Study Guide

A N AV I STA R C O M PA N Y

International VT 365, 2004 Engine, Program I: Introduction

International VT 365
®

2004 Engine

®
Program I: Introduction
Study Guide
TMT-120616
©2006 International Truck and Engine Corporation,
4201 Winfield Road, Warrenville, IL 60555.
All rights reserved. No part of this publication may be
duplicated or stored in an information retrieval system
without the express written permission of
International Truck and Engine Corporation.

TMT-120616
Table of Contents
Overview............................................................................. 2

Module I: Mechanical Features..................................... 4

Module II: Engine Systems.......................................... 10

Electronic Control System................................................................10
ECM/IDM...................................................................................10
ECM/IDM Communication.....................................................11
EGR Drive Module....................................................................12
Sensors.......................................................................................12
Air Management System...................................................................20
Turbocharger..............................................................................20
Exhaust Gas Recirculation System.......................................22
Fuel Management System.................................................................26
Fuel Supply.................................................................................26
ICP System.................................................................................29
Injectors.......................................................................................31
Base Management System...............................................................36
Cooling System ........................................................................36
Lubrication System ..................................................................38
Crankcase Ventilation...............................................................41

Module III: Unique Service Procedures VT 365........ 44

Oil Filter Replacement.......................................................................45
Fuel Filter Replacement.....................................................................46
High-Pressure Rail Removal.............................................................46
High-Pressure Rail Installation.........................................................46
Injector Removal.................................................................................. 47
Cylinder Head Removal.....................................................................49
Glow Plug Harness Removal and Installation..............................50
Glow Plug/Injector Sleeve Removal...............................................50
Glow Plug Sleeve Installation..........................................................50
EGR Valve Removal...........................................................................51
EGR Cooler Removal........................................................................51
Turbocharger Removal.......................................................................54
 Table of Contents
Intake Manifold.....................................................................................55
High Pressure Pump Cover Removal.............................................55
Front Cover Removal..........................................................................56

Conclusion....................................................................... 57
 International® VT 365, 2004 Engine, Program I: Introduction

International VT 365 ®

Engine Training

Overview
“From a design From a design standpoint, the
standpoint, the 2004 International® VT 365 is much
2004 International ® the same as the 2002 engine. But now,
VT 365 is much the 2004 offers a series of product
enhancements:
the same as the
2002 engine.” • D esign improvements can be seen
in the new EGR valve.
• Also, a new high-pressure manifold
eliminates the need for high
pressure hoses under the valve
cover, which in turn simplifies
service. The new manifold also
reduces noise.
• Improvements have been made
with a new cast iron, high-
pressure oil pump.
• For more effective crankcase
ventilation, the breather box size
has been increased.

All of these product enhancements

are a result of International Truck
and Engine Corporation’s pursuit of
continuous improvement and customer
satisfaction.

This DVD program and study guide

provide a complete introduction to the
2004 VT 365.
 Study Guide 

If you are new to International®, this “If you are new to

program gives you a comprehensive International®, this
overview of 2004 VT 365 technology. program gives you
If you’ve already completed the 2002
a comprehensive
VT 365 CBT and hands-on training, this
program covers the design changes overview of 2004
just mentioned and provides a complete VT 365 technology.”
program refresher.

This program is first in a series of

DVDs on the International® VT 365.
Program II covers complete step-by-
step diagnostic procedures. Program
III gives you an opportunity to apply
what you learn in real VT 365 engine
service situations. You’ll take care of
some basic repairs and some more
challenging cases.

We’ll even throw you some curves—

the whole idea is to give you all the
experience you need, so that once you
face the real thing, you can get the job
done right, within SRTs. With detailed
“With DVD, you
practice and testing, Program III is also
your opportunity to move a key step
won’t just sit back
closer to certification by International® and watch. Be
for 2004 VT 365 engine service. prepared to answer
questions, offer
Hopefully it’s clear that this advice, and even
educational series is different. With
take control—in
DVD, you won’t just sit back and watch.
Be prepared to answer questions, offer other words, be
advice, and even take control—in other prepared to play
words, be prepared to play a part in this a part in this DVD
DVD training series. training series.”
 International® VT 365, 2004 Engine, Program I: Introduction

Module I Mechanical Features

Objectives: The 2004 International® VT 365 is
• Describe the mechanical an eight cylinder, four stroke diesel
configuration of the VT 365. engine with a displacement of 365
cubic inches. The cylinders are
• Identify key components and
new features for 2004. arranged in a V pattern and are cast
directly into the crankcase.
“The 2004
International ®
The camshaft is located in the
VT 365 is an eight crankcase and rides on five insert-
type bushings.
cylinder, four
stroke diesel The crankshaft is supported by five
engine with a main bearings with the crankshaft thrust
displacement of being controlled by the number four
365 cubic inches.” upper main bearing insert.

Individual main bearing caps have

been replaced with a one-piece, cast
iron lower crankcase, resulting in a more
robust crankcase structure.

The rear-mounted gear train is used

to drive the camshaft, the high-pressure
pump, and the combination fuel pump
and power steering pump, which is
mounted to the lower right front side of
the rear cover. The camshaft assembly
is driven by the crankshaft gear that is
located in front of the crankshaft primary
flange.
 Study Guide 

The fuel injection system’s high-

pressure pump is mounted to the
crankcase in the engine’s valley and is
driven by the camshaft gear.

The rear cover assembly is sealed “The rear cover

to the crankcase with a push-in-place assembly is
gasket. This assembly serves as both sealed to the
the rear cover to the crankcase gear crankcase with
area and the flywheel housing.
a push-in-place
A secondary flange with an integral gasket.”
gear is pressed on the primary flange of
the crankshaft. A ball bearing supported
idler gear rides on an idler shaft and
meshes with both the secondary flange
and the power steering pump gear.

The rear oil seal carrier is bolted to

the rear cover and the rear main seal is
pressed into place.

Finally, the flywheel is attached with

10 bolts that extend through holes in the
secondary flange to the primary flange.

The valves for each cylinder are

operated by two roller-equipped
hydraulic camfollowers held by a cam
follower guide.
 International® VT 365, 2004 Engine, Program I: Introduction

Each cast iron cylinder head is sealed

to the crankcase with a multi-layered
shim-type head gasket. Each cylinder
has four valves.

The four valve-per-cylinder

configuration allows for a centrally
located injector and combustion
chamber bowl.

The horseshoe-shaped intake

manifold leaves the engine’s valley open
for the turbocharger and lubrication
system components.

“Valve bridges are Valve bridges are used to connect

used to connect the operation of the intake and exhaust
the operation of valve pairs for each cylinder. The valve
the intake and bridges allow a single rocker arm and
pushrod to operate two valves.
exhaust valve pairs
for each cylinder.” The rocker arms are mounted on
fulcrum plates that bolt to the aluminum
rocker arm carrier.
Study Guide 

NOTES
 International® VT 365, 2004 Engine, Program I: Introduction

NOTES
Study Guide 

NOTES
10 International® VT 365, 2004 Engine, Program I: Introduction

Module II Engine Systems

Objectives: Electronic Control System
• Identify individual functions
and teamwork functions of The Electronic Control System
the ECM and IDM. of the VT 365 is responsible for the
• Determine how the ECM and operation of the engine. The system
IDM power up and how they controls the turbocharger, the exhaust
operate.
gas recirculation system, the glow
• Identify the communication plug system, and the injection control
links between the ECM . pressure system.
and IDM.

“The Electronic The Electronic Control System

Control System of works by gathering sensor information,
the VT 365 is processing that information in the
responsible for the electronic control modules, and then
commanding the actuators that control
operation of the various systems.
the engine.”
ECM/IDM

The VT 365 uses both an Electronic

Control Module, or ECM, and an
Injector Drive Module, or IDM. The
two modules are mounted together
over the left bank valve cover except
for vehicles based on the 1000 series
“The ECM and IDM stripped chassis. Stripped chassis
work together to vehicles will have the ECM and IDM
mounted over the right bank valve cover.
ensure the engine
delivers the power The ECM and IDM work together to
the operator ensure the engine delivers the power
needs.” the operator needs.
 Study Guide 11

The ECM receives all engine sensor

data, such as the accelerator position,
engine temperature, and crankshaft
and camshaft speed and position.
Calculations then take place in the
ECM in order to produce the signals
for the injection pressure regulator, the
turbocharger, the glow plug relay, and
the EGR drive module.

Sensor information is also shared

with the IDM to enable the IDM to
determine the proper timing and
duration of the fuel injection. The IDM
will then send 48-volt signals to the
injector coils in the correct sequence.

ECM/IDM Communication
The ECM communicates with the “The ECM
IDM over three separate communication communicates
links. They are the CAN 2 link, the with the IDM over
Crankshaft Position Output, or three separate
CKPO, circuit, and the Camshaft
Position Output, or CMPO, circuit.
communication
links.”
The CAN 2 link is a data line that
allows the ECM to share with the IDM
sensor values it collects. It also allows
the IDM to share with the ECM injector
faults it detects.

Both the CMPO and CKPO are

single-wire links that allow the IDM
to receive information relating to the
camshaft and crankshaft positions.
12 International® VT 365, 2004 Engine, Program I: Introduction

There is also a link between the

ECM and the chassis Electrical
System Controller, or ESC, or the
Multiplexed Signal Module, or
MSM. This link allows the ECM and the
vehicle’s ESC or MSM to communicate.

EGR Drive Module

“The EGR drive The EGR drive module is mounted

module is mounted on a vertical bracket in front of the ECM
on a vertical and IDM.
bracket in front of
The module communicates with the
the ECM and IDM.” ECM over the CAN 2 link in order to
receive ECM commands.

To share desired EGR position

information with the EGR module, the
ECM sends a signal to the drive module.

The module receives the signal and

then sends voltage pulses to the EGR
motor windings.

The sequence of voltage pulses

causes the stepper motor to position
the valve pintle.
Objectives:
Sensors
• Locate the sensors on the
engine.
The ECM must receive information
• Identify “new” sensors and from a variety of sensors for proper
their functions. operation. These sensors allow the
• Match each sensor with .
ECM to calculate the position of a
its purpose. component, the rotational speed of a
 Study Guide 13

shaft, the temperature of a fluid, or the

pressure in a system.

The four temperature sensors are: “The four

intake air, manifold air, engine oil, and temperature
engine coolant. sensors are: intake
air, manifold air,
The Engine Coolant Temperature
sensor, or ECT, is located in the
engine oil, and
coolant outlet area of the front cover. engine coolant.”
The ECM uses the ECT sensor
information for the instrument cluster
gauge, the optional engine warning
and shutdown system, and the coolant
temperature compensation system.

Coolant temperature compensation

cuts back the delivery of fuel to match
the performance of the cooling system if
the engine coolant temperature exceeds
a given temperature. The optional
engine warning and shutdown system
can be enabled to warn the operator of
high coolant temperature with the red
engine lamp. The system can also be
programmed to shut the engine down if
critical temperatures occur.

The Engine Oil Temperature “The Engine Oil

sensor, or EOT, is mounted on the Temperature
oil filter base. The sensor provides sensor is mounted
information used to calculate injection- on the oil filter
timing changes required due to changes
in oil viscosity.
base.”
14 International® VT 365, 2004 Engine, Program I: Introduction

The Manifold Air Temperature

sensor, or MAT, is mounted on the
intake manifold near its connection to
the charge air cooler. The MAT sensor
provides information used to calculate
the proper degree of EGR valve opening.

The Engine Oil Pressure sensor,

or EOP, is located on the oil filter
base. The ECM uses the EOP sensor
information for the instrument cluster
gauge and for the optional engine
warning and shutdown system. The
optional engine warning and shutdown
system can be enabled to warn the
operator of low oil pressure with the red
engine lamp or to shut the engine down
when low oil pressure is encountered.

The Manifold Absolute Pressure

sensor, or MAP, is mounted on the
right bank of the intake manifold. The
MAP sensor provides information used
to calculate the proper vane position in
the turbocharger and the valve opening
in the EGR valve.

“The Injection The Injection Control Pressure

Control Pressure sensor, or ICP, is mounted on the right
sensor is mounted bank high-pressure rail. Although the rail
on the right bank is mounted under the valve cover, the
sensor protrudes through an opening in
high-pressure rail.” the valve cover, allowing service of the
sensor without valve cover removal.
 Study Guide 15

The ICP sensor is used as a

feedback signal into the closed loop
operation of the IPR valve and for
detection of injection control pressure
system faults.

The Exhaust Back Pressure

sensor, or EBP, is mounted to a tube
on the left bank of the engine. The EBP
tube connects to the left bank exhaust
manifold and allows exhaust back-
pressure to reach the sensor.

The Camshaft Position sensor, “Knowing the

or CMP, is located on the left front position of the
side of the crankcase. The sensor is camshaft allows
a magnetic pick-up type sensor that the ECM to
reacts to a single peg pressed into the
camshaft. Each time the peg passes the
determine the
sensor, an AC voltage signal is sent to position or stroke
the ECM. Knowing the position of the of each piston
camshaft allows the ECM to determine within its four-
the position or stroke of each piston stroke cycle at any
within its four-stroke cycle at any point point in time.”
in time.

The Crankshaft Position sensor,

or CKP, is located on the right front side
of the lower crankcase half. Like the
camshaft position sensor, the crankshaft
position sensor is a magnetic pick-up
type. However, the CKP sensor reacts
to a 58-tooth trigger wheel affixed to the
front of the crankshaft.
16 International® VT 365, 2004 Engine, Program I: Introduction

“The trigger The trigger wheel teeth are arranged

wheel teeth are in a 60-tooth pattern with two of the
arranged in a teeth missing. This pattern allows the
ECM to calculate engine speed and the
60‑tooth pattern
position of each piston in the engine.
with two of the
teeth missing.” There are also chassis-mounted
sensors that are input into the ECM.
They are the Accelerator Position
Sensor, or APS, the Idle Validation
Switch, or IVS, the Barometric
Pressure sensor, or BAP, and the
Intake Air Temperature sensor, or
IAT.

The APS and the IVS are mounted on

the accelerator pedal assembly.

The APS/IVS converts a reference

voltage to a variable signal that
communicates the pedal position to
the ECM.

The BAP sensor is mounted under

the instrument panel of the truck. The
BAP sensor allows the ECM to read the
altitude. Altitude information is used to
control the turbocharger vane position,
fuel injection quantity, fuel injection
timing, and glow plug on-time.

“The IAT sensor is The IAT sensor is mounted in the

mounted in the air air filter housing duct. The IAT sensor
filter housing duct.” provides information used to calculate
fuel injection timing and rate when
starting the engine in cold weather.
Study Guide 17

NOTES
18 International® VT 365, 2004 Engine, Program I: Introduction

NOTES
Study Guide 19

NOTES
20 International® VT 365, 2004 Engine, Program I: Introduction

Objectives: Air Management System

• Identify the features of the
air management system. The main components of the
Air Management System on the 2004
• Identify the various air
management system VT 365 are the turbocharger and the
components. Exhaust Gas Recirculation System.
• Match the turbo components
with their respective modes Turbocharger
of operation.
The turbocharger has three sections:
“The turbocharger the compressor, the turbine, and the
has three sections: center section with control mechanism.
The control portion of the turbocharger
the compressor,
has three main components: the control
the turbine, and valve, a set of movable vanes, and a
the center section hydraulic actuator.
with control
mechanism.” The turbocharger is assembled with
a conventional compressor wheel and
turbine wheel on a common shaft. The
center section of the turbocharger
supports the wheel shaft with precision
bearings that are lubricated with engine
oil.

The turbine housing contains a

set of movable vanes. The vanes are
positioned to control the flow of exhaust
gases through the turbine housing.

When the vanes move to a more

closed position, the smaller openings
between the vanes cause the exhaust
gases to speed up. The gases impact
the turbine wheel with greater force and
this results in higher compressor wheel
 Study Guide 21

speeds, greater intake manifold boost,

and higher exhaust backpressure, or
EBP.

The turbo vane position is controlled

by the ECM. The ECM provides a pulse
width modulated signal to the coil of the
control valve. The magnetic field created
by the signal positions a spool within
the control valve.

The spool directs a portion of the

turbocharger lube oil to either side of the
hydraulic actuator. As the signal pulse
width increases, the oil flow against the
face end of the piston moves the vanes
to a more closed position. When the
signal decreases, oil flow against the
rod side of the piston moves the vanes
to a more open position.

The ECM determines the correct EBP “The ECM

for the engine’s operating conditions determines the
and uses that value to calculate the correct EBP for the
control valve signal. The ECM then uses engine’s operating
the exhaust backpressure value from the
EBP sensor as a feedback signal for the
conditions and
vane position. uses that value
to calculate the
If the pressure is not correct, the control valve
ECM modifies the signal to the control signal.”
valve. After the signal to the valve is
updated, the ECM monitors the EBP
sensor value to determine if the desired
backpressure was achieved. This
constant positioning of the vanes is
22 International® VT 365, 2004 Engine, Program I: Introduction

used to control boost and to achieve

the correct EGR flow.

One of the government-regulated

emissions from diesel engines is oxides
of nitrogen. Oxides of nitrogen are
formed at high temperatures when fuel
is burned in the presence of nitrogen.

Since the air we breathe is part

nitrogen, and the temperatures are
high in the combustion chamber, the
formation of oxides of nitrogen from an
“The level of oxides internal combustion engine are high.
of nitrogen emitted
The level of oxides of nitrogen emitted
by the engine
by the engine can be reduced by
can be reduced lowering the combustion temperature.
by lowering the The VT 365 uses cooled exhaust gases
combustion recirculated back to the combustion
temperature.” chamber to reduce temperatures.

Exhaust Gas Recirculation

System

The EGR system is composed of the

EGR cooler, the EGR valve, and the
EGR drive module. The EGR cooler is
bolted to the bottom of the right side of
the intake manifold.
“Exhaust gases
The cooler receives hot exhaust
flow through tubes gases from the right bank exhaust
in the cooler while up‑pipe. Exhaust gases flow through
coolant flows tubes in the cooler while coolant flows
around the tubes.” around the tubes.
 Study Guide 23

Heat transfers to the coolant,

lowering the temperature of the exhaust
gases. The exhaust gases then enter
a passage in the intake manifold that
leads to the EGR valve.

The EGR valve mounts in the

manifold and meters the cooled exhaust
gases into the intake air.

The valve opening amount and the

difference between the pressure in the
intake manifold and the pressure in the
exhaust manifold determines the flow
through the EGR valve.

The EGR valve pintle position is

controlled by a DC stepper motor
contained in the upper housing of the
EGR valve.

The EGR valve receives its

commands from the EGR drive module.
The module, mounted on a bracket near
the ECM, receives a signal from the
ECM across the CAN 2 Link.
“The drive
Three sensors mounted in the valve module constantly
housing act as feedback sensors, compares the
constantly identifying the position of the desired position to
motor armature to the drive module.
the actual position
The drive module constantly and notifies the
compares the desired position to the ECM of any faults
actual position and notifies the ECM of over the
any faults over the CAN 2 link. CAN 2 link.”
24 International® VT 365, 2004 Engine, Program I: Introduction

NOTES
Study Guide 25

NOTES
26 International® VT 365, 2004 Engine, Program I: Introduction

Fuel Management System

Objectives: Fuel Supply

• Identify the components that
make up the Fuel Supply The VT 365 diesel engine uses
System. International® common rail high-
• Match each fuel supply pressure fuel injection, which features
component with their electronically controlled injectors that
respective operation and
function.
are hydraulically actuated. The system is
composed of the fuel supply system, the
injection control pressure system, and
“The VT 365 diesel the injectors. The three systems work
engine uses together to deliver the correct quantity
International® of fuel into the combustion chamber at
the right time.
common rail
high-pressure The injection control pressure system
fuel injection, takes engine lube oil and delivers it to
which features the injectors under high pressure to
electronically supply the mechanical force required
controlled to push fuel into the combustion
injectors that chambers. The fuel supply system is
mechanical but both the injector and the
are hydraulically
injection control pressure system are
actuated.” ECM-controlled.

The fuel supply system provides

fuel under pressure to the injectors.
The three main components of the fuel
system are the fuel pump, the fuel filter
module, and the fuel lines that serve to
transfer fuel through the system.

The combination fuel pump and

power steering pump is mounted on the
 Study Guide 27

right side of the rear cover and is driven

off the rear gear train.

For the pump’s protection, fuel drawn

from the tank passes through the
pump-mounted strainer before entering
the pump.

The vane-type pump moves the

fuel under pressure to the fuel filter
module where water and sediment are
separated from the fuel by the filter
element. Fuel that passes through the
element moves to the cylinder heads via
individual steel lines.

The line is connected to the head

with a banjo bolt that contains a check
valve and orifice. Fuel passes through
the valve and enters a drilled passage in
the head that feeds the injectors. There
is no fuel return from the cylinder heads.
Fuel that enters the heads will stay
in the head until it is injected into the
combustion chambers.

The fuel pressure regulator valve is “Fuel pressure

mounted on the front of the fuel filter depends on engine
module. The regulator drains fuel from speed and load.”
the unfiltered side of the element when
fuel pressure exceeds 55 psi. Fuel
pressure depends on engine speed and
load. At high-RPM, no-load conditions
in which fuel usage is low, the fuel
pressure will reach 70 psi. Fuel flow
from the regulator returns to the fuel
tank via the return line.
28 International® VT 365, 2004 Engine, Program I: Introduction

“The engine is The engine is available with two

available with optional fuel system components: a water-
two optional in-fuel sensor and a fuel heater. The water-
in-fuel sensor is mounted on the filter
fuel system
module and is exposed to the fuel in the
components: filter housing. When water is detected, a
a water-in-fuel dash lamp will warn the operator.
sensor and a
fuel heater.” The fuel heater is located in the bottom
of the filter module. The heater element
has a built-in thermostat that turns
the heater on at 45ºF (7ºC) and off at
75ºF (24ºC).

The filter module also incorporates a

drain valve. The drain valve allows the
operator to drain the filter module if water
is detected in the fuel, and gives the
technician a place to take a fuel sample.

“The fuel filter The fuel filter module has two

module has two pressure test points. The pressure tap
pressure towards the front of the filter module
test points.” allows the fuel pressure on the non-
filtered side of the element to be
measured. This location leaves the
NOTE:
factory with a test port installed. The
The fuel pressure test other location, towards the rear of the
port is not installed. module, has a plug that can be removed
Use tool #ZTSE4542 to allow fuel pressure on the filtered
from the tool kit.
side of the element to be measured.
 Study Guide 29

ICP System Objectives:

• Identify features of the

The International® fuel system injection control pressure
uses electronically-controlled and system.

hydraulically-actuated unit injectors. • Identify injection

Each injector is supplied with high- control pressure system
components.
pressure oil to provide the mechanical
force required for injector operation. • Match injection control
The high-pressure oil system’s main pressure system
components with their
components are the reservoir, the high- functions.
pressure pump, the IPR valve, the high-
pressure rails, and the tube assemblies
that allow oil to flow from the pump to
reach each of the rails.

The high-pressure pump is mounted “The high-pressure

to the crankcase in the rear of the pump is mounted
engine’s valley. The pump is gear- to the crankcase in
driven directly off the camshaft gear. the rear of the
The pump’s inlet port aligns with
an O‑ringed port on the crankcase-
engine’s valley.”
mounting surface.

This port allows the pump to draw

engine oil from the reservoir cast in the
front of the crankcase V. Oil that passes
from the reservoir to the pump must
pass through the 150-micron screen
held in place within the reservoir by the
oil cooler. The reservoir is constantly
refilled with filtered and cooled engine oil
through a passage in the oil cooler cover.

High-pressure oil from the pump

discharges through a rear-facing port
into the branch adapter and the branch
30 International® VT 365, 2004 Engine, Program I: Introduction

tube. Oil moves through the branch

tube to the case-to-head tubes and
then to the oil rails. The oil rails then
distribute the pressurized oil to each
injector’s oil inlet through pipes on the
bottom of the rail.
ENGINE FACT: The pressure created by the high-
The opening and closing of pressure pump is called Injection
the spool valves during engine Control Pressure, or ICP. The
operation can cause pressure pressure requirement for ICP constantly
waves to develop in the rails.
A check valve and orifice in varies with engine RPM and load. The
each case-to-head tube acts to ECM calculates the desired ICP and
dampen the pressure waves.
sends a signal to the injection pressure
regulator valve. The IPR signal from
the ECM positions a spool valve within
the regulator that controls the amount
NOTE:. of oil drained from the pressure side
Depending on the date
of production, the of the system. At high RPM, light load,
location of the high the pump produces a larger volume
pressure oil check of oil than what is needed for injector
valve varies. Some
valves are found in operation. Because of this, the IPR
the case-to-head tube, must drain a quantity of oil back to the
while others are built engine’s oil pan. At lower RPM and
into the port plug. heavier load, the injectors require a
larger amount of oil so the IPR will drain
less from the system.
ENGINE FACT: The ECM constantly monitors the
In addition to controlling the action of the IPR from the ICP sensor.
system pressure, the IPR
also protects the system with This pressure is then compared to
an internal pressure relief
valve that opens if the system
the desired pressure. If the pressure
pressure reaches 4,400 psi. is incorrect, the IPR signal is changed
to correct the pressure. This process
occurs constantly and is called closed
loop.
 Study Guide 31

Injectors Objectives:

• Identify the components of

Each VT 365 injector is mounted the VT 365 injector.
in a machined opening in the cylinder
• Match injector components
head with a stainless steel cup covering with their functions.
the lower portion of the opening. The
cup serves as the coolant jacket in the
bottom part of the opening, allowing
better heat transfer from the injector to “Each VT 365
the coolant. The injector is sealed in theinjector is mounted
cylinder head with an O‑ring above the
in a machined
fuel port, an O‑ring below the fuel port,
and a metal gasket at the nozzle tip.
opening in the
cylinder head with
The injector is held in the head with a stainless steel
a self-extracting clamp. The clamp fits cup covering the
into a groove on the injector body and is lower portion of
attached to the cylinder head with one the opening.”
bolt. The bolt is held to the clamp with
a ring that causes the clamp to extract
the injector from its bore when the
clamp bolt is turned counterclockwise
and pulls the injector into the bore when
turned clockwise.

Fuel from the cylinder head drilling

enters a port on the side of the injector at “The operation of
approximately 60 psi. When the injector the G2 injector can
is in the fill stage, the fuel pressure lifts be divided into
a check valve in the injector and fills the four areas: the coil
barrel and plunger area.
and spool valve,
The operation of the G2 injector can
the intensifier
be divided into four areas: the coil and piston, the barrel
spool valve, the intensifier piston, the and plunger, and
barrel and plunger, and the nozzle. the nozzle.”
32 International® VT 365, 2004 Engine, Program I: Introduction

“With the valve Oil flow into and out of the injector
open, oil from the is controlled by the IDM by positioning
rail can enter the a spool valve in the top of the injector.
injector.” The spool valve is controlled by two
coils, the open coil and the close coil.
The spool valve is located in a bore in
the top of the injector and is positioned
by the magnetic force generated when
the IDM sends a 48-volt signal to the
appropriate coil. In operation, when the
IDM signals the open coil, the spool
valve shifts to the open position and
then the signal is turned off. The spool
valve is held in position by residual
magnetism. With the valve open, oil
from the rail can enter the injector.

When high-pressure oil enters the

injector, it pushes against the intensifier
piston. The top of the intensifier piston
is approximately seven times larger
than the plunger end. Therefore, the
plunger acts upon the fuel in the barrel
with seven times the force. This allows
3,000 psi of ICP to pressurize fuel to
approximately 21,000 psi.

When the plunger begins to move

down in the barrel, and fuel pressure
below the plunger starts to rise, the fuel
inlet check valve closes. This prevents
fuel from flowing back into the fuel rail
in the cylinder head. Fuel pressure
developed by the plunger travels down
a passage to the nozzle area. When
the force in the nozzle pushing on the
 Study Guide 33

needle bevel exceeds the force of the

nozzle spring, the needle rises and the
fuel is injected through the nozzle holes
into the combustion chamber.

When the IDM determines that “When the IDM

the correct quantity of fuel has been determines that the
delivered, a 48-volt signal is sent to correct quantity
the close coil, the spool valve shifts of fuel has been
position, and the signal is turned off.
With the spool valve in the closed
delivered, a 48-volt
position, high-pressure oil flow into the signal is sent to
injector is stopped, and oil pressure the close coil…and
pushing against the intensifier piston is the signal is turned
allowed to drain through ports in the top off.”
of the injector. This action allows fuel
pressure at the nozzle to drop.
34 International® VT 365, 2004 Engine, Program I: Introduction

NOTES
Study Guide 35

NOTES
36 International® VT 365, 2004 Engine, Program I: Introduction

Base Management System

Objectives: Cooling System

• Identify the function of
each component within the The purpose of the cooling system
cooling system. is to move excess heat energy from
• Identify the numerous the engine components to the radiator.
pathways of the cooling Heat transfers to the air flowing through
system.
the radiator, removing excess heat
• Identify the proper coolant energy. Then the coolant is recirculated
type. back to the engine. Major components
of the cooling system are the front
cover with thermostat and water pump,
the coolant passages of the crankcase
and cylinder heads, and the EGR
cooler and oil cooler.
“The purpose of
the cooling system The water pump is belt driven and
is to move excess mounts in a cavity on the front cover.
heat energy The pump pulls coolant from the
from the engine radiator through the front cover coolant
components to the inlet and directs the coolant to three
radiator.” passages on the front of the crankcase.
Two passages direct coolant through
the crankcase around the cylinders,
up through passages in the crankcase
deck and head gasket to the cylinder
head. While the coolant flows through
the cylinder head, heat transfers from
the engine to the coolant once the
engine warms up.

Coolant flows in the cylinder head

from the back of the head toward the
front and then back into a passage in the
 Study Guide 37

crankcase. Coolant then enters the front

cover and is directed to the thermostat.

If coolant is at operating temperature, “If coolant is

the thermostat opens and coolant at operating
flows through the thermostat to the temperature,
radiator. If coolant is below the opening the thermostat
temperature of the thermostat, the
coolant is directed through the front
opens and coolant
cover bypass passage back to the water flows through the
pump. Circulation in bypass mode helps thermostat to
the engine achieve a quicker warm-up. the radiator.”

The third passage on the front cover

directs coolant to the oil cooler cover.
Coolant flows through a passage in the
cooler and is directed to the oil cooler
inlet. As the coolant passes through
the cooler, heat transfers from the
cooler to the coolant and reduces the
engine’s oil temperature. Coolant exiting
the oil cooler cover enters the EGR
cooler. Again, heat transfers from the
cooler to the coolant to lower EGR gas
temperatures. Then the coolant moves
through a passage in the intake manifold
back to the front cover. Coolant returned
from the EGR cooler mixes with coolant
from the cylinder heads and then moves
to the thermostat.

When the optional air compressor is

mounted, the compressor is supplied
with coolant by a hose from the front
cover. Coolant flows through the
38 International® VT 365, 2004 Engine, Program I: Introduction

ENGINE FACT: compressor, absorbing heat, and then

Extended life coolant does returns to the front cover and flows to
not need to be replaced for the thermostat.
300,000 miles, 12,000 hours, or
5 years if the extender is added
at 150,000 miles, 6,000 hours, The VT 365 is designed to use
or 30 months. extended life coolant. Extended life
coolant can be identified by its red/
ENGINE FACT: orange tint in contrast to the green tint
of conventional coolant.
The 2004 VT 365 is designed
with a single- or dual-belt
drive, depending on the If the engine is configured with an air
configuration. If it is configured compressor, a second belt drives the
with an alternator alone or
with an alternator and an air
unit.
conditioning compressor, one
belt does the job. Lubrication System

In the 2004 VT 365, lube oil is used

Objectives: for engine lubrication, valve tappet
operation, piston crown cooling, injector
• Identify the function of activation, and turbocharger control.
each component within the
lubrication system.
The main components of the system
• Identify the numerous
pathways of the lubrication
are the oil pump and regulator valve, the
system. oil cooler and filter module with valves,
and the oil passages.
• Determine the correct
capacities of the oil
lubrication system. The gerotor type oil pump gear set
rides in a cavity machined into the
front cover. The inner rotor of the gear
set is driven directly off two flats on
the crankshaft.

The pump draws oil from the oil

pan into the pick-up tube, through a
passage in the upper oil pan and lower
crankcase, then into the pump itself.
 Study Guide 39

Rotation of the pump-gear set forces

oil to the outlet side of the pump and
causes oil to leave under pressure.

The pressure regulator is mounted

on the front cover below the pump
and is accessible through a removable
plug. If oil pressure exceeds 55 psi, the
regulator piston begins to open and
dumps excess oil back to the inlet side
of the pump.

Oil discharged from the pump moves “Oil discharged

through the front cover, up a vertical from the pump
passage in the crankcase, then into the moves through the
oil cooler cover. front cover, up a
Oil travels through the cooler and into
vertical passage in
the filter housing. Oil passes through the the crankcase, then
filter media, through the standpipe and into the oil
into the crankcase passages that feed oil cooler cover.”
to the left and right bank oil galleries.

The right bank gallery feeds the right

bank cam followers, piston cooling jets,
cam bearings, and the main bearings.
The left bank gallery feeds only the left
bank cam followers and the left bank
piston cooling-jets.

Crankshaft cross-drillings between

the crankshaft main bearing journals
and the connecting rod journals allow
pressurized oil at the main bearings
to pass through the crankshaft and
lubricate the rod bearings.
40 International® VT 365, 2004 Engine, Program I: Introduction

Oil that passes through the filter also

moves through a passage in the oil filter
base to provide oil to the turbocharger
supply tube and, if equipped, the
optional air compressor.

“Oil also passes Oil also passes through an opening

through an opening in the cooler cover to fill the high-
in the cooler pressure pump reservoir.
cover to fill the
Oil from the cam followers travels up
high-pressure the push tubes, and splash lubricates
pump reservoir.” the valve train components.

To protect the engine, the oil filter

base includes a cooler bypass valve and
a filter bypass valve. During engine
operation when the oil is cold and thick,
the engine is protected from reduced oil
flow by the cooler bypass valve. When
the oil pressure at the cooler inlet is
20 psi greater than the oil pressure in
the filter, the cooler bypass valve opens
and the oil goes directly into the filter,
bypassing the oil cooler.

In addition, there is a filter bypass

valve located in the top of the oil
filter standpipe. If the filter becomes
restricted, the filter bypass valve opens
and allows oil to continue to lubricate
the engine.
 Study Guide 41

There is also an anti drain-back valve

in the oil filter base. The anti drain-back
valve is used to stop oil in the filter
housing from draining back to the sump
when the engine is shut down.

In addition to these valves, the filter ENGINE FACT:

base has a drain valve. The drain valve The service interval for the
opens automatically when the filter- engine oil and filter is 10,000
housing cap is removed and the filter is miles, 350 hours, 1,000 gallons
of fuel, or 6 months.
lifted. This facilitates draining the filter
housing of used oil during an oil change.

Crankcase Ventilation

The VT 365 has a closed crankcase.

The left bank valve cover has a
breather box connected between the ENGINE FACT:
turbocharger compressor inlet boot and
the crankcase. The system does not require
maintenance, but technicians
should be aware that
Crankcase gases that enter the recirculation of crankcase
boot are pulled into the intake charge gases back into the intake
will leave an oil residue in
and recirculated into the combustion the turbo and the charge-air-
chambers. cooler piping.
42 International® VT 365, 2004 Engine, Program I: Introduction

NOTES
Study Guide 43

NOTES
44 International® VT 365, 2004 Engine, Program I: Introduction

Module III Unique Service Procedures

VT 365
This module covers special repair
considerations for 2004 VT 365
engines. This information is provided
as a preliminary overview to help
technicians deal with any immediate
repair work that may be required.

“Before performing Before performing work of any kind,

work of any kind, refer to ISIS® for the most current
refer to ISIS® service information.
for the most
As we have already mentioned,
current service detailed step-by-step diagnostic and
information.” repair procedures will be covered in
the upcoming programs of this training
series.

As we review these VT 365 repair

procedures, keep in mind that proper
service techniques, environmental
concerns, and safety are the most
important parts of the process.

Perform service inside a well

ventilated, dry shop. Make sure the
vehicle is parked on a flat surface, with
“When working on the parking brake set and the wheels
blocked.
the engine, keep
the work area and When working on the engine, keep
tools as clean the work area and tools as clean as
as possible.” possible. Also, clean all connections
 Study Guide 45

or fittings before disconnecting or

removing components.

Use a suitable pan to catch any fluid

when disconnecting components.

All engine line openings should be

immediately plugged during removal
and remain so until reinstallation to
prevent the entry of dirt, moisture and
other foreign material.

Exercise extreme caution once the

valve cover is removed. Even the slightest
particle can cause unexpected problems.

Wear safety glasses and chemical-

blocking nitrile gloves when performing
work of any kind.

Before we get started, always

be sure you follow proper service
procedures. For example, be sure the
batteries are disconnected before
performing engine work.

Oil Filter Replacement

Loosen the oil filter cap to drain oil

from the filter housing to the crankcase.

Remove the oil filter and discard it “Remove the oil

properly. filter and discard it
properly.”
Note that the oil filter snaps into the
oil filter lid.
46 International® VT 365, 2004 Engine, Program I: Introduction

Install the new oil filter element,

and tighten the oil filter cap to the
recommended torque.

Refer to ISIS® for the appropriate

torque specification.

Fuel Filter Replacement

“Using the drain Using the drain valve located on the

valve located on side of the fuel filter housing, drain the
the side of the fuel fuel into an appropriate container.
filter housing, drain
Remove the fuel filter cap using an
the fuel into oil filter wrench. Remove and properly
an appropriate discard the element.
container.”
Close the fuel drain valve.

Install the new fuel filter element, and

fill the fuel filter housing with clean fuel.
Tighten the fuel filter cap until it’s snug.

High-Pressure Rail Removal

.
! CAUTION:.
After removing the valve cover,
Be careful not to pry remove the high-pressure rear oil
against the valve supply plug. Remove the nine high-
cover sealing surface
to remove the rail to pressure oil rail bolts. Then pull the rail
prevent damage to the from the head.
sealing surface.
Finally, remove the case-to-head tube
assembly.
 Study Guide 47

High Pressure Rail Installation

.
Install the rail onto the injectors and ! CAUTION:.
torque the nine bolts to the rocker Note that the engine
lever carrier. Refer to ISIS® for the will not start if any of
the four port plugs are
appropriate specifications. not installed in the
correct locations. Two
Lubricate the case-to-head tube of the plugs are found
assembly O‑rings, and install the tube on the left side of the
engine and two on .
into the oil rail opening. the right side of .
the engine.
Replace the high pressure rear oil
supply plug, and torque it. Refer to
ISIS® for the appropriate specifications.

Injector Removal
“To disconnect the
The injector connectors on the external engine
VT 365 are locked into the rocker lever wiring harness
carrier.
from the injector,
To disconnect the external engine push in on the
wiring harness from the injector, push in spring loaded
on the spring-loaded metal clip on the metal clip on the
harness. harness.”
To remove the injector connector .
from the rocker lever carrier, use ! CAUTION:.
ZTSE4650. Place the open end of Be sure that you don’t
the tool over the connector and push pry on the injector
inward lightly to disengage the locks. coils to remove the
injector. They may
Then pull the connector out of the be damaged and are
rocker lever carrier. not replaceable. Also,
watch for rocker-
To remove the injector, loosen the arm-to-injector
bolt that holds the injector in place. This interference.
will also unseat the injector from its bore.
48 International® VT 365, 2004 Engine, Program I: Introduction

Do NOT use air tools to remove the

injector. This can lead to injector seat
damage.

Carefully lift the injector from the

bore.

Make sure that the copper gasket at

the bottom of the injector has not fallen
into the injector bore.

Carefully remove the external O‑rings.

“Be careful not to Be careful not to scratch the injector

scratch the injector body during removal, or the replacement
body during O‑rings may not seal.
removal, or the
Carefully install new O‑rings on the
replacement injector body.
O‑rings may
not seal.” Don’t attempt to remove the oil inlet
O‑ring. It is not replaceable.

To install the copper gasket to the

.
injector tip, use a twelve point, 9 mm
! CAUTION:.
deep-well socket so that pressure
To prevent wiring is applied evenly around the gasket
damage, don’t pull during installation.
on the wires while
working with.
the injector. If the gasket is misshaped or
damaged during installation, it must be
replaced.

The oil inlet O‑ring cannot be

serviced. If the O‑ring leaks or is
otherwise damaged, the injector must
be replaced.
 Study Guide 49

Lubricate the upper and lower

O‑rings on the body of the injector.
Place the injector with its hold down
clamp into the bore.

Make sure that the copper washer

doesn’t fall off the tip of the injector.

Tighten the hold down bolt to the

specified torque. .
! CAUTION:.
Lubricate the internal O‑ring at the
Removing any of the
top of the injector. 14 mm cylinder head
bolts from the VT 365
Reinstall the rail as described earlier engine requires that
in this module. the cylinder head be
removed, and that the
cylinder head gasket
Cylinder Head Removal and the cylinder head
bolts be replaced.
The rocker lever carrier is held in
place with eight small bolts and the 10 NOTE:.
cylinder head bolts.
Special tool ZTSE4697
Remove the five small bolts that hold will allow the rocker
arms to be removed
the cylinder head to the crankcase. Lift without removing the
the cylinder head from the crankcase. 14 mm cylinder .
head bolts.
The rocker arm push rods must be
installed in their original position during .
reassembly. ! CAUTION:.
The valve bridges must be installed If the rocker arms and/
or valve bridges are
in their original position and orientation not correctly installed, .
during reassembly. premature valve train
wear may result.
50 International® VT 365, 2004 Engine, Program I: Introduction

Glow Plug Harness Removal

and Installation

“To properly To properly remove the glow plug

remove the glow wiring harness from the glow plugs,
plug wiring use ZTSE4670.
harness from the
Any other method could lead to
glow plugs, wiring harness damage.
use ZTSE4670.”
Glow Plug/Injector Sleeve
Removal

Using ZTSE4531, place the tap into

.
the glow plug sleeve, and cut threads
! CAUTION:.
into the sleeve.
The cylinder head must
be removed to replace Remove the tap, and insert the puller
the glow plug sleeve.
into the glow plug sleeve.

Turn the puller clockwise until the

sleeve is removed.

Glow Plug Sleeve Installation

Clean the old sealant residue from
the bore with a wire brush before
installing the new sleeve.

“Apply Loctite® 620 Apply Loctite® 620 sealant to the two

sealant to the two locations where the sleeve contacts the
locations where the cylinder head.
sleeve contacts the
Use ZTSE4532 to drive the glow
cylinder head.” plug sleeve into the cylinder head.
 Study Guide 51

Use a nylon brush to clean any

sealant residue from the glow plug
sleeve.

EGR Valve Removal

To remove the EGR valve, remove “To remove the

the two mounting screws from the EGR valve, remove
intake manifold. the two mounting
screws from the
Rotate the valve so that the mounting
tabs on the valve align with the EGR intake manifold.”
valve puller, tool ZTSE4543.

Position the other two legs of the

puller on the bolt bosses of the intake
manifold, and turn the forcing screw
clockwise.

When reinstalling the valve, check the

O‑rings for cuts and nicks. Replace the
O‑rings as necessary.

EGR Cooler Removal

Before removing the EGR cooler, “Before removing
you must first drain the coolant from the the EGR cooler,
cooling system. you must first
To disconnect the hose that supplies drain the coolant
coolant to the EGR cooler, rotate it and from the
pull it until the tabs release. cooling system.”
Both the inlet and outlet for exhaust
gasses are sealed with metal gaskets.

The coolant connections are sealed

with O‑rings within the hose.
52 International® VT 365, 2004 Engine, Program I: Introduction

NOTES
Study Guide 53

NOTES
54 International® VT 365, 2004 Engine, Program I: Introduction

Turbocharger Removal

The right side exhaust up-pipe can

be separated above the EGR exhaust
connection.

This connection is sealed with a

gasket.

There are two other connections

that must be removed to remove the
turbocharger.

One is at the left exhaust manifold;

this is a flange seal without a gasket.

The other connection is at the turbine

housing. It is held together with a
V band clamp.

The turbocharger oil feed line is

bolted to the oil filter base and sealed
with an O‑ring.

The connection at the turbocharger

is a bolted flange and is sealed with a
. gasket.
! CAUTION:.
Remove all three bolts to remove the
Since the VT 365 uses line from the turbocharger.
a closed crankcase
ventilation system, it is
normal to see oil carry To disconnect the crankcase
over into the intake. ventilation tube from the engine, remove
air system.
the air inlet tube from the compressor
 Study Guide 55

inlet, and rotate the vent counter

clockwise until it releases.

The turbocharger is located on the

pedestal with two dowel pins. Remove
the three turbocharger bolts. Then lift
the turbo off the pedestal.

The turbocharger oil drain tube is “The turbocharger

located under the turbocharger and is oil drain tube is
sealed with O‑rings. located under the
turbocharger and
To remove the oil drain tube, pull it
forward out of the high pressure pump
is sealed with
cover. O‑rings.”

Intake Manifold
“Note that the
When reinstalling the intake manifold, intake manifold
the locating tabs on the intake manifold gasket and
gasket should face up and toward the
bolts can be
center of the engine.
pre-assembled
Note that the intake manifold gasket to the intake
and bolts can be pre-assembled to the manifold to make
intake manifold to make installation installation easier.”
easier.

High Pressure Pump Cover

Removal

Remove the IPR Valve from the pump

before attempting to remove the high
pressure pump cover.
56 International® VT 365, 2004 Engine, Program I: Introduction

After removing the bolts that hold

the high pressure pump cover to the
crankcase, pull the cover straight up to
disengage it from the pump body.

Replace the pump cover push-in-

place gasket and the pump-to-cover
seal ring whenever the pump cover is
removed. Lubricate the pump-to-cover
seal before pushing the cover into place
over the pump body.

Front Cover Removal

The front cover gasket is sealed

.
with a dab of RTV sealant at the point
! CAUTION:.
where the two halves of the crankcase
If the dowels are meet. This sealant must be cut before
missing or damaged, removing the front cover.
the front cover could
be misaligned, and
damage to the cover or The front cover is aligned to the
oil pump could result. crankcase with dowels.

Alignment pins should be used to aid

in installation.
 Study Guide 57

The lube oil pump is positioned on “The lube oil pump

the front cover with dowels and sealed is positioned on
with a push-in-place gasket. the front cover with
dowels and sealed
When installing the front cover, a dab
of RTV sealer must be applied to the with a push-in-
joint between the upper crankcase and place gasket.”
the lower crankcase.

Be aware that if too much sealant

is applied, it could get into the lube oil
system.

Conclusion
This concludes the introduction
to 2004 VT 365 unique repairs and
Program One of this VT 365 engine
training series.
58 International® VT 365, 2004 Engine, Program I: Introduction

NOTES
Study Guide 59

NOTES