place indicator tip against secondary flange crankshaft gear 3 Lock the power steering idler gear For accurate measurement the power steering idler
55. e excess interior air pressure Crankcase pressure The force of air inside the crankcase against the crankcase housing Current The flow of electrons passing through a conductor Measured in amperes Damper A device that reduces the amplitude of torsional vibration SAE J1479 JAN85 Deaeration The removal or purging of gases air or combustion gas entrained in coolant or lubricating oil Deaeration tank A separate tank in the cooling System used for one or more ofthe following functions e Deaeration e Coolant reservoir fluid expansion and afterboil e Coolant retention Filling Fluid level indication visible Diagnostic Trouble Code DTC Formerly called a Fault Code or Flash Code A DTC is a three digit numeric code used for troubleshooting Digital Multimeter DMM An electronic meter that uses a digital display to indicate a measured value Preferred for use on microprocessor systems because it has a very high internal impedance and will not load down the circuit being measured Disable A computer decision that deactivates a System and prevents operation of the system TERMINOLOGY Displacement The stroke of the piston multiplied by the area of the cylinder bore multiplied by the number of cylinders in the engine Driver high side A transistor within an electronic module that controls the power to an actuator circuit Driver low side A transistor within an ele
56. einforcement ring flexplate and adapter hub Place flexplate assembly on crankshaft tighten two bolts to hold assembly Hand Install eight remaining M10 x 77 mounting bolts Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE D0739 Figure 588 Torque sequence for flexplate 6 Snug all bolts in the sequence shown to 1 to 7 N m 12 to 60 Ibf in 7 Torque all bolts in the sequence to the special torque Table 36 Flywheel Figure 589 Flywheel on guide pins 327 1 Install two flywheel guide pins made locally in crankshaft flange at approximately 3 o clock and 9 o clock 2 Align dowel hole in flywheel with crankshaft secondary flange dowel and slide flywheel onto guide pins 3 Align reinforcement ring with dowel and slide over guide pins Make sure lip on outer circumference of ring faces the transmission CAUTION To prevent engine damage use new bolts to install flywheel CAUTION Do not use anti seize compounds grease or lubricants Each has an adverse effect on torque results NOTE New phosphate coated bolts do not require oil before torquing 4 Install two new M10 x 77 bolts to secure flywheel to crankshaft Remove both guide pins 5 Install eight remaining M10 x 77 bol
57. el up to the filter cap threads 4 Replace fuel filter cap and tighten Engage starter for 30 seconds and allow starter to cool for two minutes NOTE Return ignition key to RUN only between starts to decrease load on batteries This will prevent glow plugs from recycling CAUTION To prevent damage to the starter if engine fails to start within 30 seconds release ignition switch and wait 2 to 3 minutes to allow starter motor to cool Repeat above procedure 6 Repeat step 5 until engine starts and runs on its own Three to five cranking periods will be required to start vehicle Additional cranking periods may be required if fuel filter is not primed NOTE Engines in bus applications require more cranking time since the rear tank is farther from the engine FUEL SYSTEM Priming with Vacuum Source NOTE If the fuel system will not prime during diagnosis the engine will exhibit white to black smoke and pulsating fuel pressure See Combustion Leaks to Fuel in Section 4 of Engine Diagnostics Manual EGES 240 1 Add fuel to tank If equipped with dual tanks add fuel to passenger side tank Check fuel level in operator side tank to verify transfer pump is operating correctly Figure 541 Unfiltered fuel pressure test port 2 Install fuel pressure test fitting in unfiltered fuel test port 3 Attach vacuum source to fuel pressure test coupling and connect to fuel pressure test fitting 4 Draw fuel from
58. ercooler reduces the charge air temperature by transferring heat from the charge air to a cooling medium usually air Ambient temperature The environmental air temperature in which a unit is operating In general the temperature is measured in the shade no solar radiation and represents the air temperature for other engine cooling performance measurement purposes Air entering the radiator may or may not be the same ambient due to possible heating from other sources or recirculation SAE J1004 SEP81 Ampere amp The standard unit for measuring the strength of an electrical current The flow rate of a charge in a conductor or conducting medium of one coulomb per second SAE J1213 NOV82 Analog A continuously variable voltage Analog to digital converter A D A circuit in the ECM processing section that converts an analog signal DC or AC to a usable digital signal for the microprocessor American Trucking Association ATA Datalink A serial datalink specified by the American Trucking Association and the SAE Boost pressure 1 The pressure of the charge air leaving the turbocharger 2 Inlet manifold pressure that is greater than atmospheric pressure Obtained by turbocharging Bottom Dead Center BDC The lowest position of the piston during the stroke Brake Horsepower bhp The power output from an engine not the indicated horsepower The power output of an engine sometimes called flywheel
59. essor Tool ZTSE4697 EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 354 IN CHASSIS PROCEDURES EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation TERMINOLOGY 355 Table of Contents Terminology it mE 357 EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 356 TERMINOLOGY EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation TERMINOLOGY Terminology Accessory work The work per cycle required to drive engine accessories normally only those essential to engine operation Actuator A device that performs work in response to an input signal Aeration The entrainment of air or combustion gas in coolant lubricant or fuel Aftercooler Charge Air Cooler A heat exchanger mounted in the charge air path between the turbocharger and engine intake manifold The aft
60. essure oil pump assembly and STC fitting 1 High pressure oil pump assembly 2 Snap To Connection STC fitting 53 Remove STC fitting 54 Remove branch tube assembly Installation Figure 602 High pressure oil pump assembly and STC fitting 1 High pressure oil pump assembly 2 STC fitting CAUTION To prevent engine damage a new STC fitting must be installed 1 Install a new STC fitting for the high pressure oil pump CAUTION To prevent engine damage do not over tighten the STC fitting if over tightened the STC fitting will fail 2 Tighten new STC fitting to the special torque Table 68 D13133 Figure 603 Mounting block on branch tube assembly 1 M6 x 40 torx bolt 2 Grease 3 Mounting block CAUTION To prevent engine damage a new branch tube assembly must be installed 3 Grease each M6 x 40 torx bolt and insert into mounting blocks of new branch tube assembly CAUTION To prevent engine damage do not drop mounting bolts into crankcase 4 Position new branch tube assembly for mounting in crankcase EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation IN CHASSIS PROCEDURES Figure 604 Installation of O ring CAUTION To prevent engine damage a new O ring 7 must be installed 5 Install new O ring in the recess
61. ety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 298 FUEL SYSTEM EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation Fuel injector assembly 4 Fuel rail plug assembly right cylinder head Cylinder head right side Fuel supply line right cylinder head Fuel supply line left cylinder head Cylinder head left side Fuel rail plug assembly left cylinder head Figure 528 Fuel system components 8 9 10 11 12 13 14 15 FUEL SYSTEM Fuel injector assembly 4 Banjo bolt 12 mm with check valve left cylinder head Fuel filter water drain tube assembly Fuel and power steering pump assembly gear driven Filter strainer assembly Fuel from pump to filter Fuel supply from tank Fuel supply to filter from pump EGES295 2 16 17 18 19 299 D1116B Fuel return to tank Fuel filter regulator valve assembly Fuel filter housing assembly Banjo bolt 12 mm with check valve right cylinder head Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 300 FUEL SYSTEM
62. f the primary flange or the inner mounting surface of the secondary flange EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 322 REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE Figure 572 Application of Loctite on the primary crankshaft flange D06137 4 Apply Loctite on the outside diameter of the Figure 574 Crankshaft secondary flange primary crankshaft flange installation studs ZTSE4720 6 Install two Crankshaft Secondary Flange Installation Studs evenly spaced into the crankshaft flange 7 Align the dowel pin hole with the crankshaft dowel pin and slide secondary flange onto the studs NOTE You have 5 minutes to fully draw the secondary flange onto the crankshaft flange Figure 573 Application of Loctite on the primary crankshaft flange 5 Spread the Loctite evenly around primary crankshaft flange Do not get any Loctite on the face of the crankshaft flange CAUTION To prevent damage to the engine transmission or vehicle seat the secondary flange onto crankshaft in one step When two surfaces are mated air is removed Loctite sets up within 8 Install two nuts and washers Seat the flange by 5 minutes Installation after Loctite amp has set will alternately tightening nuts on the studs break the seal between the crank
63. his manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 360 Output State Test OST An On demand test that forces the processor to activate actuators High or Low for additional diagnostics pH A measure of the acidity or alkalinity of a solution Particulate matter Particulate matter includes mostly burned particles of fuel and engine oil Piezometer An instrument for measuring fluid pressure Positive On Shaft Excluder POSE A Positive On Shaft Excluder is a separate piece from the rest of the front or rear seal used to keep out dust debris Power Power is a measure of the rate at which work is done Compare with Torque Power TakeOff PTO Accessory output usually from the transmission used to power a hydraulic pump for a special auxiliary feature garbage packing lift equipment etc Pulse Width Modulation PWM The time that an actuator such as an injector remains energized Random Access Memory RAM Computer memory that stores information Information can be written to and read from RAM Input information current engine speed or temperature can be stored in RAM to be compared to values stored in Read Only Memory ROM All memory in RAM is lost when the ignition switch is turned off Rated gross horsepower Engine gross horsepower at rated speed as declared by the manufacturer SAE J1995 JUN90
64. igure 629 Metric fasteners Classification and identification INTERNATIONAL MATERIAL THERMAL HEAD MARKING designation TREATMENT Preferred Optional CLASS METRIC FASTENERS Medium carbon Quench and tempered ES Tory 10 R Medium carbon Roll threaded after heat Alloy steel treatment V Lf p OON oop 10 9 Medium carbon Quench and tempered a 108 f Alloy steel ka VL Medium carbon Quench and tempered TN Yo oT 12 9R Alloy steel Roll threaded after heat treatment Wane Eg D31369 Figure 630 Special fasteners Classification and identification EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX B TORQUES Many conditions affect torque and the results of torque applications The major purpose in tightening a fastener to a specified torque is to obtain tension in the fastener bolt and nut which in turn develops a clamping load which exceeds any possible loading imposed on parts due to engine rpm or vibration New phosphate coated fasteners do not require oil lubrication during assembly and torque application Reused fasteners even if originally phosphate coated do require oil lubrication to the threads and under head area for correct torque application Threads that are dry excessively rough battered or filled with dirt require considerab
65. instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 374 APPENDIX B TORQUES EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX B TORQUES Torque Guidelines CAUTION To prevent engine damage do not substitute fasteners Original equipment standard hardware is defined as Class 10 9 metric or Grade 8 standard coarse thread bolts and nuts and hardened flat washers Rockwell C 38 45 all phosphate coated The standard torque charts provide the tightening torque for general application of standard hardware listed in the Parts Catalog for original equipment NOTE Inspect parts for cleanliness and defects before assembly Standard Torques Table 53 Standard Torques Pipe Thread Thread Size Torque 1 8 in NPT 11 N m 90 Ibf in 1 4 in NPT 14 N m 120 Ibf in 3 8 in NPT 20 N m 180 Ibf in 1 2 in NPT 34 N m 25 Ibf ft 3 4 in NPT 41 N m 30 Ibf ft Tolerances are 10 of nominal value 375 Table 54 Standard Torques Class 10 9 Metric Bolts and Studs Thread Thread Pitch Torque Diameter mm thread 6 mm 1 13 N m 115 Ibf in 8 mm 1 25 31 N m 23 lbf ft 10 mm 1 5 62 N m 45 Ibf ft 12 mm 1 75 107 N m 79
66. ion EGES295 2 94 469 mm 3 7192 in 93 290 mm 3 7122 in 0 9000 mm 0 0354 in 0 0441 to 0 0909 mm 0 0017 to 0 0036 in 65 073 to 65 327 mm 2 5619 to 2 5719 in 33 9975 to 34 0025 mm 1 3385 to 1 3387 in 0 0115 to 0 0240 mm 0 00045 to 0 00094 in 0 013 to 0 022 mm 0 0005 to 0 0009 in 0 24 mm 0 009 in 95 mm 3 74 in 0 165 mm 0 0065 in 0 051 to 0 102 mm 0 0020 to 0 0040 in Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX A SPECIFICATIONS 369 Table 45 Connecting Rods and Piston Assemblies cont Oil control Ring gap in bore Top compression Intermediate compression Oil control Crankcase Crankshaft and Bearings Camshaft and Bushings Table 46 Crankshaft and Camshaft and Bushings Crankshaft Main Bearing Journal Diameter Standard size 0 254 mm 0 010 in under size 0 508 mm 0 020 in under size 0 762 mm 0 030 in under size Main bearing thrust face maximum runout Oil seal journal maximum runout Vibration damper mounting area maximum runout Flywheel mounting surface maximum runout Main bearing to crankshaft running clearance Connecting Rod Journal Diameter Standard size 0 254 mm 0 010 in under size 0 508 mm 0 020 in under size 0 762 mm 0 030 in under size Crankshaft end play maximum Camshaft Bearing journal diameter a
67. ional Truck and Engine Corporation APPENDIX B TORQUES 383 Crankcase Crankshaft and Bearings Camshaft and Bushings Figure 637 Torque sequence for outer lower crankcase bolts 2004 Model Year NOTE For 2004 Model Year install eight M8 x 30 bolts around outside of lower crankcase and torque in sequence to 31 N m 23 Ibf ft EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 384 APPENDIX B TORQUES Figure 638 Tightening sequence for main bearing bolts in lower crankcase 1 Initially torque bolts to 122 N m 90 Ibf ft 2 Increase torque for bolts to 163 N m 120 Ibf ft 3 Finally torque bolts to 231 N m 170 Ibf ft Table 62 Crankcase and Heater Element See tightening procedure and sequence Lower crankcase main bearing cap bolts Figure 637 Lower crankcase outer bolts M8 x 30 standard torque Coolant heater element 41 N m 30 Ibf ft Oil Cooler and Oil Filter Table 63 Oil Cooler and Oil Filter EGR cooler coolant supply port cover M6 10 1 2 N m 84 12 Ibf in Oil cooler mounting bolts M6 x 23 10 1 2 N m 84 12 Ibf in Oil cooler cover mounting bolts M8 x 23 22 2 Nm 17 x 1 Ibf ft Oil filter housing mounting bolts M8 x 75 22 2 Nm 17 x 1 Ibf ft New base plate 6 N m 50 Ibf in Oil filter return tube bo
68. it has a longer ignition delay time Charge air Dense pressurized heated air discharged from the turbocharger Charge Air Cooler CAC See Aftercooler Closed crankcase A crankcase ventilation that recycles crankcase gases through a breather then back to the clean air intake Closed loop operation A system that uses a sensor to provide feedback to the ECM The ECM uses the sensor to continuously monitor variables and adjust to match engine requirements Cloud point The point when wax crystals occur in fuel making fuel cloudy or hazy Usually below 12 C 10 F EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 358 Cold cranking ampere rating battery rating The sustained constant current in amperes needed to produce a minimum terminal voltage under a load of 7 2 volts per battery after 30 seconds Continuous Monitor Test An ECM function that continuously monitors the inputs and outputs to ensure that readings are within set limits Coolant A fluid used to transport heat from one point to another Coolant level switch A switch sensor used to indicate low coolant level Crankcase The housing that encloses the crankshaft connecting rods and allied parts Crankcase breather A vent for the crankcase to releas
69. l System Table 51 Fuel Filter and Pressure Regulating Valve Fuel Filter Type Normal fuel pressure after fuel filter Fuel pressure in filter not to exceed Fuel Pressure Regulating Valve Valve opening pressure Heater element activates Heater element deactivates Rear Cover Flywheel and Power Steering and Fuel Pump 10 micron with water separation 345 to 482 kPa 50 to 70 psi 448 kPa 132 L h 65 psi 35 gal h 351 31 kPa 51 4 5 psi 3 6 to 10 8 C 38 5 to 51 5 F 19 1 to 29 6 C 66 5 to 83 5 F Table 52 Rear Cover Flywheel and Power Steering and Fuel Pump Flywheel Flywheel surface maximum runout manual Flexplate ring gear T I R runout automatic Rear Cover Rear cover face maximum runout Power Steering and Fuel Pump Drive Gear Backlash Crankshaft to idler gear Idler gear to pump drive gear Power Steering Pump Maximum operating pressure EGES295 2 0 25 mm 0 010 in 1 27 mm 0 050 in 0 51 mm 0 020 in 0 173 to 0 288 mm 0 0068 to 0 0113 in 0 173 to 0 288 mm 0 0068 to 0 0113 in 17 5 MPa 2 538 psi Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX B TORQUES 373 Table of Contents Torque G ideliNes RII I IR ene ee ee er RR ends Ea EEEEENNN NE GOE 375 Standard Torques ind d due Ra ee ce cow cece deed nda a
70. l not run if the fuel filter element is not installed The fuel filter element is required to open the valve in the center stand pipe allowing fuel to flow into the filter 3 Move fuel filter drain lever to close Fuel Injectors NOTE See the Cylinder Head and Valve Train section Removal page 106 for installation NOTE If the fuel system has been completely procedures drained prime the fuel system to aid starting Fill the filter housing with clean diesel fuel up to the filter cap threads before installing the cap Priming is not necessary if only the filter housing was drained for regular filter replacement EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 308 FUEL SYSTEM Specifications Table 32 Fuel Filter and Pressure Regulating Valve Fuel Filter Type Normal fuel pressure after fuel filter Fuel Pressure Regulating Valve Valve opening pressure Heater element activates Heater element deactivates Special Torque Table 33 Fuel System Components Fuel supply tube assembly at filter Fuel return tube assembly at filter Left and right cylinder head supply tubing at filter Banjo bolt 12 mm Fuel rail plug assembly 12 mm back of cylinder head Power steering pump inlet elbow fitting Power steering pump outlet elbow fitting Power steering t
71. le effort just to rotate Then when the clamping load is developed or the bolt tension is applied the torque reading mounts rapidly due to thread friction to the specified torque value However the desired bolt tension and maximum clamping effect is not achieved This condition can lead to failure of the fastener to maintain component integrity The correct bolt tension and clamping effect can never be attained if the fastener is dry The fastener threads must have a film of clean lubricant engine oil to be considered lubricated Torque Wrench Extension and Adapters An extension crowfoot or adapter may be needed with a torque wrench to torque a bolt or line fitting that is difficult to reach Adding adapters or extensions will alter the actual clamping force at the fastener Use the following formula to determine the torque wrench setting to achieve the known standard or special torque value lu Tw F H31003 Figure 631 Torque wrench extension 377 e F Force applied by technician L Length through which force is applied to fastener Le Length of extension e L Length of torque wrench Te Torque applied at fastener T Torque applied at end of torque wrench Ts Torque wrench setting Ts Te Lw Lw Le Example A component has a known torque value of 88 N m 65 Ibf ft and an extension is required What should the torque wrench setting be to compensate for the
72. ll journals Bearing inside diameter Journal bushing running clearance Camshaft end play Camshaft gear backlash Maximum permissible cam lobe wear Camshaft thrust plate thickness EGES295 2 0 038 to 0 084 mm 0 0015 to 0 0033 in 0 29 to 0 55 mm 0 011 to 0 021 in 1 40 to 1 66 mm 0 055 to 0 065 in 0 24 to 0 50 mm 0 009 to 0 019 in 80 9873 to 81 0127 mm 3 188 to 3 150 in 80 7333 to 80 7587 mm 3 178 to 3 140 in 80 4793 to 80 5047 mm 3 168 to 3 130 in 80 2253 to 80 2507 mm 3 158 to 3 120 in 0 051 mm 0 002 in 0 05 mm 0 002 in 0 05 mm 0 002 in 0 020 to 0 086 mm 0 0008 to 0 0034 in 0 025 mm 0 001 in 68 99 to 69 01 mm 2 716 to 2 717 in 68 73 to 68 75 mm 2 706 to 2 707 in 68 48 to 68 50 mm 2 696 to 2 697 in 68 23 to 68 25 mm 2 686 to 2 687 in 0 222 mm 0 0087 in 61 987 to 62 013 mm 2 440 to 2 441 in 62 05 to 62 14 mm 2 443 to 2 446 in 0 037 to 0 153 mm 0 0015 to 0 0060 in 0 051 to 0 211 mm 0 002 to 0 008 in 0 179 to 0 315 mm 0 007 to 0 012 in 0 51 mm 0 02 in 3 589 to 3 649 mm 0 1413 to 0 1436 in Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 370 APPENDIX A SPECIFICATIONS Table 46 Crankshaft and Camshaft and Bushings cont Camshaft lobe lift maximum Intake Exhaust Valve timing no 1 cylinder
73. lt Reinstallation 3 N m 23 Ibf in Oil filter cap 25 N m 18 Ibf ft EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX B TORQUES Engine Electrical Table 64 Engine Electrical Exhaust Back Pressure EBP sensor Engine Coolant Temperature sensor ECT Engine Oil Temperature sensor EOT Engine Oil Pressure sensor EOP Glow plug Injection Control Pressure ICP sensor Injection Pressure Regulator IPR Manifold Absolute Pressure MAP sensor Manifold Air Temperature MAT sensor High pressure Oil Pump Table 65 Oil Pump Cover IPR and Heat Shields High pressure oil pump cover bolts Branch tube adapter bolts M6 x 25 Injection Pressure Regulator IPR Rear exhaust heat shield M6 x 12 Rear heat shield M10 x 16 Fuel System Table 66 Fuel System Components Fuel supply tube assembly at filter Fuel return tube assembly at filter Left and right cylinder head supply tubing at filter Banjo bolt 12 mm Plug assembly 12 mm back of cylinder head Power steering pump inlet elbow fitting Power steering pump outlet elbow fitting Power steering tube EGES295 2 12 2 3 N m 385 108 12 Ibf in 108 12 Ibf in 12 2 Nm 108 12 Ibf in 12 2 Nm 12 2 N m 108 12 lbf in 19 N m 168 Ibf in 12 2 Nem 108 18 lbf in 5
74. minimum 110 C 230 F oil temperature Discharge pressure 2 500 rpm End clearance inner and outer rotor to housing Radial clearance between outer rotor and housing Thermostat Type Minimum recommended coolant operating temperature Start to open temperature 0 381 mm 0 015 in stroke Full open temperature 8 mm 0 315 in stroke Connecting Rods and Pistons Table 45 Connecting Rods and Piston Assemblies Connecting Rods Connecting rod length center to center Bushing bore diameter pin end Piston pin bushing inside diameter Material Bearing bore diameter crankshaft end Bearing bore maximum out of round EGES295 2 0 635 mm 0 025 in 1 5 mm 0 060 in Gerotor Crankshaft Gerotor oil pump housing 69 kPa 10 psi 276 kPa 40 psi 483 to 621 kPa 70 to 90 psi 0 025 to 0 095 mm 0 001 to 0 004 in 0 17 to 0 295 mm 0 007 to 0 012 in Balanced pressure wax pellet 71 C 160 F 87 to 91 C 188 to 196 F 104 C 219 F 176 mm 6 929 in 36 98 to 37 02 mm 1 456 to 1 457 in 34 0140 to 34 0215 mm 1 3391 to 1 3394 in I Beam Section Powdered 72 987 to 73 013 mm 2 8735 to 2 8745 in 0 013 mm 0 0005 in Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 368 APPENDIX A SPECIFICATIONS Table 45 Connecting Rods and Piston
75. mostat sensing high air temperature forces fluid through a special coupling The fluid activates the fan Volt v A unit of electromotive force that will move a current of one ampere through a resistance of one Ohm Voltage Electrical potential expressed in volts Voltage drop Reduction in applied voltage from the current flowing through a circuit or portion of the circuit current multiplied by resistance Voltage ignition Voltage supplied by the ignition switch when the key is ON Washcoat A layer of alumina applied to the substrate in a monolith type converter EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 362 TERMINOLOGY EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX A SPECIFICATIONS 363 Table of Contents Variable Geometry Turbocharger VGT ccsssseeeeeenHHH nsnm nnn 365 Manifolds and Exhaust Gas Recirculation EGR eeeeeeeee neeeeeeeeeeeees 365 Cylinder Head and Valve Train ccc cece cece eee e eee e eee Innen 365 Front Cover Vibration Damper and Gerotor Oil Pump eee nnne 367 Connecti
76. n section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 390 APPENDIX C SPECIAL SERVICE TOOLS EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX C SPECIAL SERVICE TOOLS Special Tools Special tools for the VT 365 engine can be ordered from the SPX Corporation 1 800 520 2584 Mounting Engine on Stand Table 69 Mounting Engine on Stand Description Engine Stand Mounting Bracket Variable Geometry Turbocharger VGT Table 70 VGT Description Cap Kit all Dial Indicator with Magnetic Base Intake Guard Manifolds and Exhaust Gas Recirculation EGR Table 71 Manifolds and Exhaust Gas Recirculation EGR Description Anti Seize Compound Cap Kit all EGR Cooler Pressure Test Plates EGR Valve Puller Feeler Gauge Injector Sleeve Brush Intake Manifold Pressure Test Plates Intake Manifold Pressure Test Plug Replaces EGR Valve Intake Port Covers cylinder heads Pressure Test Adaptor intake Straightedge EGES295 2 391 TOOL NUMBER ZTSE4507 Tool Number ZTSE4610 Obtain locally ZTSE4548 Tool Number Obtain locally ZTSE4610 ZTSE4545 ZTSE4669 Obtain locally ZTSE43041 ZTSE4527 ZTSE4544 ZTSE4559 ZTSE4554 Obtain locally Read all safety ins
77. ng Rods and PiStons ccccee cece eee cece e cece nemen nemen 367 Crankcase Crankshaft and Bearings Camshaft and Bushings 369 Oil Cooler and Oil Filt t 2icasi aa ey uaa su rex ERR Re oc cee Seabee Keg EX EXER Er gue U rur dee 371 Engine Electrical iiiinniillee da Rau fiR RR adc ERAROdecia a iaee ERRARRRRRbr lE Rcresa aai 371 High pressure Oil Pump a a M Rmen nar re rn ERE ERR cnc Mede tL aa aE 371 Fuel System sss ren kh aad4addd s AR eet Shia EEEE NAANA AAE RR RR eae 372 Rear Cover Flywheel and Power Steering and Fuel Pump Luuueeees 372 EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 364 APPENDIX A SPECIFICATIONS EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX A SPECIFICATIONS 365 Variable Geometry Turbocharger VGT Table 41 VGT Shaft Maximum turbine shaft axial end play Maximum turbine shaft radial shaft movement play Manifolds and Exhaust Gas Recirculation EGR Table 42 Intake and Exhaust Manifolds Exhaust Manifold Maximum allowable warpage Intake Manifold Maximum allowable clea
78. ngine Corporation APPENDIX A Oil Cooler and Oil Filter Table 48 Oil Cooler and Oil Filter Oil Cooler Type Location Oil Filter Type Location Filter bypass location Oil filter bypass opening pressure Engine Electrical Table 49 Engine Electrical Glow Plugs Location Quantity Camshaft Position CMP Sensor Location Crankshaft Position CKP Sensor Location Operating actuator speed Operating temperature Injection Control Pressure ICP Sensor Operating pressure range Injection Pressure Regulator IPR Valve Operating temperature range Maximum operating pressure High pressure Oil Pump Table 50 Injection Pressure Regulator IPR Valve IPR valve cracking pressure IPR valve maximum pressure SPECIFICATIONS 371 Full flow fin bundle Engine valley forward Cartridge full flow disposable Front oil cooler mounted Oil filter return tube assembly 220 41 kPa 32 6 psi Cylinder Head 8 Crankcase left side Crankcase right side 15 to 2 000 rpm 40 to 130 C 40 to 266 F 3 5 to 20 7 MPa 500 to 3 000 psi 40 to 220 40 to 428 F 28 MPa 4 061 psi Injection Pressure Regulator IPR Valve 31 MPa 4 500 psi 37 MPa 5 400 psi EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 372 APPENDIX A SPECIFICATIONS Fue
79. ol Power TakeOff PTO and remote hand throttle system Steady state condition An engine operating at a constant speed and load and at stabilized temperatures and pressures SAE J215 JAN80 Strategy A plan or set of operating instructions that the microprocessor follows for a desired goal Strategy is the computer program itself including all equations and decision making logic Strategy is always stored in ROM and cannot be changed during calibration Stroke Stroke is the movement of the piston from Top Dead Center TDC to Bottom Dead Center BDC Substrate Material that supports the washcoating or catalytic materials Sulfur dioxide SO Sulfur dioxide is caused by oxidation of sulfur contained in fuel System restriction air The static pressure differential that occurs at a given air flow from air entrance through air exit in a system Usually measured in inches millimeters of water SAE J1004 SEP81 Tachometer output signal Engine speed signal for remote tachometers EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation TERMINOLOGY 361 Thermistor A semiconductor device A sensing element that changes resistance as the temperature changes Thrust load A thrust load pushes or reacts through a bearing in a direction pa
80. on of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation IN CHASSIS PROCEDURES 331 Table of Contents Branch Tube Assembly llllllclexxx x EAEEREN EEEE EEEE re ERR ENEE NEE NANANA EEEE REX ER ERE 333 Removal sirrinin tne ana d a IS BDTRDD E IRRRReiraa ng UR wheats See NERA ARE aaa RAE na aa SAna 333 EIE 340 ore CIg up HemRA 346 Removal ult ceu uri iaa Adna E a a aaa ERR D RR RARNN RD beh ERRARE ett tedio eminus 346 Cleaning and Inspection sso issis tinere e eteneeentee a n x a XR x E cU EE 350 Ic mE 351 CRDIIdCIMPIGI HERES 353 Special Service Tools oorr iiia ette ERR ERR SGTIBAIDRRRRRRIRG BOO AAAA ARAN ccc cccddade d aas 353 EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 332 IN CHASSIS PROCEDURES EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation IN CHASSIS PROCEDURES Branch Tube Assembly Removal A waanine To prevent personal injury or death shift transmission to park or neutral set parking brake and block wheels before doing diagnostic or service procedures A warne To preven
81. or plate onto top of valve bridge inserting small point of plate between the exhaust rocker and valve bridge NOTE If exhaust rocker is severely worn insert a small pry bar between the exhaust rocker arm and valve bridge Compress the valve bridge down to raise the rocker for enough clearance to rotate the small point of the compressor plate between the two components Figure 622 Valve spring compressor plate installed 1 Valve spring compressor plate 2 Exhaust rocker arm 12 Once compressor plate is in position install valve spring compressor bolt through plate and into valve spring compressor base 13 Using a hand wrench tighten bolt to compress valve springs until plate contacts top of valve spring compressor base CAUTION To prevent engine damage do not use power tools 14 Disengage rocker arm from push rod while rotating rocker arm and compressing rocker arm clip simultaneously 15 Remove rocker arm and retaining clip CAUTION To prevent engine damage account for two 3 8 rocker arm pivot balls If balls fall onto cylinder head retrieve balls with magnet IN CHASSIS PROCEDURES CAUTION To prevent engine damage account for each rocker arm pivot and pivot retainer Failure to account for broken pieces requires removal of oil pan to retrieve Figure 623 Damaged rocker arm pivot and retainer 1 Retainer partially missing unaccounted for 2 Retainer cracked intact and accounted for 16
82. oration IN CHASSIS PROCEDURES 335 D31507 Figure 592 Parts for removal 1 Turbocharger air inlet duct 6 Pump gasket heat shield 10 EGR Drive Module 2 Glow plug relay 7 Rear cover 3 Turbocharger exhaust flange 8 V clamp Shielded tube exhaust 4 Rear engine mounting bracket assembly to turbocharger 2 9 Electronic Control Module 5 V clamp Right exhaust tube to ECM Injector Drive Module EGR cooler IDM 14 Loosen V clamp connecting shielded tube 15 Loosen V clamp connecting right exhaust tube to exhaust assembly to turbocharger EGR cooler EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 336 Figure 593 Air Management System parts 1 2 3 20 21 22 Shielded tube exhaust assembly 4 Turbocharger exhaust flange 5 Exhaust tube assembly right Remove two M8 bolts and nuts connecting shielded tube exhaust assembly to left exhaust manifold Remove two M8 bolts and nuts connecting right exhaust tube to right exhaust manifold Leaving right exhaust tube attached remove shielded tube exhaust assembly Remove three bolts from pump gasket heat shield and remove heat shield Unplug the EGR drive module and remove module and mounting bracket Unplug ECM and IDM electrical connectors See Engine Service
83. propane or mixing propane with the recommended fuels specified in the Engine Operation and Maintenance Manual could cause engine damage International Truck and Engine Corporation will not honor warranty claims against engines that have used fuels other than recommended fuels 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 D06152 Figure 530 Removal of prescreen element 1 Power steering pump 2 Fuel pump 3 Prescreen bowl 1 Use a 30 mm box end wrench to remove prescreen bowl from fuel pump assembly 2 Clean prescreen element after inspection or replace if necessary EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 302 FUEL SYSTEM Fuel Filter Element 1 Place a suitable container at end of fuel drain line to catch draining fuel 1 Place a suitable container at end of fuel drain line to catch draining fuel 2 Move fuel filter drain lever to DRAIN and shut drain lever when filter is empty Figure 531 Fuel filter drain lever to DRAIN Move fuel filter drain lever to DRAIN Remove fuel filter cap Use an oil filter wrench if necessary Figure 533 Fuel supply and re
84. rallel to the shaft Top Dead Center TDC The uppermost position of the piston during the stroke Torque A force having a twisting or turning effect For a single force the cross product of a vector from some reference point to the point of application of the force within the force itself Also known as moment of force or rotation moment Torque is a measure of the ability of an engine to do work Truck Computer Analysis of Performance and Economy TCAPE Truck Computer Analysis of Performance and Economy is a computer program that simulates the performance and fuel economy of trucks Turbocharger A turbine driven compressor mounted to the exhaust manifold The turbocharger increases the pressure temperature and density of intake air to charge air Variable capacitance sensor A variable capacitance sensor is measures pressure The pressure forces a ceramic material closer to a thin metal disc in the sensor changing the capacitance of the sensor Vehicle Electronic System Programming System The computer system used to program electronically controlled vehicles Vehicle Retarder Enable Engage Output from the ECM to a vehicle retarder Vehicle Speed Sensor VSS Normally a magnetic pickup sensor mounted in the tailshaft housing of the transmission used to indicate ground speed Viscosity The internal resistance to the flow of any fluid Viscous fan A fan drive that is activated when a ther
85. rance Injection Control Pressure ICP Sensor Operating pressure range Cylinder Head and Valve Train Table 43 Cylinder Head and Valve Train Exhaust Valves Stem diameter Stem to guide clearance max allowable before replacement Face to stem runout T I R max Valve face angle Valve margin minimum Valve recession in head Intake Valves Stem diameter Stem to guide clearance max allowable before replacement Face to stem runout T I R max Valve face angle Valve margin minimum Valve recession in head EGES295 2 0 091 mm 0 0036 in 0 5 mm 0 02 in 0 08 mm 0 003 in Between ports 0 13 mm 0 005 in Total 0 25 mm 0 010 in 3 5 to 20 7 MPa 500 to 3 000 psi 6 947 to 6 965 mm 0 2735 to 0 2742 in 0 140 mm 0 0055 in 0 038 mm 0 0015 in 37 5 1 35 mm 0 053 in 0 50 0 18 mm 0 020 0 007 in 6 947 to 6 965 mm 0 2735 to 0 2742 in 0 140 mm 0 0055 in 0 0038 mm 0 0015 in 30 0 1 40 mm 0 055 in 0 50 0 18 mm 0 020 0 007 in Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 366 APPENDIX A SPECIFICATIONS Table 43 Cylinder Head and Valve Train cont Cylinder Heads Valve guide inside diameter 7 003 to 7 029 mm 0 276 to 0 277 in Valve guide bore runout 0 05 mm 0 002 in Valve guide taper maximum
86. s cautions and notes 2006 International Truck and Engine Corporation APPENDIX C SPECIAL SERVICE TOOLS Front Cover Vibration Damper and Gerotor Oil Pump Table 73 Front Cover Vibration Damper and Gerotor Oil Pump Description Dial Indicator with Magnetic Base Fan Hub Wrench 2 inch Fan Wrench pulley bolts Front Seal Wear Sleeve Installer Front Wear Sleeve Remover Liquid Gasket RTV 6 oz tube Loctite amp Hydraulic Sealant Connecting Rods and Pistons Table 74 Connecting Rods and Pistons Description Dial Indicator with Magnetic Base Piston Gauge Pins 0 082 in Piston Ring Compressor Cope Piston Ring Expansion Pliers Telescoping Gauge Set EGES295 2 393 Tool Number Obtain locally ZTSE43972 ZTSE4587 ZTSE4516 ZTSE4517 1830858C1 Obtain locally Tool Number Obtain locally ZTSE4513 ZTSE4514 Obtain locally Obtain locally Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 394 APPENDIX C SPECIAL SERVICE TOOLS Crankcase Crankshaft and Bearings Camshaft and Bushings Table 75 Crankcase Crankshaft and Bearings Camshaft and Bushings Description Accessory Drive Gear Puller Camshaft Bushing Kit Camshaft Bushing Remover Installer expanding collet Crankshaft Timing Tool Cylinder Bore Gauge Deglazing Hone four inch Dial Indicator wi
87. s performance as a gear thrust surface EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE 2 Make sure that the rear cover gasket is in place before installing the rear cover A WARNING To prevent personal injury or death get help when installing the rear cover Figure 569 Rear cover 3 Install rear cover assembly with the aid of an assistant D06150 Figure 570 Rear cover mounting bolts 1 Bolts marked A M10 x 55 5 2 Bolts marked B M10 x 70 2 3 Bolts marked C M10 x 60 4 321 4 Install eleven rear cover mounting bolts Tighten all bolts to the standard torque Secondary Flange CAUTION To prevent possible damage to the engine transmission or truck correct dowel pin protrusion is critical when aligning the flywheel or flexplate and the reinforcement ring 1 Install the dowel pin in the secondary flange gear Figure 571 gear Dowel pin in the secondary flange 2 Use a dial caliper to verify the protrusion height Dowel pin protrusion should be 8 0 0 25 mm 0 315 0 01 in 3 Clean the inside surfaces and the inner face surface of the secondary flange gear CAUTION To prevent possible damage to the engine or truck do not apply sealant on the face o
88. s it is pumped through the fuel system Fuel strainer A pre filter in the fuel system that keeps larger contaminants from entering the fuel system EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation TERMINOLOGY Fully equipped engine A fully equipped engine is an engine equipped with only those accessories necessary to perform its intended service A fully equipped engine does not include components that are used to power auxiliary systems If these components are integral with the engine or for any reason are included on the test engine the power absorbed may be determined and added to the net brake power SAE J1995 JUN90 Fusible link fuse link A fusible link is a special section of low tension cable designed to open the circuit when subjected to an extreme current overload SAE J1156 APR86 Gradeability The maximum percent grade which the vehicle can transverse for a specified time at a specified speed The gradeability limit is the grade upon which the vehicle can just move forward SAE J227a Gross Combined Weight Rating GCWR Maximum combined weight of towing vehicle including passengers and cargo and the trailer The GCWR indicates the maximum loaded weight that the vehicle is allowed to tow Gross brake horsepower The power of a complet
89. shaft flange and the secondary flange and cause leakage Figure 575 Secondary flange 9 Remove nuts washers and studs after flange has been seated EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE CAUTION To prevent possible engine or vehicle damage do not drive the idler gear onto the shaft this could damage the gear and gear teeth For correct fit rotate the gear for the power steering and fuel pump assembly CAUTION To prevent possible engine or vehicle damage ensure the circular witness groove is facing you Installing the gear in backwards will cause abnormal wear and damage to the gear Figure 576 Power steering idler gear 10 Install power steering idler gear on shaft NOTE The gear of the power steering and fuel pump assembly may have to be rotated for correct fit of the gears Do not drive the gear onto the shaft 11 Verify correct gear orientation and gear teeth engagement AM nin To prevent personal injury or death wear safety glasses with side shields to protect eyes 323 Figure 577 Power steering idler gear retaining ring on shaft 12 Install retaining ring onto the shaft for the power steering idler gear Figure 578 Idler gear backlash 13 Check the idler gear ba
90. t cylinder head tube assembly 305 4 Connect fuel tubing fittings to fuel filter assembly and leave hand tight Connect banjo fitting ends to the left and right cylinder heads Anchor right fuel tubing to EGR cooler stud Tighten all fittings to the special torque Table 33 Figure 539 Connections for fuel supply and return tubing 1 Fuel return tube assembly 2 Fuel supply tube assembly 5 Connect chassis fuel supply and return tube assembly to fuel filter assembly and tighten fittings to the special torque Table 33 NOTE Fuel filter drain lever must be closed Priming the Fuel System Priming without Vacuum Source NOTE If the fuel system will not prime during diagnosis the engine will exhibit white to black smoke and pulsating fuel pressure See Combustion Leaks to Fuel in Section 4 of Engine Diagnostics Manual EGES 240 If the engine is out of fuel do the following steps 1 Add fuel to tank If equipped with dual tanks add fuel to passenger side tank Check fuel level in operator side tank to verify transfer pump is operating correctly EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 306 Figure 540 Removal of fuel filter cap 2 Remove fuel filter cap using a band wrench Leave filter in housing 3 Fill fuel filter housing with diesel fu
91. t personal injury or death make sure the engine has cooled before removing components A 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 discard clothing and rags contaminated with engine fluids 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 pour fluids on the ground in sewers or bodies of water 333 A warnine To prevent personal injury or death always disconnect main negative battery cable first Always connect the main negative battery cable last 1 Disconnect negative battery cable and Electronic Control Module ECM ground 2 Drain air tanks if equipped 3 Remove inside engine cover from truck if equipped See Truck Service Manual 4 Remove the right inner fender well if required EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 334 IN CHASSIS PROCEDURES Figure 591 Parts for removal Engine In chassis 4100 truck 1 Air intake duct 5 Air conditioning compressor 9 Air filter housing 2 Air compressor 6 Serpentine drive belt 10 Exhaust down pipe 3 Turbocharger air inlet duct 7 Belt
92. tank using vacuum source until level in fuel filter housing reaches fitting 5 Disconnect vacuum source and fuel pressure test coupler from fuel pressure test fitting 6 Engage starter for 30 seconds and allow starter to cool for two minutes NOTE Return ignition key to RUN only between starts to decrease load on batteries This will prevent glow plugs from recycling EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation FUEL SYSTEM CAUTION To prevent damage to the starter if engine fails to start within 30 seconds release ignition switch and wait 2 to 3 minutes to allow starter motor to cool Repeat above procedure 7 Repeat step 6 until engine starts and runs on its own Three to five cranking periods will be required to start vehicle Additional cranking periods may be required if fuel filter is not primed 8 After engine has been started and is running smoothly stop engine and remove fuel pressure test fitting and reinstall plug in filter housing Fuel Filter Element 307 1 Apply coating of diesel fuel to new bevel gasket and install on fuel filter assembly 2 Install new fuel filter element in fuel filter housing and tighten cap onto fuel filter assembly CAUTION To prevent engine damage tighten fuel cap on fuel filter assembly The engine wil
93. th Magnetic Base Freeze Plug Installer Front Seal Wear Sleeve Installer Front Wear Sleeve Remover Head Bolt Bottoming Tap Hot Plate Liquid Gasket RTV 6 oz tube Oil Gallery Cleaning Brush Oil Gallery Plug Driver Piston Gauge Pins 0 082 in Straightedge Telescoping Gauge Set Oil Cooler and Oil Filter Table 76 Oil Cooler Description Magnetic Cover Oil Cooler Pressure Test Plate Engine Electrical Table 77 Engine Electrical Description Cap Kit all EGR Valve Puller Glow Plug Connector Remover Installer EGES295 2 Tool Number ZTSE4520 ZTSE2893A ZTSE4489 ZTSE4519 Obtain locally ZTSE4349 Obtain locally ZTSE4509 ZTSE4516 ZTSE4517 ZTSE4508 Obtain locally 1830858C1 ZTSE4511 ZTSE4512 ZTSE4513 Obtain locally Obtain locally Tool Number ZISE4557 ZISE4525 Tool Number ZTSE4610 ZTSE4669 ZTSE4670 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation APPENDIX C SPECIAL SERVICE TOOLS High pressure Oil Pump Table 78 High pressure Oil Pump Description Cap Kit all Dial Indicator with Magnetic Base IPR Valve Removal Tool Liquid gasket RTV 6 oz tube Magnetic Cover Quick Release Tool Fuel System Table 79 Fuel System Description Cap Kit all Dial Indicator with Magnetic Base IPR Valve Removal Tool Liquid Gasket RTV 6 oz tube Magneti
94. th a stiff brush and suitable solvent Dry all with filtered compressed air Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE Installation Rear Cover and Power Steering Idler Shaft A warnine To prevent personal injury or death wear safety glasses with side shields to protect eyes 1 If removed install the power steering idler shaft into the rear cover Make sure the bore of the idler shaft is clean D06117 Figure 562 Retaining ring on idler shaft 2 Place a retaining ring on the end of the shaft without the threaded hole Figure 563 installation tool Idler shaft and retaining ring in 319 3 Put the threaded hole end of the idler shaft into the installation tool to set the correct height 34 6 X 0 15 mm 1 362 0 006 in Figure 564 Power steering idler shaft in transmission side of rear cover 1 Power steering idler shaft Section A A A warnine To prevent personal injury or death wear safety glasses with side shields to protect eyes Figure 565 Idler shaft in the rear cover assembly CAUTION To prevent engine damage do not allow the retaining ring to contact the rear cover Contact may distort the retaining ring adversely affecting its performance as a gear thrust surfa
95. the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 342 IN CHASSIS PROCEDURES Figure 607 Air Management System parts 1 Shielded tube exhaust assembly 4 Exhaust manifold right 6 Pump gasket heat shield 2 Turbocharger exhaust flange 5 V clamp Shielded tube exhaust 7 Exhaust manifold left 3 Exhaust tube assembly right assembly to turbocharger 15 Position pump gasket heat shield and install three 21 See Engine Service Manual Rear Cover bolts finger tight Flywheel and Power Steering Gear Drive for 16 Tighten two M6 x 12 heat shield bolts to the metalation fne Tellowing special torque Table 68 and one M10 x 16 heat Rear cover assembly shield bolt to the special torque Table 68 Crankshaft secondary flange 17 Position shielded exhaust tube assembly on engine with right exhaust tube and EGR cooler SFOWOESISOnHg idlotgeak gasket attached Install four M8 exhaust bolts and Rear oil seal carrier nuts finger tight to secure assembly to exhaust manifolds Power steering and fuel pump assembly 18 Position V clamp to connect shielded tube ELO I LUE exhaust assembly to turbocharger and tighten 22 Reinstall wiring clips on rear cover if necessary V clamp to the special torque Table 68 23 Install rear engine mounting brackets on the rear 19 Position V clamp to connect right exh
96. tor removal 4 Push in the spring loaded clip in the engine 1 Injector Connector Release Tool harness connector to the fuel injector connector 2 Fuelinjector connector and remove engine harness connector 5 Install the Injector Connector Release Tool Table 40 6 Push Injector Connector Release Tool to pop loose spring clips on the injector connector and remove connector from the rocker arm carrier D31554 Figure 614 Fuel Injector Hold Down Wrench EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 348 Figure 615 Removal of fuel injector hold down clamp 1 Fuel injector assembly 2 Hold down clamp 3 Fuel Injector Hold Down wrench 7 Remove the fuel injector hold down clamp assembly using the Fuel Injector Hold Down Wrench Table 68 8 Remove injector and place into injector cup CAUTION To prevent engine damage insert a clean paper towel inside injector sleeve to keep foreign material out Figure 616 On engine Valve Spring Compressor Tool 1 Valve spring compressor plate 2 Valve spring compressor base 3 Valve spring compressor bolt IN CHASSIS PROCEDURES Figure 617 Fuel injector hold down clamp assembly 1 Bolt M8 X 45 2 Retainer 3 Clamp alignment index Figure 618 Fuel injector hold down clamp
97. tructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 392 APPENDIX C SPECIAL SERVICE TOOLS Cylinder Head and Valve Train Table 72 Cylinder Head and Valve Train Description Bottoming Tap metric Case to head Removal Tool Cylinder Head Lifting Bracket Cylinder Head Pressure Test Plate Dye Penetrant Kit Fuel Gallery Cleaning Brush Fuel Injector Hold Down Wrench Fuel Injector Rack Holder Fuel Injector Tip Cleaning Brush Glow Plug Sleeve Brush nylon Glow Plug Sleeve Installer Glow Plug Sleeve Remover both the tap and the bolt and sleeve adapter Glow Plug Sleeve Seat Wire Brush Injector Connector Remover Injector Sleeve Brush Injector Sleeve Installer Injector Sleeve Remover both the tap and the slide hammer adapter Liquid Gasket RTV 6 oz tube Quick Release Tool Quick Release Tool Kit Slide Hammer Kit Straightedge Valve Guide Gauge Tool C Type Valve Spring Compressor Valve Spring Tester EGES295 2 TOOL NUMBER ZTSE4508 ZTSE4694 ZTSE4535 ZTSE4534 PT 7191 ZTSE4541 ZTSE4524 ZTSE4299B ZTSE4301 ZTSE4533 ZTSE4532 ZTSE4531 ZTSE4589 ZTSE4650 ZTSE43041 ZTSE4529 ZTSE4528 1830858C1 ZTSE4581 ZTSE4454 ZTSE4398 Obtain locally ZTSE4577 ZTSE1846 ZTSE2241 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warning
98. ts D0739 Figure 590 Torque sequence for flywheel 6 Snug bolts in the sequence to 1 to 7 N m 12 to 60 Ibf in 7 Torque all bolts in the sequence to the special torque Table 36 8 Reinstall safety guards shields and covers EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation 328 REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE 9 Make sure tools cleanliness covers loose parts and service equipment are removed from the engine area EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE Specifications 329 Table 35 Flywheel Rear Cover Power Steering and Fuel Pump Flywheel Flywheel surface maximum runout manual Flexplate ring gear T I R runout automatic Idler Gear Idler gear shaft height Dowel Pin Dowel pin protrusion in secondary flange Rear Cover Rear cover face maximum runout Power Steering and Fuel Pump Drive Gear Backlash Crankshaft to power steering and fuel pump idler gear Power steering idler gear to power steering and fuel pump drive gear Power Steering Pump Maximum operating pressure
99. turn tubing 4 Remove and discard the bevel cut gasket and 1 Fuel return tube clean mating surfaces 2 Fuel supply tube 5 Lift fuel filter element from housing Remove chassis fuel supply tube Fuel Filter Assembly and Tubing Remove chassis fuel return tube Remove fuel filter water drain tubing Dap g Remove left cylinder head fuel supply tubing from fuel filter assembly NOTE To remove the right cylinder head fuel supply tubing it may be necessary to remove the oil filter cap assembly from the oil filter housing This allows counterclockwise movement of the tube to be removed from the intake manifold 7 Remove right cylinder head fuel supply tubing 8 Cap all openings to the fuel filter assembly Figure 532 Fuel filter lever to DRAIN EGES295 2 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation FUEL SYSTEM 303 9 Remove two M10 x 20 bolts that secure fuel filter support bracket to intake manifold 10 Remove fuel filter assembly Fuel Injectors NOTE See Cylinder Head and Valve Train section Removal page 106 for removal procedures Inspection 1 Inspect fuel lines for damage Replace fuel lines Figure 534 Removal of fuel filter support bracket if necessary EGES295 2 Read all safety instructions in the Safety Information section of this m
100. ube Special Service Tools Table 34 Fuel System Description Cap Kit All Fuel Gallery Cleaning Brush EGES295 2 10 micron with water separation 345 to 482 kPa 50 to 70 psi 351 31 kPa 51 5 psi 3 6 to 10 8 C 38 5 to 51 5 F 19 1 to 29 6 C 66 5 to 83 5 F 41 4Nm 25 2Nm 25 2Nm 38 4 Nm 27 1Nm 90 10 N m 45 4 Nm 79 4 N m 30 3 Ibf ft 19 2 Ibf ft 18 2 Ibffft 28 3 Ibf ft 20 1 Ibf ft 66 7 lbf ft 33 3 Ibf ft 5 58 3 Ibf ft Tool Number ZTSE4610 ZTISE4541 Read all safety instructions in the Safety Information section of this manual before doing any procedures Follow all warnings cautions and notes 2006 International Truck and Engine Corporation REAR COVER FLYWHEEL AND POWER STEERING GEAR DRIVE 309 Table of Contents hiuc 311 Preliminary Checks 2 04d digi i i ecccu illl llemlli tete Rad RR ARRA d RR Rn nns 311 Flexplate Automatic Transmission ceeseeeeeen II 311 Flywheel Manual Transmission cseeeeeeeeee nmm nnn 311 Flywheel Surface Runout rre eere nnn nta n x Rex ENTM MI MEE RAE nuu 311 Rear Cover R noUt 22ccsdididddadaddsi ara Raga usua uaa aser rrr KANENN N NANA NARE RR RR 311 Backlash Test for Secondary Flange Crankshaft Gear eeeseeeeeeee 312 Backlash Test for Power Steering Idler Gear ccccceeee eee eee eee eee eeeeeeeeeeeeeeeeee 312

Service Manual 04-06 Part 4 (Fuel System).

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