International VT 365 Service Manual

SERVICE MANUAL

INTERNATIONAL® VT 365

DIESEL ENGINE

2004-2006 Model Years

SERVICE MANUAL

EGES-295-2

INTERNATIONAL® VT 365

DIESEL ENGINE

EGES-295-2

2004-2006 Model Years

Printed in the United States of America

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 TURB

MANIFOLDS AND EXHAUST GAS RECIRCULATION (EGR).....................................................73

CYLINDER HEAD AND VALVE TRAIN................................................................................99

FRONT COVER, VIBRATION DAMPER, and GEROTOR OIL PUMP

OIL PAN, UPPER OIL PAN, and OIL PICKUP TUBE. .. .. ... . . .... . ... . . ... . . . . ... . .. ... . . ... . . ... . . ... . . ... . . ....175

POWER CYLINDERS..................................................................................................183

CRANKCASE, CRANKSHAFT and BEARINGS, CAMSHAFT

OIL COOLER and FILTER HOUSING................................................................................229

ENGINE ELECTRICAL.................................................................. ...............................245

HIGH-PRESSURE OIL PUMP.. ..................... ..................................................................281

FUEL SYSTEM...................................... ....................................................................297

REAR COVER, FLYWHEEL, and POWER STEERIN

IN-CHASSIS PROCEDURES..........................................................................................331

G GEAR DRIVE...........................................309

OCHARGER (VGT)................... ...55

...........................................157

and BUSHINGS............................ ...203

Terminology.............................................................................................................355

Appendix A – Speciﬁcations...................................................................... ...................363

Appendix B – Torques.................................................................................................373

Appendix C – Special Service Tools

Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.

.......................................................... ......................389

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II ENGINE SERVICE MANUAL

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Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.

Follow all warnings, cautions, and notes.

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 fo 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 followingorder information isfor 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

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Follow all warnings, cautions, and notes.

2 ENGINE SERVICE MANUAL

Service Diagnosis

Service diagno sis 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 speciﬁc Engine 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

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Follow all warnings, cautions, and notes.

ENGINE SERVICE MANUAL 3

Safety Information

This manual provides general and speciﬁcservice proceduresessential for reliable engineoperationand 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 instructionsbefore doing any service and test procedures for the engine or vehicle. See related application manuals for more information.

DisregardforSafety Instructions, Warnings, Cautio 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 saf operation of the engine: Warning, Caution, and

Warning: A warning describes actions necessar prevent or eliminate conditions, hazards, an practices that can cause personal injury

or death.

Caution: A caution describes actions nec to prevent or eliminate conditions that c

an cause

damage to the engine or vehicle. Note: A note describes actions necessar

yforcorrect,

efﬁcient engine operation.

SAFETY INSTRUCTIONS

Vehicle

• Make sure the vehicle is in neutral, th brake is set, and the wheels are block doing any work or diagnostic proc

ed before

edures on the

engine or vehicle.

Work area

• Keep work area clean, dry, and org

anized.

• Keep tools and parts off the ﬂoor.

• Make sure the work area is ventil

• MakesureaFirstAidKitisavail

ated and well lit.

able.

Safety equipment

• Use correct lifting devices.

• Use safety blocks and stands.

Protective measures

ns,

Note

yto

d unsafe

essary

eparking

• 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 exposebatteries to openﬂames orsparks.

• 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.

• Wear protective glasses and sa

Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.

fety shoes.

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Follow all warnings, cautions, and notes.

4 ENGINE 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 overﬁll the fueltank. Over ﬁll creates a ﬁre hazard.

• Do not smoke in the work area.

• Do not refuelthe tank when the engineis 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.

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Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.

Follow all warnings, cautions, and notes.

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

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Follow all warnings, cautions, and notes.

6 ENGINE SYSTEMS

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Follow all warnings, cautions, and notes.

Engine Identiﬁcation

Engine Serial Number

Figure 1 Engine serial number

ENGINE SYSTEMS 7

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

Emission Labels (2004 and 2005 M

Twoemissionlabelsareontherig

sequence

odel Years)

ht valve cover:

Figure 2 50 – State Exhaust Emissions Label (example)

The 50 – State Exhaust Emissions Label includesthe 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)

• 50 – State Exhaust Emissions Labe

• U.S. Federal Family Emission L

Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.

imits Label

The U.S. Federal Family Emission Limits Label identiﬁes the engine family and emission limits established by the manufacturer and certiﬁed by the EPA.

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Follow all warnings, cautions, and notes.

8 ENGINE SYSTEMS

Emission Label (2006) Model Year

One emission label is on the right valve cover.

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

Figure 4 50 – State Exhaust Emissions Label (example)

Labels or identiﬁcation plates include information and speciﬁcations helpful to vehicle operators and technicians.

EGES295-2

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Follow all warnings, cautions, and notes.

ENGINE SYSTEMS 9

Engine Description

Table 1 Engine Features and S peciﬁcations

International® VT 365 engine features and speciﬁcations

Engine Diesel, 4 cycle Conﬁguration 4 OHV/1 Cam-in-Crankcase-V8 Displacement Bore and stroke Compression ratio Aspiration Rated power @ rpm Peak torque @ rpm

365 cu. in (6.0L) 95 mm x 105 mm (3.74 in x 4.134 in)

18.0:1 VGT turbocharged and Charge Air Cooling (CAC) 175 bhp @ 2600 rpm

460 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

Base 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.

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Follow all warnings, cautions, and notes.

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 iscontrolled 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 valvelash. 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 o n 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 b ypass 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 controlledby twoengine 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

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Follow all warnings, cautions, and notes.

Engine Component Locations

ENGINE SYSTEMS 11

Figure 5 Engine components – Front

1. Manifold Absolute Pressure (MAP) sensor

2. Lube oil pressure test port

3. Fuel ﬁlter assembly

4. Fuel return

Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.

5. Fuel supply

6. Engine Coolant Temperature

7. Port for coolant deaeration tank

8. Coolant outlet and thermostat

Follow all warnings, cautions, and notes.

(ECT) sensor

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9. Front cover assembly

10. Crankshaft vibration damper

11. Coolant inlet

12. Water pump pulley

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

Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.

5. Valve cover

6. Rear cover

7. Exhaust manifold

8. Camshaft Position(CMP)sensor

9. Glow plug harness

EGES295-2

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10. Engine Coolant Temperature (ECT) sensor

11. Lube oil ﬁll tube

ENGINE SYSTEMS 13

Figure 7 Engine components – R ear

1. Injection Pressure Regulator (IPR valve)

2. Turbocharger exhaust outlet

3. Exhaust tube assembly, right

Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.

Follow all warnings, cautions, and notes.

4. Flywhee l or ﬂexplate assembly

5. Rear cover assembly

6. Reinforcement ring

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7. Shielded exhausttubeassembly, left

8. Lifting eye (3)

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

Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.

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

Follow all warnings, cautions, and notes.

11. Exhaust Manifold

12. Glow plug harness

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ENGINE SYSTEMS 15

Figure 9 Engine compon

1. Fuel ﬁlter assembly

2. Oil ﬁlter housing

3. Exhaust Gas Recircul

(EGR) valve

4. Intake manifold air i

5. Manifold Absolute Pre

(MAP) sensor

Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.

ation

nlet

ssure

ents–Top

6. Intake manifold

7. Compressor outlet

8. Manifold Air Tempera sensor

9. ICP sensor

10. EGR cooler

11. VGT control valve

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ture (MAT)

12. Glow plug relay

13. VGT

14. High-pressure oil pu

15. Air inlet duct

16. Breather hose assembl pitot tube

17. Lube oil ﬁll

mp cover

ywith

16 ENGINE SYSTEMS

Engine Systems

The primary engine systems are AirManagementand 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 S ystem provides lubrication and heat transfer to engine components.

EGES295-2

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Follow all warnings, cautions, and notes.

Air Management System (AMS)

ENGINE SYSTEMS 17

Figure 11 Air Management System (AMS)

1. Intake manifold

2. EGR cooler

3. Left cylinder head

4. Left exhaust manifold

Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.

5. Shielded tube exhaust assembly

6. VGT with mounting bracket

7. Air inlet duct

8. Righ t cylinder head

Follow all warnings, cautions, and notes.

9. Right exhaust manifold

10. Exhaust tube assembly, right

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18 ENGINE SYSTEMS

The Air Management system includes the following:

•Airﬁlter assembly

• Closed crankcase breather

• Chassis mounted Charged Air Cooler (CAC)

• Variable Geometry Turbocharger (VGT)

• Intake manifold

• Exhaust Gas Recirculation (EGR) system

• Exhaust system

• Catalytic converter– dependent on application

• Catalyzed Diesel Particulate Filter (CDPF) – dependent on application

EGES295-2

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Follow all warnings, cautions, and notes.

ENGINE SYSTEMS 19

Figure 12 Air ﬂow diagram

Air ﬂow

Airentersand ﬂows throughtheairﬁlterassembly and mixes with air from crankcase ventilation. The VGT compressestheairmixturebeforeitenterstheCharge Air Cooler (CAC). Cooled compressed air ﬂows from the CAC into the air intake manifold that directs air to the intake ports for each cylinder head.

After combustion, hot exhaust gas is forced through the exhaust manifolds to the EGR cooler and VGT.

• Somehotexhaust gas is cooled intheEGRcooler and ﬂows through the EGR control valve back through the air intake manifold to mix with ﬁltered air. This reduces nitrogen oxide (NOx) emissions and noise.

EGES295-2

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Follow all warnings, cautions, and notes.

• Therestof the hot exhaust gas expandsandﬂows to the VGT, spins the turbine wheel, and ﬂows from the VGT outlet to the engine exhaust pipe.

• The VGT compressor wheel, on the same shaft as the turbine wheel, compresses the mixture of ﬁltered air and air from crankcase ventilation.

The VGT responds directly to engine loads. During heavy load, an increased ﬂow of exhaust gases turns the turbine wheel faster. This increased speed turns the compressor impeller faster and supplies more air or greater boost to the intake manifold. Conversely, when engine load is light, the ﬂow of exhaust gases decreases and less air is pumped into the intake manifold.

20 ENGINE SYSTEMS

The VGT modiﬁes more efﬁcient exhaust ﬂow characteristics.

Charge Air Cooler (CAC)

Figure 13 Charge Air Cooler

1. Air outlet

2. Charge Air Cooler

3. Air inlet

4. Radiator

The CAC cooler is mounted on top of the radiator. Air from the VGT is pushed through a network of heat exchanger tubes before entering the air intake manifold. Outside air ﬂowing over the tubes and ﬁns cools the charged air. Charged air is cooler and denser than the uncooled air; cooler and denser air improves the fuel-to-air ratio during combustion, resulting in improved emission control and power output.

EGES295-2

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Follow all warnings, cautions, and notes.

Variable Geometry Turbocharger (VGT)

ENGINE SYSTEMS 21

Figure 14 VGT

1. Actuator

2. VGT control valve

3. Unison ring

4. Vanes

The key feature of the VGT is actuated vanes in the turbine housing. The vanes modify ﬂow characteristics of exhaust gases through the turbine housing. The beneﬁt is the ability to con trol boost pressure needed to accommodate various engine speeds and load conditions. An additional beneﬁtis lower exhaust emissions.

EGES295-2

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Follow all warnings, cautions, and notes.

VGT closed loop system

Figure 15 VGT closed loop system

22 ENGINE SYSTEMS

The V GT is a closed loop system that uses the Exhaust Back Pressure (EBP) sensor t o provide feedback to the ECM. The ECM uses the EBP sensor to continuously monitorEBP and adjust the dutycycle to the VGT to match engine requirements.

VGT control

links all the vanes. When the unison ring moves, all vanes move to the same position. Unison ring movement occurs when either side of the actuator piston is pressurized by engine oil.

Exhaust gas ﬂow can be regulated depending on required exhaust back pressure for enginespeed and load.

Exhaust Gas Recirculation (EGR) System

The EGR system includes the following:

• EGR drive module

•EGRvalve

• EGR cooler

• Air intake manifold

• Exhaust tube assembly, right The Exhaust Gas Recirculation (EGR) system

reduces Nitrogen Oxide (NOx) emissions. NO

forms during a reaction between nitrogen and

oxygen at high temperature during combustion. Combustion starts when fu el is injected into the cylinder before or slightly after the piston reaches top-dead-center.

Figure 16 VGT control

The solenoid receives a pulse width modulated signal from the ECM that indicates the on / off time that the control valve is energized. The control valve directs lube oil ﬂow to both sides of the piston in the actuator housing. Directing oil to different sides of the piston increases or decreases exhaust back pressure.

Actuated vanes are mounted around the inside circumference of the turbine housing. A unison ring

EGES295-2

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Follow all warnings, cautions, and notes.

EGR ﬂow

Some exhaust from the right exhaust tube assembly ﬂows into the EGR cooler. Exhaust from the EGR cooler ﬂows in to a passage in the air intake manifold that intersects with the EGR valve.

When EGR is commanded, the EGR control valve opens allowing cooled exhaust gases to enter the intake manifold to be mixed with ﬁltered intake air then recycled through the combustion process.

EGR valve

ENGINE SYSTEMS 23

Figure 18 EGR control

Figure 17 EGR valve

1. Ac tuator coil

2. Valve heads (2)

3. Common shaft

A DC motor, in EGR valve, moves and controls the position of a two head valve assembly.

The EGR valve, installed in the top fron intake manifold, has th ree major co head valve assembly, a DC motor, an Circuit (IC). The IC has three Hal sensors that monitor valve movem

The EGR drive module, mounted on t module mounting bracket abov assembly, controls the DC mo

mponents: a two

d an Integrated

l effect position

ent.

he EGR drive

e the ECM/IDM

tor.

toftheair

Figure 19 EGR closed loop operation

EGES295-2

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Follow all warnings, cautions, and notes.

24 ENGINE SYSTEMS

The EGR system is closed loop control, using EGR position signals.

The EGR drive module receives the desired EGR valve position from the ECM across the CAN 2 datalink to activate the EGR valve for exhaust gas recirculation. The EGR drive module provides feedback to the ECM on the valve position, interprets the ECM command, and sends the command using three pulse width modulated signals to the DC motor.

Exhaust System

The exhaust system includes the following:

• Exhaust valves

• Exhaust manifolds

• Turbocharger

• Exhaust piping

•Mufﬂer and catalytic converter – dependent on application

• Catalyzed Diesel Particulate Filter (CDPF) – if equipped.

The exhaust s ystem rem o ves exhaust gases from the engine. Exhaust gases exit from exhaust ports, through exhaust valves, and ﬂow into the exhaust manifolds. Expanding exhaust gases are directed through the exhaust tubes. The right exhaust tube directs some exhaust gases into the Exhaust Gas Recirculation (EGR) cooler. Exhaust gases ﬂowing into the VGT drive the turbine wheel. Exhaust gases exit the VGT and ﬂow into the exhaust piping, through the mufﬂer and catalytic converter or CDPF, and out the discharge pipe to the atmosphere.

EGES295-2

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Follow all warnings, cautions, and notes.

Fuel Managem ent System

Fuel Injection

ENGINE SYSTEMS 25

Figure 20 Fuel management system

The fuel management system includes the following:

• Injection Control Pressure (ICP) system

• Fuel injectors

EGES295-2

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Follow all warnings, cautions, and notes.

• Electronic control system

• Lubrication system

• Fuel supply system

26 ENGINE SYSTEMS

Injection Control Pressure (ICP) System

Figure 21 High-pressure o

1. High-pressure oil pump c fasteners (8)

2. Oil rail assembly (2)

3. High-pressure oil pump co

4. Pump-to-cover seal ring

5. High-pressure oil pump c seal

il system

over

ver

over

6. High-pressure oil pump fasteners (3)

7. Case-to-head tube assem

8. High-pressure oil pump assembly

9. Branch tube adapter bol

10. Branch tube assembly

High-pressure Oil Flow

A gear driven, high-pressure oil pump draws oil through a screen in the oil reservoir for the high-pressure oil pump. The oil reservoir, in the top of the crankcase below the oil cooler, is kept full by the engine lubrication system.

TheIPR valve maintains the ICP pressurebydumping excess oil back to the 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.

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11. Snap to Connection (STC)

12. Branch tube adapter

13. O-ring

14. IPR valve

High-pressure oil from the pump ﬂows through a branch tube assembly to each case-to-head tube assembly to each high-pressure oil rail.

High-pressure oil in the oil rails enter the fuel injectors through sealed ports in the top of the fuel injectors.

When the OPEN coilfor each injectoris energized, the injector uses high-pressure oil to inject and atomize fuel into the combustion chamber. The CLOSE coils are energized to end injection. Exhaust oil exits through two ports in the top of the injector and drains back to the crankcase.

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