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