International VT 365 Diesel Engine Service Manual 2004-2006

SERVICE MANUAL INTERNATIONAL® VT 365 DIESEL ENGINE EGES-295-2 2004-2006 Model Years SERVICE MANUAL INTERNATIONAL® VT 365 DIESEL ENGINE 2004-2006 Model Years EGES-295-2 © 2006 International Truck and Engine Corporation Printed in the United States of America

Page 1

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

Follow all warnings, cautions, and notes. ©2006 International Truck and Engine Corporation

Page 3

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

Page 4

ENGINE SERVICE MANUAL 1 Foreword Technical Service Literature International Truck and Engine Corporation is committed to continuous research and development to improve products and introduce technological advances. Procedures, specifications, and parts defined in published technical service literature may be altered. 1171814R2 VT 365 Engine Operation and Maintenance Manual EGES-295-2 VT 365 Engine Service Manual EGES-240 VT 365 Engine Diagnostic Manual EGED-245 VT 365 Hard Start and No Start Diagnostic Form NOTE: Photo illustrations identify specific parts or assemblies that support text and procedures; other areas in a photo illustration may not be exact.

EGED-250 VT 365 Performance Diagnostics Form This manual includes necessary information and specifications for technicians to maintain International® diesel engines. See vehicle manuals and Technical Service Information (TSI) bulletins for additional information. EGED-320-1 VT 365 Electronic Control System Diagnostic Form CGE-575 Engine Diagnostic Trouble Codes Technical Service Literature is revised periodically and mailed automatically to “Revision Service” subscribers. If a technical publication is ordered, the latest revision will be supplied. NOTE: The following order information is for technical service literature only.

International Truck and Engine Corporation Printing and Distribution Services C/O Moore Wallace North America 1750 Wallace Avenue St. Charles, IL 60174 Telephone: 630-313-7507 EGES295-2 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©2006 International Truck and Engine Corporation

Page 5