International VT 365 User manual

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

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

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

ENGINE SERVICE MANUAL 1
Foreword
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.
NOTE: Photo illustrations identify specific parts or
assemblies that support text and procedures; other
areas in a photo illustration may not be exact.
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.
Technical Service Literature
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
EGED-250 VT 365 Performance Diagnostics
Form
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 informationis 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: [phone]
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

2ENGINE SERVICE MANUAL
Service Diagnosis
Service diagnosis is an investigative procedure that
must be followed to find and correct an engine
application problem or an engine problem.
If the problem is engine application, see specific
vehicle manuals for further diagnostic information.
If the problem is the engine, see specificEngine
Diagnostic Manual for further diagnostic information.
Prerequisites for Effective Diagnosis
• Availability of gauges and diagnostic test
equipment
• Availability of current information for engine
application and engine systems
• Knowledge of the principles of operation for
engine application and engine systems
• Knowledge to understand and do procedures in
diagnostic and service publications
Technical Service Literature required for Effective
Diagnosis
•Engine Service Manual
•Engine Diagnostic Manual
• Diagnostics Forms
• Electronic Control Systems Diagnostics Forms
• Service Bulletins
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

ENGINE SERVICE MANUAL 3
Safety Information
This manual provides general and specificservice
procedures essential for reliable engine operation and
your safety. Since many variations in procedures,
tools, and service parts are involved, advice for all
possible safety conditions and hazards cannot be
stated.
Read safety instructions before doing any service and
test procedures for the engine or vehicle. See related
application manuals for more information.
Disregardfor Safety Instructions, Warnings, Cautions,
and Notes in this manual can lead to injury, death or
damage to the engine or vehicle.
SAFETY TERMINOLOGY
Three terms are used to stress your safety and safe
operation of the engine: Warning, Caution, and Note
Warning: A warning describes actions necessaryto
prevent or eliminate conditions, hazards, and unsafe
practices that can cause personal injury or death.
Caution: A caution describes actions necessary
to prevent or eliminate conditions that can cause
damage to the engine or vehicle.
Note: A note describes actions necessaryforcorrect,
efficient engine operation.
SAFETY INSTRUCTIONS
Vehicle
• Make sure the vehicle is in neutral, theparking
brake is set, and the wheels are blocked before
doing any work or diagnostic procedures on the
engine or vehicle.
Work area
• Keep work area clean, dry, and organized.
• Keep tools and parts off the floor.
• Make sure the work area is ventilated and well lit.
• MakesureaFirstAidKitisavail
able.
Safety equipment
• Use correct lifting devices.
• Use safety blocks and stands.
Protective measures
• Wear protective glasses and safety shoes.
• Wear appropriate hearing protection.
• Wear correct work clothing.
• Do not wear rings, watches, or other jewelry.
• Restrain long hair.
Fire prevention
• Make sure charged fire extinguishers are in the
work area.
NOTE: Check the classification of each fire
extinguisher to ensure that the following fire types
canbeextinguished.
1. Type A — Wood, paper, textiles, and rubbish
2. Type B — Flammable liquids
3. Type C — Electrical equipment
Batteries
Batteries produce highly flammable gas during and
after charging.
• Always disconnect the main negative battery
cable first.
• Always connect the main negative battery cable
last.
• Avoid leaning over batteries.
• Protect your eyes.
• Do not expose batteries to open flames or sparks.
• Do not smoke in workplace.
Compressed air
• Limit shop air pressure for blow gun to 207 kPa
(30 psi).
• Use approved equipment.
• Do not direct air at body or clothing.
• Wear safety glasses or goggles.
• Wear hearing protection.
• Use shielding to protect others in the work area.
Tools
• Make sure all tools are in good condition.
• Make sure all standard electrical tools are
grounded.
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

4ENGINE SERVICE MANUAL
• Check for frayed power cords before using power
tools.
Fluids under pressure
• Use extreme caution when working on systems
under pressure.
• Follow approved procedures only.
Fuel
• Do not over fill the fuel tank. Over fill creates a fire
hazard.
• Do not smoke in the work area.
• Do not refuel the tank when the engine is running.
Removal of tools, parts, and equipment
• Reinstall all safety guards, shields, and covers
after servicing the engine.
• Make sure all tools, parts, and service equipment
are removed from the engine and vehicle after all
work is done.
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

ENGINE SYSTEMS 5
Table of Contents
Engine Identification.....................................................................................................7
Engine Serial Number..........................................................................................7
Emission Labels (2004 and 2005 Model Years)............................................................7
Emission Label (2006) Model Year...........................................................................8
Engine Description..............................................................................................9
Engine Component Locations..... . ......... . . . ........ . . . ........ . . ........... ........... . ......... . . . .....11
Engine Systems.........................................................................................................16
Air Management System (AMS).............................................................................17
Charge Air Cooler (CAC)............................................................................20
Variable Geometry Turbocharger (VGT)..........................................................21
Exhaust Gas Recirculation (EGR) System.......................................................22
Exhaust System......................................................................................24
Fuel Management System....................................................................................25
Fuel Injection..........................................................................................25
Injection Control Pressure (ICP) System.........................................................26
Fuel Injectors...................................................................................................28
Fuel Supply System... ........ . . . ........ . . ....... . . ......... . . ...... . . ......... . . ......... ........ . . . ........30
Fuel Flow........................................................................................................31
Lubrication System... .........................................................................................33
Cooling System................................................................................................37
Electronic Control System.............................................................................................39
Electronic Control System Components ..................................................................39
Injection Drive Module (IDM).................................................................................41
Engine and Vehicle Sensors.................................................................................42
Glow Plug Control System.............................................................................................47
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

6ENGINE SYSTEMS
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

ENGINE SYSTEMS 7
Engine Identification
Engine Serial Number
Figure 1 Engine serial number
The engine serial number is stamped on the
crankcase pad on the rear left side of the crankcase
below the cylinder head.
The engine serial number is also on an identification
sticker on the valve cover.
Engine serial number examples
6.0HM2Y0000500
6.0HA2U0000508
Engine serial number codes
6.0 – Engine displacement
H–Diesel, turbocharged, Charge Air Cooled, and
electronically controlled
M2 – Truck
A2 – Service
U–USA
Y–USA Huntsville
7digitsuffix–Engine serial number sequence
Emission Labels (2004 and 2005 Model Years)
Twoemissionlabelsareontherig
ht valve cover:
• 50 – State Exhaust Emissions Label
• U.S. Federal Family Emission Limits Label
Figure 2 50 – State Exhaust Emissions Label
(example)
The 50 – State Exhaust Emissions Label includes the
following:
• Year the engine was certified to meet EPA
emission standards
• Engine model code
• Service applications
• Advertised brake horsepower ratings
Figure 3 U.S. Federal Family Emission Limits
label (example)
The U.S. Federal Family Emission Limits Label
identifies the engine family and emission limits
established by the manufacturer and certified by the
EPA.
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

8ENGINE SYSTEMS
Emission Label (2006) Model Year
One emission label is on the right valve cover.
Figure 4 50 – State Exhaust Emissions Label
(example)
The 50 – State Exhaust Emissions Label includes the
following:
• Year the engine was certified to meet EPA
emission standards
• Engine model code
• Service applications
• Advertised brake horsepower ratings
Engine accessories
The following engine accessories may have
manufacturer’s labels or identification plates:
• Air compressor (for brake or suspension system )
• Air conditioning compressor
• Alternator
• Cooling fan clutch
• Variable Geometry Turbocharger (VGT)
• Power steering / fuel pump
•Startermotor
Labels or identification plates include information
and specifications helpful to vehicle operators and
technicians.
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

ENGINE SYSTEMS 9
Engine Description
Table 1 Engine Features and Specifications
International® VT 365 engine features and specifications
Engine Diesel, 4 cycle
Configuration 4 OHV/1 Cam-in-Crankcase-V8
Displacement 365 cu. in (6.0L)
Bore and stroke 95 mm x 105 mm (3.74 in x 4.134 in)
Compression ratio 18.0:1
Aspiration VGT turbocharged and Charge Air Cooling (CAC)
Rated power @ rpm 1175 bhp @ 2600 rpm
Peak torque @ rpm 1460 lbf•ft @ 1400 rpm
Engine rotation, facing flywheel Counterclockwise
Combustion system Digital Direct Injection (DDI)
Total engine weight (auto with oil) 459 kg (1094 lb)
Cooling system capacity (engine only) 10.2 liters (10.8 qts)
Lube system capacity (including filter) 18 liters (19 qts)
Lube system capacity (dry) 21.8 liters (23 qts)
Firing order 1–2–7–3–4–5–6–8
1Base rating shown. See Appendix A for other ratings.
Major features
Air Management System (AMS)
• Variable Geometry Turbocharger (VGT)
• Exhaust Gas Recirculation (EGR) system
• Chassis mounted Charge Air Cooling (CAC)
Digital Direct fuel Injection (DDI)
Two piece crankcase
One piece cylinder head with four valves per cylinder
Dual timing
Rear gear train
Closed crankcase ventilation
Oil cooler
The firing order is 1-2-7-3-4-5-6-8. When viewing the
engine from the rear (flywheel end), the right side
cylinders are numbered 1, 3, 5, and 7. Number one
is the front position. The left side is numbered 2, 4, 6,
and 8.
A two piece crankcase has been specially designed
to withstand the loads of diesel operation. The lower
crankcase has integral main bearing caps. Coolant
and oil passages are cast and machined in the
crankcase and front cover housing.
The crankshaft has five main bearings with fore and
aft thrust controlled at the upper half of the number 4
main bearing. Two connecting rods are attached to
each crankshaft journal. The piston pin moves freely
inside the piston and rod. Piston pin retaining rings
secure the piston pin within the piston.
EGES295-2
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Follow all warnings, cautions, and notes.
©2006 International Truck and Engine Corporation

10 ENGINE SYSTEMS
One piece aluminum alloy pistons are fitted with
one keystone cut compression ring, one rectangular
intermediate compression ring, and a two piece oil
control ring. The combustion bowl (in the piston
crown) reduces exhaust emissions.
The camshaft is supported by five insert bushings
pressed into the crankcase. Two cam lobes, cam
followers, push rods and valve bridges control four
valves per cylinder. The camshaft is gear driven
from the rear end of the crankshaft. A thrust flange
is located between the camshaft gear and the
crankcase. Camshaft thrust is controlled with the rear
surface of the number 5 cam journal and the cam
gear.
Hydraulic cam followers maintain zero valve lash
and minimize engine noise. This eliminates periodic
adjustment of valve lash. The hydraulic cam followers
have rollers which provide excellent cam lobe and
cam follower durability.
The lubrication system uses a crankshaft driven
gerotor pump mounted on the front cover. The oil
pressure regulator is built into the front cover and
is accessible from outside the engine. Lube oil is
routed through an oil cooler equipped with a pressure
controlled bypass valve. Lube oil moves through
passages in the crankcase to lubricate all internal
components and to supply the piston cooling tubes
and high pressure pump reservoir. The VGT and air
compressor use external oil lines.
The VGT is electronically controlled and hydraulically
actuated. The VGT provides boost control at low and
high speeds for improved throttle response.
An exhaust gas recirculation valve allows water
cooled exhaust gases to be fed into the inlet air
stream to reduce exhaust emissions.
A closed crankcase breather system recirculates
crankcase vapors back into the intake air system.
A chassis mounted Charge Air Cooler (CAC), an
air-to-air heat exchanger, increases the density of the
air charge.
Engine operation is controlled by two engine mounted
control modules:
• Electronic Control Module (ECM)
• Injector Drive Module (IDM)
The ECM receives signals from engine and chassis
mounted sensors. The ECM controls engine
operation with the following actuators:
•IPR
• VGT control valve
•EGR
• Glow plug relay
The IDM controls fuel injector operation using data
from the ECM.
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

ENGINE SYSTEMS 11
Engine Component Locations
Figure 5 Engine components – Front
1. Manifold Absolute Pressure
(MAP) sensor
2. Lube oil pressure test port
3. Fuel filter assembly
4. Fuel return
5. Fuel supply
6. Engine Coolant Temperature
(ECT) sensor
7. Port for coolant deaeration tank
8. Coolant outlet and thermostat
9. Front cover assembly
10. Crankshaft vibration damper
11. Coolant inlet
12. Water pump pulley
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Follow all warnings, cautions, and notes.
©2006 International Truck and Engine Corporation

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

ENGINE SYSTEMS 13
Figure 7 Engine components – Rear
1. Injection Pressure Regulator
(IPR valve)
2. Turbocharger exhaust outlet
3. Exhaust tube assembly, right
4. Flywheel or flexplate assembly
5. Rear cover assembly
6. Reinforcement ring
7. Shielded exhaust tubeassembly,
left
8. Lifting eye (3)
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Follow all warnings, cautions, and notes.
©2006 International Truck and Engine Corporation

14 ENGINE SYSTEMS
Figure 8 Engine components – Right
1. Valve cover
2. Glow plug relay
3. Injection Control Pressure (ICP)
sensor
4. Crankshaft Position (CKP)
sensor
5. Fuel return line
6. Fuel supply line
7. Fuel filter strainer
8. Fuel supply pump (transfer)
9. Power steering line
10. Power steering pump
11. Exhaust Manifold
12. Glow plug harness
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Follow all warnings, cautions, and notes.
©2006 International Truck and Engine Corporation

ENGINE SYSTEMS 15
Figure 9 Engine components–Top
1. Fuel filter assembly
2. Oil filter housing
3. Exhaust Gas Recirculation
(EGR) valve
4. Intake manifold air inlet
5. Manifold Absolute Pressure
(MAP) sensor
6. Intake manifold
7. Compressor outlet
8. Manifold Air Temperature (MAT)
sensor
9. ICP sensor
10. EGR cooler
11. VGT control valve
12. Glow plug relay
13. VGT
14. High-pressure oil pump cover
15. Air inlet duct
16. Breather hose assemblywith
pitot tube
17. Lube oil fill
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

16 ENGINE SYSTEMS
Engine Systems
The primaryengine systems are Air Management and
Fuel Management, which share some subsystems or
have a subsystem that contributes to their operation.
• The Electronic Control System controls the Air
Management System and Fuel Management
System.
• The Coolant System provides heat transfer for
EGR gases and lubrication oil.
• The ICP system uses lube oil for hydraulic fluid to
actuate the fuel injectors.
• The Fuel Supply System pressurizes fuel for
transfer to the fuel injectors.
• The Lube Oil System provides lubrication and
heat transfer to engine components.
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