International VT 275 V6 Manual
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International VT 275 V6 Manual

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VT 275
V6 ENGINE
model year 2005

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Summary of Contents for International VT 275 V6

  • Page 1 ® VT 275 V6 ENGINE model year 2005...

  • Page 2: Safety Information

    1. Type A - Wood, paper, textiles, and rubbish 2. Type B - Flammable liquids 3. Type C - Electrical equipment International ® VT 275 V6 Engine...

  • Page 3: Table Of Contents

    INDEX ............108 International ® VT 275 V6 Engine...
  • Page 5 • Rear Gear Train • Primary Balancer • Regulated Two-Stage Turbocharging System • Four Valves per Cylinder • Cooled Exhaust Gas Recirculation • Electro-Hydraulic Generation 2 Fuel Injection System • Top Mounted Oil and Fuel Filters International ® VT 275 V6 Engine...

  • Page 6: Overview

    1800 rpm. The engine has a high idle speed of 2775 rpm with automatic transmission. The engine idle speed is set at 700 rpm and is not adjustable. Torque (ft-lb) Power (HP) Engine Speed (RPM) International ® VT 275 V6 Engine...
  • Page 7 • The cylinders on the VT 275 are numbered from the front of the right bank 1, 3, 5 and from the front of the left bank 2, 4 and 6. • The engine firing order is 1-2-5-6-3-4 International ® VT 275 V6 Engine...

  • Page 8: Component Locations

    O O I I L L P P U U M M P P C C O O V V E E R R O O I I L L P P U U M M P P C C O O V V E E R R International ® VT 275 V6 Engine...
  • Page 9 S S M M O O O O T T H H I I D D L L E E R R P P U U L L L L E E Y Y International ® VT 275 V6 Engine...
  • Page 10 F F U U E E L L R R E E T T U U R R N N T T O O T T A A N N K K F F U U E E L L R R E E T T U U R R N N T T O O T T A A N N K K International ® VT 275 V6 Engine...
  • Page 11 R R E E A A R R C C O O V V E E R R R R E E A A R R C C O O V V E E R R International ® VT 275 V6 Engine...
  • Page 12 H H I I G G H H P P R R E E S S S S U U R R E E P P U U M M P P C C O O V V E E R R International ® VT 275 V6 Engine...
  • Page 13 L L O O W W E E R R O O I I L L P P A A N N L L O O W W E E R R O O I I L L P P A A N N International ® VT 275 V6 Engine...
  • Page 14 C C R R A A N N K K C C A A S S E E C C R R A A N N K K C C A A S S E E International ® VT 275 V6 Engine...
  • Page 15 A A N N D D F F A A N N D D R R I I V V E E A A N N D D F F A A N N D D R R I I V V E E International ® VT 275 V6 Engine...
  • Page 16 L L O O W W P P R R E E S S S S U U R R E E T T U U R R B B O O C C O O M M P P R R E E S S S S O O R R H H O O U U S S I I N N G G International ® VT 275 V6 Engine...
  • Page 17 ( ( A A L L T T E E R R N N A A T T O O R R N N O O T T S S H H O O W W N N ) ) International ® VT 275 V6 Engine...

  • Page 18: Design Features

    P P L L A A T T E E C C O O N N N N E E C C T T O O R R O O P P E E N N I I N N G G International ® VT 275 V6 Engine...
  • Page 19 C C R R A A N N K K C C A A S S E E C C R R A A N N K K C C A A S S E E International ® VT 275 V6 Engine...
  • Page 20 C C R R A A N N K K S S H H A A F F T T F F L L A A N N G G E E & & G G E E A A R R International ® VT 275 V6 Engine...
  • Page 21 • Couple imbalance forces in the engine are offset by the balance shaft forces as it rotates at crankshaft speed but in the opposite direction. International ® VT 275 V6 Engine...

  • Page 22: Electronic Control System

    Magnetic pick-up sensors feature high reliability and accuracy. • The VT 275 engine uses a twin turbocharger with ECM boost control. EGR DRIVE APS / IVS MODULE International ® VT 275 V6 Engine...
  • Page 23 ECM X1 and X2 connectors are for engine sensor inputs and X3 and X4 are for chassis inputs. The IDM X1 and X2 connectors are for injector operation and chassis inputs communication between the ECM and IDM. International ® VT 275 V6 Engine...
  • Page 24 I I N N L L E E T T A A I I R R H H E E A A T T E E R R International ® VT 275 V6 Engine...
  • Page 25 The valve contains a pressure relief valve for the system that opens if system pressure reaches 4500 psi. The IPR is protected by a heat shield that must be reinstalled after servicing. International ® VT 275 V6 Engine...
  • Page 26 This voltage is then converted into a variable frequency that is sent to the ECM. The MAF value can be read with MasterDiagnostics ® software in lb./min. International ® VT 275 V6 Engine...
  • Page 27 3. The two fuses are in series, with F4 feeding both the IDM and ECM relays, and F41 dedicated to protecting the ECM circuit alone. Pin 1 supplies voltage to the relay coil. International ® VT 275 V6 Engine...
  • Page 28 PDC F-4 fuse to IDM relay pin 30 and 85 at all times. Pin 85 supplies voltage to the relay coil. Pin 86 takes that voltage through pin 8 of the engine 12-way connector to pin X3-27 of the IDM. International ® VT 275 V6 Engine...
  • Page 29 The EOT signal is thermistor's resistance changes. input into calculations that When the temperature is low, the determine the fuel quantity and timing. sensor's resistance is high and the International ® VT 275 V6 Engine...
  • Page 30 40 psi. When the oil pressure is gauge that senses changes in that determine fueling quantities below 5 psi, MasterDiagnostics ® pressure. Sensor mounted and the desired EGR valve position. will display 0 psi. electronic circuitry converts the International ® VT 275 V6 Engine...
  • Page 31 The peg the magnet. The two tooth gap passes the sensor once per allows the ECM to calculate the camshaft revolution producing an position of the crankshaft. AC signal in the coil. International ® VT 275 V6 Engine...
  • Page 32 Warm up time decreases as warm up. Air Heater Test. The test can only barometric air pressure increases. be activated twice per key cycle. The glow plugs may continue to be energized after start-up reduce emissions. International ® VT 275 V6 Engine...
  • Page 33 4 of the engine 12-way connector. The other end of the coil receives 12 volts from ECM pin X1-18 to close the relay contacts. International ® VT 275 V6 Engine...
  • Page 34 ECM. The correct key-on, engine-off frequency is 400+100 Hz. International ® VT 275 V6 Engine...
  • Page 35 Module (HFCM) contains a fuel heater. When the key is ON, the fuel heater relay latches and provides power to pin 1 of the heater connector. The heater element contains thermostat that controls the heater operation. International ® VT 275 V6 Engine...
  • Page 36 ECM when the changes. pedal is in the idle position. If the ECM detects an APS signal out of range high or low, the ECM will ignore the APS signal and operate at low idle. International ® VT 275 V6 Engine...
  • Page 37 One lead of each coil set is armature occurs. connected to the respective motor circuit on the drive module. The other leads from all of the nine coils are joined together. International ® VT 275 V6 Engine...
  • Page 38 Crank Position Output (CKPO) desired EGR valve position with the • The CKPO signal is a 0-12V digital EGR drive module over the CAN 2 signal used to communicate the link. The EGR Drive Module International ® VT 275 V6 Engine...
  • Page 39 (HPSW) interrupts compressor • The A/C demand signal originates satisfied, the thermostat will open operation in the event of high at the ECM as a reference voltage and the demand signal will be 5V. system pressures. International ® VT 275 V6 Engine...

  • Page 40: Air Management System

    EGR valve, and the turbocharger boost Left Exhaust system exhaust in control solenoid. Left cylinder Right cylinder Left exhaust Right exhaust head head manifold manifold valve Intake manifold cooler Exhaust to dual stage turbocharger Exhaust tube assembly Left Right International ® VT 275 V6 Engine...
  • Page 41 Air The exhaust passes through the that leaves low-pressure International ® VT 275 V6 Engine...
  • Page 42 EGR valve is open and the exhaust backpressure is higher than the boost pressure. • The manifold has an additional internal passage for coolant from the EGR cooler to return to the front cover. International ® VT 275 V6 Engine...
  • Page 43 (BCS) pressure turbine housing, causing closed. When the BCS is closed, low-pressure turbine boost pressure builds in the compressor to spin. pneumatic actuator, and when boost is sufficient, the actuator will International ® VT 275 V6 Engine...
  • Page 44 T T U U R R B B I I N N E E H H O O U U S S I I N N G G T T U U R R B B I I N N E E H H O O U U S S I I N N G G International ® VT 275 V6 Engine...
  • Page 45 When the BCS is open, the pressure in the black tube is vented to atmosphere through the green tube. When the BCS is closed, pressure in the manifold will build in the actuator. ACTUATOR exhaust MANIFOLD International ® VT 275 V6 Engine...
  • Page 46 P P O O I I N N T T change the relationship of the two mounting points and require that a special mounting and torque sequence be used. See the Service Manual for further details. International ® VT 275 V6 Engine...
  • Page 47 O-rings. • When the EGR valve opens, exhaust gases flow into the intake charge air from both the top and bottom of the passage, providing better distribution of the gases. International ® VT 275 V6 Engine...

  • Page 48: Fuel Supply System

    The valve regulates recirculation through the system to assist the heater in warming the fuel. The secondary filter and fuel pressure regulator valve are mounted on the engine. International ® VT 275 V6 Engine...
  • Page 49 WIF sensor. but will not run properly. Pressurized fuel from the pump is routed to the engine-mounted filter. Fuel flows through the filter, then International ® VT 275 V6 Engine...
  • Page 50 After the valve closes, all returned fuel is directed back to the tank. International ® VT 275 V6 Engine...
  • Page 51 • Each fuel line fitting is sealed to the B B A A N N J J O O B B O O L L T T cylinder head by two copper gaskets that must be replaced if the bolt is removed. International ® VT 275 V6 Engine...
  • Page 52 R R E E A A R R O O F F E E N N G G I I N N E E R R E E A A R R O O F F E E N N G G I I N N E E International ® VT 275 V6 Engine...

  • Page 53: Fuel Management System

    Oil discharged by the pump enters the rear branch tube. The branch tube serves to transfer the oil to the case-to-head tubes. International ® VT 275 V6 Engine...
  • Page 54 P P U U M M P P C C O O V V E E R R P P U U M M P P C C O O V V E E R R International ® VT 275 V6 Engine...
  • Page 55 • The front port plug is used to block oil from leaking into the valve train area. Both port plugs must be in place for the engine to build ICP sufficient to start the engine. International ® VT 275 V6 Engine...

  • Page 56: Injector Operation

    The coils draw needed to inject fuel into the 20 amps. cylinders. Each injector has two coils. International ® VT 275 V6 Engine...
  • Page 57 N N O O Z Z Z Z L L E E H H O O L L E E S S N N O O Z Z Z Z L L E E H H O O L L E E S S International ® VT 275 V6 Engine...
  • Page 58 • When fuel pressure rises above the valve opening pressure, the nozzle needle lifts off its seat and injection begins. Oil Pressure High Pressure Oil Atmosphereic Pressure Fuel Pressure Fuel Supply Pressure Above 3100 PSI International ® VT 275 V6 Engine...
  • Page 59 N N O O Z Z Z Z L L E E G G A A S S K K E E T T G G A A S S K K E E T T International ® VT 275 V6 Engine...

  • Page 60: Lubrication System

    R R E E G G U U L L A A T T O O R R R R E E G G U U L L A A T T O O R R International ® VT 275 V6 Engine...
  • Page 61 After passing through the cooler, oil enters the oil adapter assembly and is directed to the filter. The top of the filter standpipe International ® VT 275 V6 Engine...
  • Page 62 • All of the passages from the front cover to the crankcase are sealed with a silicon-in- metal, one-piece gasket. International ® VT 275 V6 Engine...
  • Page 63 R R E E G G U U L L A A T T O O R R S S P P R R I I N N G G International ® VT 275 V6 Engine...
  • Page 64 O O I I L L F F I I L L T T E E R R B B A A S S E E • The oil filter adapter mounts the oil pressure switch and the oil temperature sensor, and feeds oil to the turbocharger lubrication line. International ® VT 275 V6 Engine...
  • Page 65 O O I I L L F F I I L L T T E E R R H H O O U U S S I I N N G G International ® VT 275 V6 Engine...
  • Page 66 The screen in the reservoir filters any large debris that may be in the oil before it gets to the high-pressure pump. S S C C R R E E E E N N International ® VT 275 V6 Engine...
  • Page 67 EGR cooler. 5. Filter Drain: Allows drain oil from the filter to reach the oil pan when the filter is removed. 6. Reservoir: Feed to the high-pressure pump. International ® VT 275 V6 Engine...

  • Page 68: Cooling System

    Coolant leaving the water pump is also directed to the oil cooler where it travels between the plates of the oil cooler and then to the EGR cooler. International ® VT 275 V6 Engine...
  • Page 69 To prevent mixing of oil and coolant, the area between the two seals is vented through a weep hole on the cooler cover. This allows leakage past either seal to weep out of the cooler cover. International ® VT 275 V6 Engine...
  • Page 70 I I N N J J E E C C T T O O R R S S L L E E E E V V E E I I N N J J E E C C T T O O R R S S L L E E E E V V E E International ® VT 275 V6 Engine...
  • Page 71 • The smaller smooth pulley is the lower idler on the right side of the front cover when viewed from the front of the engine. Power steering pump A/C Compressor Vibration Damper International ® VT 275 V6 Engine...
  • Page 72 R R E E A A R R C C O O V V E E R R R R E E A A R R C C O O V V E E R R International ® VT 275 V6 Engine...

  • Page 73: Unique Repair Procedures

    Tighten all bolts in sequence to specification using the torque sequence. Use an alternating pattern across the center to evenly pull down 1 1 0 0 1 1 0 0 the flexplate. International ® VT 275 V6 Engine...
  • Page 74 L L O O W W P P R R E E S S S S U U R R E E T T U U R R B B I I N N E E O O U U T T L L E E T T Removing Turbocharger • Lift the turbocharger from the high- pressure pump cover. International ® VT 275 V6 Engine...
  • Page 75 T T U U R R B B I I N N E E M M A A T T I I N N G G C C L L A A M M P P International ® VT 275 V6 Engine...
  • Page 76 A small amount of soap and water solution maybe needed to get the seal over the turbine inlet. International ® VT 275 V6 Engine...
  • Page 77 I I N N J J E E C C T T O O R R P P A A S S S S T T H H R R O O U U G G H H injector hold-down clamp bolts are removed. International ® VT 275 V6 Engine...
  • Page 78 C C A A S S E E - - T T O O - - H H E E A A D D T T U U B B E E the oil rail. Torque the port plug to specification. • Note: The O-rings are not serviceable. Inspect the O-rings and replace the case- to-head tube and port plug if the seals are damaged. International ® VT 275 V6 Engine...
  • Page 79 Reinstall the rocker arms using the compressor tool. • Caution: Be careful not to drop the rocker arm ball into the engine. International ® VT 275 V6 Engine...
  • Page 80 ( ( E E X X H H A A U U S S T T ) ) ( ( E E X X H H A A U U S S T T ) ) International ® VT 275 V6 Engine...
  • Page 81 I I N N T T A A K K E E on the gasket. M M A A N N I I F F O O L L D D G G A A S S K K E E T T International ® VT 275 V6 Engine...
  • Page 82 • Tighten all bolts 9 through 12 in sequence to 23 lb-ft. Vibration Damper • If the vibration damper bolts are removed, they are not reusable and must be discarded. Torque the new bolts to specifications in the proper sequence. International ® VT 275 V6 Engine...
  • Page 83 C C R R A A N N K K S S H H A A F F T T F F L L A A N N G G E E B B O O L L T T S S International ® VT 275 V6 Engine...
  • Page 84 T T H H R R U U S S T T P P L L A A T T E E flat on the shaft and a flat on the counterweight. International ® VT 275 V6 Engine...
  • Page 85 T T I I M M I I N N G G the balance shaft gear dot, the flange gear D D O O T T S S dot and the timing-pin hole will be in a straight line. International ® VT 275 V6 Engine...

  • Page 86: Special Tools

    • IPR Valve Socket • Fuel Inlet Restriction Adapter Part No. 180971C91 ZTSE4515A • Oil Fill Extension • Rear Seal/Wear Sleeve installer ZTSE4518 ZTSE4581 • Rear Wear Sleeve • Quick Release Tool Removal Tool International ® VT 275 V6 Engine...
  • Page 87 ZTSE4559 ZTSE4694 • Intake Port Magnetic • Case-to-head Tube Covers Removal Tool ZTSE4531 ZTSE4532 • Glow Plug Sleeve • Glow Plug Sleeve Remover Installer ZTSE4528 ZTSE4529 • Injector Sleeve • Injector Sleeve Remover Installer International ® VT 275 V6 Engine...
  • Page 88 ZTSE4664 ZTSE4696 • EGR Valve Breakout • Fuel Pressure Test Harness Adapter ZTSE7559 ZTSE4510 • Vacuum Pump and • Crankcase Pressure Gauge Test Adapter ZTSE4665 ZTSE4650 • 12-Pin Brakeout • Injector Connector Harness Remover International ® VT 275 V6 Engine...
  • Page 89 Test Coupler Pump Magnetic Covers ZTSE4682 ZTSE4542 • Intake Manifold • Fuel Pressure Test Pressure Test Cap Fitting (used for oil pressure measurement) ZTSE4409 ZTSE4594 • Gauge Bar Tool • ICP System Test Adapter International ® VT 275 V6 Engine...
  • Page 90 S " c t i " s International ® VT 275 V6 Engine...
  • Page 91 < < n i t y t i o i t c i t International ® VT 275 V6 Engine...
  • Page 92 ° ° o l i l i o n i l . t s y f i n i l y f i n i l i t c International ® VT 275 V6 Engine...
  • Page 93 , e l c i l c i t International ® VT 275 V6 Engine...
  • Page 94 • If the fuel continues to show signs of aeration, check the suction side of the system for air leaks. *Consult service literature for latest information before attempting any repairs International ® VT 275 V6 Engine...
  • Page 95 0-30 in/hg pressure gauge and record the restriction. • If inlet restriction causes a gauge reading of greater than 6 in/Hg, check the lines from the fuel tank to the pump for restrictions. International ® VT 275 V6 Engine...
  • Page 96 • Inspect the IPR connector for corrosion. Perform the KOEO Standard test. The standard test will verify the IPR circuit. If the circuit has a fault, a 241 DTC Oil drain to sump will be set. International ® VT 275 V6 Engine...
  • Page 97 This verifies the ECM signal can operate the IPR valve internally. If the faint air leak stops when the IPR is given power and ground, perform the pump test. International ® VT 275 V6 Engine...
  • Page 98 Leave the valve covers off. Crank the engine while measuring ICP pressure. If the engine starts or ICP pressure exceeds 500 psi, the leak causing the low ICP is in the right bank. International ® VT 275 V6 Engine...
  • Page 99 Oil should come up from the High Pressure Pump Test Verifies the pump’s operation pump passage indicating that the reservoir has oil. If the reservoir had oil, the pump is inoperative. International ® VT 275 V6 Engine...

  • Page 100: Diagnostic Trouble Codes

    315* EWPS Engine speed above warning level *indicates amber ENGINE lamp on when DTC is set ** indicates red ENGINE lamp on when Engine Warning Protection System is enabled and a DTC is set International ® VT 275 V6 Engine...
  • Page 101 Calibration level incompatible Programmable parameter memory content corrupt *indicates amber ENGINE lamp on when DTC is set ** indicates red ENGINE lamp on when Engine Warning Protection System is enabled and a DTC is set International ® VT 275 V6 Engine...

  • Page 102: Engine & Chassis Schematic

    1 3 5 n i l n i l n i l s t i o l l e t i n i l n i l 1 2 3 e t l t u l International ® VT 275 V6 Engine...
  • Page 103 ) - ( ) - ( c i t y l l c t i y l l c t i ) - ( t u l t u l ) - ( © International ® VT 275 V6 Engine...
  • Page 104 POWER DISTRIBUTION CENTER Consult service literature for latest information before attempting any repairs International ® VT 275 V6 Engine...
  • Page 105 CONJOINER 2 TRANS TRAILER BATT A/C CLUTCH RELAY CIGAR LIGHTER FOG LAMPS HAZARD IDM RELAY KEYLESS WIPER RADIO STARTER RELAY DOME BLANK BLANK PARK LAMPS ABS PUMP TRANS RELAY DIODE BLANK *indicates engine related fuse International ® VT 275 V6 Engine...

  • Page 106: Glossary

    EGR Valve A data link between the vehicle modules and ECM. A valve that regulates the flow of exhaust gasses into the intake manifold. CAN 2 The private link between the ECM and IDM. International ® VT 275 V6 Engine...
  • Page 107 Boost pressure in the manifold that is a result of the turbocharger. Manifold Absolute Pressure (MAP) Sensor A variable capacitance sensor that measures boost pressure. Manifold Air Temperature (MAT) Sensor A thermistor style sensor used to indicate air temperature in the intake manifold. International ® VT 275 V6 Engine...

  • Page 108: Index

    Counter Weight, 21 High Pressure Oil Rail, 52, 55, 57 Crankcase Breather, 40 High Pressure Pump, 16, 52, 54, 99 Crossover Tube, 14, 41, 46, 75, 76 Horizontal Full Conditioning Module (HFCM), 35, 48-50 International ® VT 275 V6 Engine...
  • Page 109 Pulse Width Modulated (PWM), 24, 37, 45 Water-In-Fuel Sensor, 35 Reference Voltage (VREF), 36, 107 Water Pump, 64, 67-69, 71 Rear Cover, 11, 72, 84, 85 Rear Gear Train, 5, 20 Rocker Arm, 18, 79, 80 International ® VT 275 V6 Engine...
  • Page 110 NOTES International ® VT 275 V6 Engine...
  • Page 111 NOTES International ® VT 275 V6 Engine...
  • Page 112 ® © 2005 I NTERNATI O NAL TRU CK AN D EN G I N E CO RPO R ATI O N TMT-120502 PRI NTED I N TH E U.S.A.

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