International VT365 Service Manual Part 3
International VT365 Service Manual Part 3
International VT365 Service Manual Part 3
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Valve Covers, ICP Sensor, and Rear Heat Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Injection Control Pressure (ICP) Sensor (right high-pressure oil rail). . . . . . . . . . . . . . . . . . . .106
Valve Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
ICP Sensor (right high-pressure oil rail). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
High-pressure Oil Rail Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Rocker Arm Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Valve Bridges and Pushrods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Cylinder Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Hydraulic Cam Followers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Removing Valves from Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Fuel Injector Sleeve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Glow Plug Sleeve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Rocker Arm Carrier Fulcrum Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Fuel Injector Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Glow Plug Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Install Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Rocker Arm Carrier Fulcrum Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Hydraulic Cam Follower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Cylinder Head Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Valve Bridges and Push Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Rocker Arm Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Tightening Sequence for Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
M14 x 193 Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
M8 x 70 Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Replace Copper Gasket and O-rings for Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
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
100 CYLINDER HEAD AND VALVE TRAIN
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
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
CYLINDER HEAD AND VALVE TRAIN 101
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
102 CYLINDER HEAD AND VALVE TRAIN
Exploded Views
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 103
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
104 CYLINDER HEAD AND VALVE TRAIN
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 105
Figure 134 Rocker arm carrier and cylinder head components (typical)
1. Injector harness connector (4) 5. Exhaust fulcrum plate 9. Fulcrum plate (dual) (3)
2. Case-to-head tube assembly 6. Injector assembly (4) 10. Intake fulcrum plate
3. Intake rocker arm (4) 7. Glow plug (4)
4. Exhaust rocker arm (4) 8. Valve bridge (8)
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
106 CYLINDER HEAD AND VALVE TRAIN
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
CYLINDER HEAD AND VALVE TRAIN 107
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
108 CYLINDER HEAD AND VALVE TRAIN
NOTE: Unless replacing the breather housing, leave 9. Remove four breather opening gaskets. Keep
breather housing on the left valve cover. gaskets for cleaning and inspection
6. Remove the left valve cover gasket. Keep gasket
for cleaning and inspection. ICP Sensor (right high-pressure oil rail)
Breather Housing
NOTE: Remove the breather housing for replacement
only. The breather housing may be removed with the
left valve cover on or off the engine.
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 109
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
110 CYLINDER HEAD AND VALVE TRAIN
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 111
Fuel Injectors
NOTE: Do not drain the fuel rail, if removing an injector
from chassis.
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
112 CYLINDER HEAD AND VALVE TRAIN
CAUTION: To prevent damage to fuel injector 1. Using a circular pattern loosen and remove ten
assemblies, do not use air power tools to remove M14 x 193 bolts from cylinder head. Begin with
or install injectors. the outer bolts and move inward.
4. Use the Fuel Injector Hold Down Wrench (Table
12) to remove the hold down clamp assembly.
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 113
Figure 158 2005 Model Year (two M8 mounting Figure 160 Rocker arm carrier
bolts for rocker arm carrier)
1. Alignment guide (2) 3. Lift rocker arm carrier assembly from cylinder
2. M8 x 50 bolt (2) head and set aside for disassembly, cleaning,
inspection, and assembly.
Figure 159 2006 Model Year (two M10 mounting Figure 161 Valve bridge (left cylinder head)
bolts for rocker arm carrier)
1. Alignment guide (2)
1. Identify each valve bridge and corresponding
2. M10 x 50 bolt (2)
valve set so they can be installed in their original
locations.
2. Remove bolts from rocker arm carrier. Example: 2 - I
• Cylinder number 2 as counted from the front
of engine
• I = Intake, E = Exhaust
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
114 CYLINDER HEAD AND VALVE TRAIN
Cylinder Heads
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 115
Figure 166 Cylinder head removal Figure 167 Cam followers and roller follower
guides
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
116 CYLINDER HEAD AND VALVE TRAIN
Figure 169 Valve spring compression Figure 171 Valve spring retainer
1. Use a “C” Type Valve Spring Compressor (Table 3. Remove valve spring.
12), to compress valve springs. Remove valve
retainer keys. A small magnet is useful.
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 117
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
118 CYLINDER HEAD AND VALVE TRAIN
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 119
CAUTION: To prevent engine damage, if replacing 2. Cut threads in the glow plug sleeve – at least 1/2
glow plug sleeves in chassis, put a small plug in the inch deep for the Glow Plug Sleeve Remover (bolt
bottom of the glow plug sleeve before cutting threads. and sleeve adapter) (Table 12).
The plug will prevent small metal chips from entering
the combustion chamber.
NOTE: Glow plug sleeve removal is not required
unless sleeves are damaged. If sleeve replacement
is required, see Cleaning, Inspection, and Testing in
this section.
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
120 CYLINDER HEAD AND VALVE TRAIN
1. Remove eight M8 x 65 bolts and spacers holding exhaust fulcrum plate from the rocker arm carrier.
rocker arm fulcrums to the rocker arm carrier. Do steps 3 through 6 to disassemble.
2. Remove – as assemblies – the intake fulcrum
plate, three dual rocker fulcrum plates, and
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 121
Figure 186 Separation of rocker arm from Figure 188 Rocker arm clip removed (typical)
fulcrum plate (typical)
1. Fulcrum plate
1. Rocker arm 2. Rocker arm clip
2. Fulcrum plate
3. Rocker arm clip
6. Remove and discard rocker arm clip.
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
122 CYLINDER HEAD AND VALVE TRAIN
Cleaning, Inspection, and Testing 6. Use a Bottoming Tap (metric) (Table 12) to clean
each tapped hole in crankcase top deck. Remove
Cylinder Head and Crankcase Components
debris with filtered compressed air.
1. With valves installed to protect seats, use a
7. Thoroughly clean pushrods with a suitable
scraper and wire brush to remove deposits and
solvent. Dry with filtered compressed air.
gasket material from valve heads and gasket
surface. Do not damage gasket surface of
cylinder head.
Cylinder Head Inspection – Valves Installed
2. Use a suitable solvent to remove dirt, grease, and
NOTE: Inspect cylinder head for thickness, warping,
deposits from removed parts.
cracks, and valve leakage.
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 123
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
124 CYLINDER HEAD AND VALVE TRAIN
Figure 196 Spraying developer onto cylinder 9. Position cylinder head on wooden blocks with
head gasket surface facing down and spray mineral
spirits into intake and exhaust ports.
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 125
Cylinder Head Inspection – Valves Removed 4. Install pressure test regulator and gauge
assembly to cylinder head test plate (Table 12).
WARNING: To prevent personal injury or 5. With the valves removed from the cylinder head,
possible death, wear safety glasses with side clean all valve guides using a nylon brush, soap
shields to protect eyes. Limit compressed air and water. Blow out any residue with filtered
pressure to 207 kPa (30 psi). compressed air.
1. Pressure testing the cylinder head will reveal 6. Position an inspection light at the bottom of the
cracks in ports or sleeve leakage which cannot valve guide bores and examine the walls for
be seen, using dye penetrant. Pressure test the burning or cracking. Replace the cylinder head,
cylinder head as follows: if necessary.
Figure 200 Cylinder head test plate Figure 201 Measurement of Small Hole Gauge
(valve guide ID)
1. Mounting bolt (15)
2. Pressure test plate
3. Pressure gauge and regulator 7. Measure each valve guide by using a small
hole gauge (Table 12) and a 0-1 inch outside
micrometer.
2. Fasten Cylinder Head Pressure Test Plate (Table
12) with rubber gasket attached to gasket side of 8. Record each valve guide inner diameter so
cylinder head. Secure plate with ten M14 and five valve-to-guide running clearance may be
M8 mounting bolts. determined.
3. Immerse cylinder head in water. Apply air • If valve guide inner diameter exceeds
pressure and adjust to 124 to 138 kPa (18 to specifications (Table 10), replace cylinder
20 psi) and inspect for leaks in the following head.
places. If leaks are seen, install new cylinder 9. Using the valve guide inside diameter and
head. valve stem diameter measurements, determine
• Ports valve stem-to-guide running clearance. See
Specifications (Table 10). Replace valve if
• Upper cylinder head deck necessary.
• Lower cylinder head deck 10. Clean valve seat area using suitable solvent,
• Nozzle sleeve area before inspection.
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
126 CYLINDER HEAD AND VALVE TRAIN
11. Inspect the exhaust valve seats for burned or locations 90° apart. See Specifications (Table 10).
cracked conditions. If any of these conditions Replace valves that exceed the specification for
exist, replace cylinder head. minimum stem diameter.
NOTE: The intake valve has a larger diameter head.
Push Rods
1. Inspect pushrods for wear and deposits that
may restrict oil flow into rocker arm assemblies.
Replace pushrod 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
CYLINDER HEAD AND VALVE TRAIN 127
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
128 CYLINDER HEAD AND VALVE TRAIN
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 129
Rocker Fulcrums
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
130 CYLINDER HEAD AND VALVE TRAIN
Installation
Fuel Injector Sleeve
Do the following steps when installing a new fuel
injector sleeve:
1. Verify injector bore is completely clean and dry.
2. Put fuel injector sleeve on Injector Sleeve
Installer. (Table 12).
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
CYLINDER HEAD AND VALVE TRAIN 131
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
132 CYLINDER HEAD AND VALVE TRAIN
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 133
3. Position lower part of rocker arm under rocker arm 6. Assemble the dual rocker fulcrum plates to
clip, push up with your palm, and use thumb back carrier assembly by orienting the E and I up and
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
134 CYLINDER HEAD AND VALVE TRAIN
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 135
NOTE: See” High-pressure Oil Pump” section, for to the standard value (Standard Torques, page
procedure to mount branch tube assembly over rear 375).
cam follower guides.
4. Install an M6 x 15 bolt with washer on roller
follower guides (front guides only) and torque bolt
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
136 CYLINDER HEAD AND VALVE TRAIN
Figure 226 2004 and 2005 Model Year (eight M8 mounting bolts for rocker arm carrier)
1. Cylinder head gasket 3. Fuel injector hold down clamp 5. M8 dowel sleeve bushing (2)
2. 18 mm spring dowel pin (2) (4) 6. Rocker arm carrier
4. Cylinder head 7. M8 bolt (8)
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 137
Figure 227 2005 Model Year (two M8 mounting bolts for rocker arm carrier)
1. Cylinder head gasket 3. Fuel injector hold down clamp 5. M10 dowel sleeve bushing (2)
2. 18 mm spring dowel pin (2) (4) 6. Rocker arm carrier
4. Cylinder head 7. M8 bolt (2)
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
138 CYLINDER HEAD AND VALVE TRAIN
Figure 228 2006 Model Year (two M10 mounting bolts for rocker arm carrier)
1. Cylinder head gasket 3. Fuel injector hold down clamp 5. M10 dowel sleeve bushing (2)
2. 20 mm spring dowel pin (2) (4) 6. Rocker arm carrier
4. Cylinder head 7. M10 mm bolt (2)
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 139
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
140 CYLINDER HEAD AND VALVE TRAIN
CAUTION: Threads in crankcase bolt holes must be NOTE: Use care to avoid scratching blue compound
clean and blown dry with filtered compressed air. Dirt on cylinder head gaskets.
or oil left in holes may cause binding or a false torque
3. Align new cylinder head gasket with spring dowel
reading during assembly.
pins and press to install.
CAUTION: To prevent engine damage, make sure
• For 2004 and 2005 cylinder heads, use
cylinder head and head gasket are clean and
cylinder head gasket with 18 mm with
free of debris. A contaminated seal between the
clearance holes for two spring dowel pins.
cylinder head and gasket can lead to oil, coolant, and
compression leakage. Do not apply sealer to head • For 2006 cylinder heads, use cylinder head
gasket surfaces. gasket with 20 mm with clearance holes for
two spring dowel pins.
NOTE: Cam followers cannot be removed or replaced
when cylinder head is bolted to the crankcase. Be
sure to complete required work on cam followers,
before installing cylinder head.
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 141
Figure 236 Attached hoist hook 8. Install three middle M8 x 70 bolts – cylinder head
to crankcase. Run threads down until finger tight.
5. Attach hoist hook or lifting sling to lifting bracket. Valve Bridges and Push Rods
Raise cylinder head and align with dowel sleeves
previously installed in crankcase.
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
142 CYLINDER HEAD AND VALVE TRAIN
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
CYLINDER HEAD AND VALVE TRAIN 143
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
144 CYLINDER HEAD AND VALVE TRAIN
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
CYLINDER HEAD AND VALVE TRAIN 145
Figure 249 Special torque sequence for cylinder head mounting bolts (typical)
NOTE: All M14 x 193 cylinder head mounting bolts 1. See Cylinder Head Mounting Bolt Special Torque
must be torqued first, before torquing M8 x 70 bolts. Sequence (Figure 249) for the following steps:
1. Torque new lubricated bolts in the sequence 2. Torque M8 bolts in the sequence numbered 11
numbered 1 through 10 to 88 N·m (65 lbf·ft). through 15 to 24 N·m (18 lbf·ft).
2. Torque bolts 1, 3, 5, 7 and 9 in sequence to 116 3. Torque all M8 bolts in the sequence numbered 11
N·m (85 lbf·ft). through 15 to 31 N·m (23 lbf·ft).
3. Torque all bolts in sequence numbered 1 through 4. M8 x 70 torque sequence complete.
10, clockwise 90°.
4. Torque all bolts in sequence numbered 1 through
Fuel Injectors
10, a second time clockwise 90°.
Replace Copper Gasket and O-rings for Fuel
5. Torque all bolts in sequence numbered 1 through
Injector
10, a third time clockwise 90°.
CAUTION: To prevent engine damage, do not use air
6. M14 x 193 torque sequence complete.
tools when installing fuel injectors. Do not scratch
injector surfaces.
M8 x 70 Bolts CAUTION: To prevent engine damage, replace
external O-rings and copper gasket each time a fuel
CAUTION: To prevent engine damage, do not
injector is removed.
lubricate the M8 x 70 bolts. Too much oil will cause
hydrostatic lock and give incorrect torque reading. 1. Remove the old copper gasket with a small hand
Lubricants have an adverse effect on torque results. tool. Wipe injector nozzle with a lint free cloth.
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
146 CYLINDER HEAD AND VALVE TRAIN
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
CYLINDER HEAD AND VALVE TRAIN 147
Fuel Injector Assembly 1. Align injector assembly clamp alignment slot with
hold down clamp alignment index. This aligns the
CAUTION: To prevent engine damage, verify hold
injector correctly.
down bolt retainer is in position when installing injector
hold down clamp 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
148 CYLINDER HEAD AND VALVE TRAIN
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
CYLINDER HEAD AND VALVE TRAIN 149
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
150 CYLINDER HEAD AND VALVE TRAIN
Glow Plugs
NOTE: The square socket short crankcase-to-head 1. Install glow plugs in cylinder head.
tube plug and crankcase-to-head tube assembly is not 2. Tighten glow plugs to the special torque (Table
available for service. 11).
CAUTION: To prevent engine damage, install new
crankcase-to-head tube plug (long – with check
valve) and crankcase-to-head tube. D-rings are not ICP Sensor and Valve Cover Seal Ring for ICP
replaceable. sensor (right high-pressure oil rail)
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
CYLINDER HEAD AND VALVE TRAIN 151
1. Install valve cover seal ring for the ICP sensor and Valve Covers
high-pressure oil rail.
Right Side Valve Cover
2. Put new O-ring on ICP sensor.
CAUTION: To prevent engine damage, do not use air
powered tools, when installing valve covers.
Figure 269 ICP sensor • Tube assembly, filter to right hand cylinder head.
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
152 CYLINDER HEAD AND VALVE TRAIN
Left Side Valve Cover IDM bracket and other harness routing hardware.
Leave finger tight until all bolts are started.
4. Tighten all bolts to the special torque (Table 11).
5. Install oil filler extension tube on valve cover.
6. If removed for any reason, install the lifting eyes
on the rear of each rocker arm carrier and one on
the left front carrier. Tighten bolts to the special
torque (Table 11).
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
CYLINDER HEAD AND VALVE TRAIN 153
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
154 CYLINDER HEAD AND VALVE TRAIN
Specifications
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
CYLINDER HEAD AND VALVE TRAIN 155
Special Torque
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
156 CYLINDER HEAD AND VALVE TRAIN
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
FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP 157
Table of Contents
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Front Cover Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Front Oil Seal and Wear Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
Gerotor Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Gerotor Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Front Oil Seal and Wear Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
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
158 FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP
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
FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP 159
Description
Front Cover Components
The front cover includes components for the cooling
system, lube oil delivery, and vibration damper.
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
160 FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP
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
FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP 161
Front Oil Seal and Wear Sleeve 2. Thread a slide hammer with correct size screw in
one of the two holes.
NOTE: The VT 365 is not equipped with a wear sleeve
during factory production. Wear sleeves are available 3. Slide hammer until one side of the seal begins to
with an oil seal service kit. pull out the gerotor cover. Move the slide hammer
to the other hole and repeat until the front oil seal
NOTE: If removing only the seal, do steps 1 through 3.
is removed completely.
Otherwise, remove seal and wear sleeve doing steps
1 through 4. NOTE: The following steps are necessary, if the
engine has a front wear sleeve. Wear sleeves are
only available in oil seal service kits.
WARNING: To prevent personal injury or
death, wear safety glasses with side shields to 4. Do the following steps to install the front wear
protect eyes. sleeve remover (Table 15):
CAUTION: To prevent engine damage, do not
immerse damper in petroleum based solvents.
Damage to rubber damping element may result.
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
162 FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP
1. Remove five mounting bolts from gerotor oil pump Water Pump
cover.
NOTE: If removing the front cover, the water pump
2. Carefully remove cover to expose gerotor. and thermostat do not need to be removed; however,
3. Use a permanent marker to mark the front of each the water pump pulley must be removed.
gerotor for correct reassembly orientation.
CAUTION: To prevent engine damage, do not
use paint to identify internal components or their
orientation. Use a permanent marker only.
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
FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP 163
NOTE: If not using a air impact wrench, use a holding 1. Remove two M8 x 30 bolts that secure thermostat
device to lock the water pump pulley when removing assembly to left side of front cover.
the bolts.
Thermostat
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
164 FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP 165
Cleaning, Inspection, and Testing NOTE: The inner and outer gerotors are a
matched set and cannot be replaced individually.
Vibration Damper
NOTE: If installing new gerotors, correct
CAUTION: To prevent engine damage, do not
orientation is not necessary. If installing old
immerse damper in petroleum based solvents. The
gerotors, correct orientation is necessary.
rubber damping element could be damaged.
6. Place inner and outer gerotors in oil pump
1. Clean vibration damper with soap, water, and a
housing.
soft parts brush.
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
166 FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP
8. Check oil pump end clearance as follows: 10. Inspect oil pressure regulator components and
a. With the gerotors in place in the front cover, bore for wear.
put straightedge across housing.
b. Insert feeler gauge under straightedge at Front Cover and Water Pump
inner and outer gerotors. Compare end
clearance with specifications (Table 13).
WARNING: To prevent personal injury or
c. If measurements are not within specifications, death, wear safety glasses with side shields to
replace both gerotors (as a set). protect eye. Limit compressed air pressure to 207
9. Use a 12 mm internal hex wrench to remove oil kPa (30 psi).
pressure regulator. 1. Wash thoroughly in a suitable cleaning solvent.
2. Dry with filtered compressed air.
3. Inspect front cover for cracks.
4. Inspect water pump for leaks, cracks, bearing
failure, and problems with bearings or shaft seal.
Replace if necessary.
5. Replace front cover if cracked.
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
FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP 167
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
168 FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP
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
FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP 169
Thermostat
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
170 FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP
2. Install water pump assembly on front cover over 1. Lubricate inner gear with lithium assembly grease
the new O-ring and secure with four M8 x 25 and install on crankshaft. Wipe off excess grease.
mounting bolts. Tighten bolts to the special
2. Lubricate outer gear with lithium assembly grease
torque (Table 14).
and mesh with inner gear rotor in oil pump
3. Install water pump pulley with four M8 x 12 bolts. housing. Wipe off excess grease.
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
FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP 171
Vibration Damper
1. Align vibration damper with dowel pin on the front
of the crankshaft.
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
172 FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP
Figure 305 Vibration damper on crankshaft 3. Vibration damper bolt torque sequence:
1. Mounting bolts (4) a. Tighten each bolt to the special torque (Table
2. Vibration damper 14) using the above sequence.
b. Torque each bolt an additional 90° using the
above sequence.
2. Install four new M12 x 59 bolts to secure vibration
damper on crankshaft. 4. Reinstall all safety guards, shields, and covers.
5. Make sure all tools, cleanliness covers, loose
parts, and service equipment are removed from
the engine work 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
FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP 173
Specifications
Special Torque
Table 14 Front Cover, Vibration Damper, Water Pump, and Oil Pan Drain Plug
Oil pan drain plug 25 ± 5 N·m (18 ± 4 lbf·ft)
Front cover module bolts 24 N·m (18 lbf·ft)
Water pump mounting bolts 23 ± 1 N·m (17 ± 1 lbf·ft)
New bolts only: 68 N·m (50 lbf·ft) + 90°
Vibration damper mounting bolts
rotation. (Figure 306)
EGES295-2
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
174 FRONT COVER, VIBRATION DAMPER, AND GEROTOR OIL PUMP
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
OIL PAN, UPPER OIL PAN, AND OIL PICKUP TUBE 175
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Lower Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Oil Pickup Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Upper Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Upper Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Oil Pickup Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Lower Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
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
176 OIL PAN, UPPER OIL PAN, AND OIL PICKUP TUBE
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
OIL PAN, UPPER OIL PAN, AND OIL PICKUP TUBE 177
Removal
WARNING: To prevent personal injury or
death, read all safety instructions in the “Safety
Information” section of this 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
178 OIL PAN, UPPER OIL PAN, AND OIL PICKUP TUBE
1. Remove three oil pickup tube mounting bolts and Upper Oil Pan
oil pickup tube.
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
OIL PAN, UPPER OIL PAN, AND OIL PICKUP TUBE 179
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
180 OIL PAN, UPPER OIL PAN, AND OIL PICKUP TUBE
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
OIL PAN, UPPER OIL PAN, AND OIL PICKUP TUBE 181
Lower Oil Pan 2. Place lower oil pan on upper oil pan mating
surface.
1. Put a new gasket on upper oil pan (lower surface).
3. Install 16 M6 lower oil pan mounting bolts. Tighten
bolts to the standard torque (Standard Torques,
page 375).
4. Reinstall all safety guards, shields, and covers.
5. Make sure all tools, cleanliness covers, loose
parts, and service equipment are removed from
the engine work 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
182 OIL PAN, UPPER OIL PAN, AND OIL PICKUP TUBE
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
POWER CYLINDERS 183
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Connecting Rod and Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
Piston and Ring Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
Connecting Rod and Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
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Follow all warnings, cautions, and notes.
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184 POWER CYLINDERS
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Follow all warnings, cautions, and notes.
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Follow all warnings, cautions, and notes.
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186 POWER CYLINDERS
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Follow all warnings, cautions, and notes.
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188 POWER CYLINDERS
5. When removed, make sure matching connecting CAUTION: To prevent engine damage, note the
rod and cap numbers stay together as a set. A cap engine serial number (stamped on the crankcase
from one connecting rod is not interchangeable pad, left side rear of the crankcase) and piston part
with any other connecting rod. number (stamped on the piston crown). Multiple
pistons are available for service applications. Do not
install pistons having different part numbers.
Piston Disassembly
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POWER CYLINDERS 189
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190 POWER CYLINDERS
Cleaning and Inspection 3. Install the piston gauge pins (0.082 in) (Table 18)
in the top ring groove. Piston gauge pins must be
NOTE: Do not use a caustic solution, wire brush or
parallel.
bead blast material to clean aluminum pistons.
4. Use a 3 - 4 inch outside micrometer to measure
1. Use a soap and water solution to clean aluminum
diameter over piston gauge pins.
pistons. Soak piston first, and then clean piston
with a nonmetallic brush. 5. If measurement over the gauge pin is not within
specifications (Table 16), excessive piston groove
2. Clean piston ring grooves thoroughly.
wear exists. Replace piston.
3. The following disassembled components may be
cleaned using a suitable solvent:
• Piston pins
• Piston pin retainers
• Connecting rods
4. Thoroughly clean connecting rod bolt holes and
threads.
Pistons
1. Inspect pistons for scuffed or scored skirts,
cracked or worn ring lands, and cracked or
scuffed pin bores. Replace damaged pistons.
2. Check top compression ring groove for wear.
NOTE: Top compression ring groove is a
keystone design which requires measurement Figure 326 Ring groove clearance check
over gauge pins to determine ring groove wear. (intermediate ring shown)
1. Compression ring groove
2. Intermediate compression ring groove
3. Feeler gauge
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© 2006 International Truck and Engine Corporation
POWER CYLINDERS 191
a. Place outer edge of new ring in oil control ring If cylinder bore is suitable for use without
groove. reconditioning, deglaze bore using a glaze
breaker brush, then reassemble.
b. Roll ring entirely around piston in its
respective groove. Make sure ring moves 11. See (Cylinder Deglazing, page 215) for the correct
freely in groove. deglazing procedure.
c. Use a feeler gauge to check side clearance
of oil control ring in its respective groove.
Excessive side clearance indicates
ring groove wear and requires piston
replacement.
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192 POWER CYLINDERS
Figure 329 Piston ring end gap clearance in Figure 330 Inside diameter of piston pin bushing
cylinder bore
1. Piston pin bushing
1. Piston ring 2. Telescoping gauge
2. Feeler gauge
3. Crankcase
3. Inspect connecting rod piston pin bushing for wear
as follows:
c. If gap does not meet specifications (Table 16),
a. Use a telescoping gauge (Table 18) and a
select another ring or recheck cylinder bore
1-2 inch micrometer to measure pin bore
wear.
at two locations 90° apart. Record both
measurements.
Connecting Rods b. If inside diameter of piston pin bushing
exceeds specification (Table 16), replace
CAUTION: If the rod cap is reversed when assembled
connecting rod.
to the connecting rod or a rod cap is not installed on its
original matching connecting rod, the fractured mating
surfaces will be useless. The entire connecting rod
Connecting Rod Bore Out-of-round and Taper
assembly must be replaced.
Check
CAUTION: To prevent engine damage, keep fractured
CAUTION: To prevent engine damage, check
mating surfaces clean and free of debris. Do not
connecting rod bolts for binding. Bolts should
allow mating surfaces to rest on other surfaces.
thread into connecting rod freely, when lubricated
Do not bump mating surfaces or drop connecting
with clean engine oil. If not, discard the connecting
rod or cap. This could cause wear and chipping of
rod. Connecting rod threads cannot be retapped,
fractured surface, resulting in incorrect mating during
if binding. Check thread condition carefully during
installation.
inspection.
1. Inspect connecting rod bolts for nicks or damage.
1. Lubricate connecting rod bolts with clean engine
Replace as required.
oil. Assemble cap to rod without bearing insert.
2. Inspect connecting rod and cap mating surfaces Tighten bolts to special torque (Table 17).
and bearing bore for any indication of damage.
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation
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194 POWER CYLINDERS
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POWER CYLINDERS 195
Installation
Piston and Ring Assembly
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196 POWER CYLINDERS
2. Use piston ring expansion pliers (Table 18), to c. Install intermediate ring into middle piston
install piston rings. groove. The intermediate ring is identified
by two ’OO’ marks on the top surface of the
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Follow all warnings, cautions, and notes.
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Follow all warnings, cautions, and notes.
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198 POWER CYLINDERS
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Follow all warnings, cautions, and notes.
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200 POWER CYLINDERS
Specifications
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Special Torque
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202 POWER CYLINDERS
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Follow all warnings, cautions, and notes.
© 2006 International Truck and Engine Corporation