International® T 444E Diesel Engine Workshop Repair Service Manual

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This Workshop Service Repair manual PDF download for the T-444E International® Diesel Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

INTERNATIONAL® T 444E DIESEL ENGINE
MODEL : YEARS LATE 1997-2003
SERIAL NUMBER : 634234 AND UP


TABLE OF CONTENTS :

Foreword
Service Diagnosis
Safety Information
Introduction
Mounting Engine On Stand
Turbocharger
Manifolds
Cylinder Head And Valves
Oil Pan, Vibration Damper, Oil Pump Water Pump, And Front Cover
Valve Train: Push Rods, Hydraulic Valve Lifters And Camshaft
Crankcase, Crankshaft, Connecting Rods, And Pistons
Thermostat And Coolant Filter
Oil Cooler And Filter
Engine Electrical
High-pressure Oil Pump
Fuel System
Appendix A – Specifications
Appendix B — Torques
Appendix C — Special Service Tools


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : EGES-205
Total Pages : 298


This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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SAFETY TERMINOLOGY
SAFETY INSTRUCTIONS
Table of Contents
Engine Identification
Serial Number Location
Explanation of the Engine Serial Number
Emission Label
Engine Component Location
Engine Description
General Features
Chassis Mounted Charge Air Cooler
Cooling System
Description
Thermostat Operation
Lubrication System
Description
Oil Flow
Air Induction and Exhaust System
Description
Fuel System
Description
Operation
Injection Control Pressure System
Operation
Injection Pressure Control
IPR Valve Operation
Fuel Injector
Description
Component Description
Operation
Glow Plug Controller System
Table of Contents
Mounting Engine On Stand
Table of Contents
Bellows Exhaust System Feature
Removal
Standard Torque Turbocharger
High Torque Turbocharger
Cleaning
Turbocharger
Related Components
Disassembly (Standard Torque Only)
Remove EBP Control Valve
Remove Turbocharger Pedestal
Inspection
Check Exhaust Inlet Adapter/Exhaust Tube Mating Surface
Compressor Impeller, Turbine Wheel and Turbocharger Pedestal
Check Axial End Play
Rebuild EBP Piston Rod Assembly
Check Wastegate Actuator
Assembly (Standard Torque Only)
Install Turbocharger Pedestal
Install EBP Control Valve
Installation
Standard Torque Turbocharger
High Torque Turbocharger
Table of Contents
Removal
Left Exhaust Manifold
Right Exhaust Manifold
Left Intake Manifold Cover
Right Intake Manifold Cover
Cleaning
Inspection
Exhaust Manifold
Installation
Right Exhaust Manifold
Left Exhaust Manifold
Right Intake Manifold Cover
Left Intake Manifold Cover
Table of Contents
Cylinder Head Disassembly
Remove Left Valve Cover
Remove Right Valve Cover
Disconnect Under Valve Cover Harness
Remove Glow Plug
Remove Oil Director Spout
Remove Valve Lever
Remove Push Rod
Drain Fuel Gallery and Oil Rail
Remove Fuel Injector
Remove EBP and ICP Sensors
Remove Cylinder Head
Cleaning
Crankcase
Cylinder Head
Inspection
Check For Warp
Check Cylinder Head Thickness
Check Valve Recession
Surface Height Gauge Method
Straightedge and Feeler Gauge Method
Check for Valve Leakage (Using Mineral Spirits)
Check for Cracks (Using Dye Penetrant)
Cylinder Head Pressure Test
Valves
Removal
Cleaning
Inspection
Refacing
Valve Face
Valve Stem
Valve Guides
Cleaning
Inspection
Valve Seats
Cleaning
Inspection
Resurfacing
Valve Springs
Cleaning
Inspection
Valve Rotators And Retainer Keys
Cleaning And Inspection
Testing Operation
Fuel Injector Sleeve
Removal
Cleaning Bores, Fuel Galleries and Oil Galleries
Installation
Cylinder Head Assembly
Install Valve Assemblies
Install Oil and Fuel Rail Plugs
Oil Rail End Plug
Drain Plugs
Oil Gallery Plugs
Valve Lever
Disassembly
Cleaning
Inspection
Assembly
Fuel Injector O-rings And Seals
Removal
Installation
Cylinder Head Installation
Install Fuel Injector
Install Oil Director Spout
Install Push Rods
Install Valve Lever
Install Glow Plug
Connecting Under Valve Cover Harness
Installing Valve Covers
Crankcase Breather
Removal
Cleaning
Installation
Table of Contents
Removal
Oil Pan
Oil Pick-Up Tube
Vibration Damper
Vibration Damper Wear Sleeve
Front Oil Seal
Oil Pump
Water Pump
Front Cover
Cleaning
Oil Pan
Vibration Damper
Oil Pump
Water Pump
Front Cover
Inspection
Oil Pick-Up Tube
Vibration Damper
Oil Pump
Water Pump
Front Cover
Installation
Vibration Damper Wear Sleeve
Front Cover and Water Pump
Oil Pump
Front Oil Seal
Vibration Damper
Oil Pick-Up Tube
Oil Pan
Table of Contents
Push Rods and Hydraulic Valve Lifters
Operation
Removal
Disassembly
Cleaning
Inspection
Assembly
Leak Down Test
Installation
Camshaft and Gear
Check Gear Backlash and Camshaft End Play
Removal
Cleaning
Inspection
Assembling Cam Gear to Camshaft
Installation of Camshaft
Table of Contents
Flywheel and Flywheel Housing
Removal
Cleaning
Inspection
Resurfacing (Manual Transmissions)
Installation of Flywheel Housing
Check Flywheel Housing Bore Concentricity
Check Flywheel Housing Face Runout
Check Flywheel Surface Runout
Check Crankshaft Pilot Concentricity
Installation of Flywheel
Rear Oil Seal and Wear Sleeve
Removal
Rear Oil Seal
Wear Sleeve
Installation
Rear Cover
Removal
Cleaning
Installation
Connecting Rods, Pistons and Piston Rings
Check Piston Protrusion
Checking Connecting Rod Side Clearance
Removal
Disassembly
Cleaning
Inspection
Check Width of Top Compression Ring Groove
Checking Side Clearance Of Oil Control Ring And Intermediate Com
Piston Replacement
Check Piston Ring End Clearance in Cylinder Bore
Connecting Rods
Check Inside Diameter of Piston Pin Bushing
Check Connecting Rod Bearing Bore for Out-of-Round and Taper
Check Connecting Rod for Bend or Twist
Check Piston Pin Clearance
Bearing Fitting Procedure For Old Style Connecting Rod
Feeler Gauge Test
Dial Indicator Test
Assembly •23 Old Style Connecting Rod
Assembly •23 New Style Connecting Rod
Installation •23 Old Style Connecting Rod
Installation •23 New Style Connecting Rod
Crankshaft and Main Bearings
Removal
Cleaning
Inspection
Check Crankshaft Journals for Out-of-Round and Taper
Installation of Crankshaft
Main Bearing Fitting Procedure
Installation of Main Bearing Caps
Check Crankshaft End Play
Piston Cooling Jets
Removal
Cleaning and Inspection
Installation
Crankcase Reconditioning
Cleaning
Inspect Short Circuit Valve
Replace Crankcase Cup Plugs
Check Crankcase Surface for Flatness
Check Cylinder Bore for Out-of-Round and Taper
Deglazing
Camshaft Bushings
Check for Wear and Proper Running Clearance
Removal
Inspection
Installation
Table of Contents
Thermostat
Removal
Testing Operation
Installation
Coolant Filter and Header
Removal (Front of Engine)
Installation (Front of Engine)
Table of Contents
Oil Cooler
Removal
Leakage Test
Disassembly
Cleaning
Inspection
Assembly
Installation
Filling Crankcase With Oil
Table of Contents
Camshaft Position (CMP) Sensor
Exhaust Back Pressure (EBP) Sensor
Engine Oil Pressure (EOP) Sensor
Engine Coolant Temperature (ECT) Sensor
Engine Oil Temperature (EOT) Sensor
Injection Control Pressure (ICP) Sensor
Injection Pressure Regulator (IPR) Valve
Manifold Absolute Pressure (MAP) Sensor
Intake Air Temperature
Electronic Control Module (ECM)
Removal
Inspection
Installation
Main Engine Wiring Harness
Removal
Inspection
Installation
Verifying CMP Sensor Clearance (Air Gap)
Glow Plug Relay
Removal
Inspection
Installation
Table of Contents
Removal
High-pressure Oil Pump Reservoir
High-pressure Oil Pump and Drive Gear
Injection Pressure Regulator (IPR) Valve
Installation
Injection Pressure Regulator (IPR) Valve
High-pressure Oil Pump and Drive Gear
Check Drive Gear Backlash
High-pressure Oil Pump Reservoir
Table of Contents
Fuel Filter Tower, Bracket and Piping
Removal
Installation
Fuel Strainer
Removal
Installation
Fuel Filter
Removal
Installation
Fuel Transfer Pump
Removal
Inspection
Installation
Fuel Injectors
Table of Contents
Table of Contents
General Torque Guidelines
Table of Contents
tables
Engine Mounting Special Torques
Engine Mounting Special Service Tools
Bellows Exhaust Service Kits for Standard Torque International®
Turbocharger Specifications
Turbocharger Special Torques
Turbocharger Special Service Tools
Manifolds
Manifolds Special Torques
Manifolds Special Service Tools
Cylinder Head
Cylinder Head Special Torques
Cylinder Head Special Service Tools
Vibration Damper, Lubricating Oil Pump, Oil Pan, Oil Pick-Up Tub
Vibration Damper, Lubricating Oil Pump, Oil Pan, Oil Pick-Up Tub
Vibration Damper, Lubricating Oil Pump, Oil Pan, Oil Pick-Up Tub
Valve Train
Valve Train Special Torques
Valve Train Special Service Tools
Crankcase, Camshaft Bushing, Crankshaft and Main Bearing, Connec
Crankcase, Crankshaft, Connecting Rods and Piston Special Torque
Crankcase, Crankshaft, Connecting Rods and Piston Special Servic
Thermostat and Coolant Filter
Thermostat and Coolant Filter Special Service Tools
CMP Sensor Clearance Worksheet
Engine Electrical
Electrical System Special Torques
Special Service Tools
High-pressure Lube Oil System
High-pressure Lube Oil System Special Torques
High-pressure Lube Oil System Special Service Tools
Fuel System Specifications
Fuel System Special Torques
Fuel System Special Service Tools
Turbocharger
Manifolds
Cylinder Head
Vibration Damper, Lubricating Oil Pump, Oil Pan, Oil Pick-Up Tub
Valve Train
Crankcase, Camshaft Bushing, Crankshaft and Main Bearing, Connec
Thermostat and Coolant Filter
Engine Electrical
High-pressure Lube Oil System
Fuel System
Standard Torques •23 Pipe Thread
Standard Torques •24 Class 10.9 Metric Bolts and Studs
Standard Torques •24 Class 12.9 Metric Bolts and Studs
Engine Mounting Special Torques
Turbocharger Special Torques
Manifolds Special Torques
Cylinder Head Special Torques
Vibration Damper, Lubricating Oil Pump, Oil Pan, Oil Pick-Up Tub
Valve Train Special Torques
Crankcase, Crankshaft, Connecting Rods and Piston Special Torque
Electrical System Special Torques
High-pressure Lube Oil System Special Torques
Fuel System Special Torques
Engine Mounting Special Service Tools
Turbocharger Special Service Tools
Cylinder Head Special Service Tools
Vibration Damper, Lubricating Oil Pump, Oil Pan, Oil Pick-Up Tub
Valve Train Special Service Tools
Crankcase, Crankshaft, Connecting Rods and Piston Special Servic
Thermostat and Coolant Filter Special Service Tools
High-pressure Lube Oil System Special Service Tools
Fuel System Special Service Tools

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