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Technical Service

Information

TSI091207

A NAVISTAR COMPANY

This TSI replaces TSI 041215 and TSI 071201.

Date: July 2009


Subject File: Engines
Subject: Navistar, Inc. Diesel Engine Service Publications Application Guide
Engine Family: All Navistar diesel engines
SN Range: All diesel engines

Description

availability and pricing, contact your International


dealer.

Navistar Diesel Engine Service Publications are


available in print, on the ISIS system of the
Dealer Communications Network II, and on Quarterly
Revision Renewal System DVD.
When ordering technical service literature, contact
your International dealer.
NOTE: On ISIS, if a French or Spanish translation
is selected and these manuals are not available, no
manual number will appear.
The following tables can be used to identify which
manuals are to be used when servicing specific
Navistar engines. These tables do not include every
engine service publication available. For complete

A.

Inline Engine Diagnostic Manuals (Table 1)

B.

Inline Engine Diagnostic Forms (Table 2)

C.

Inline Engine Service Manuals (Table 3)

D.

V8 Engine Diagnostic Manuals (Table 4)

E.

V8 Engine Diagnostic Forms (Table 5)

F.

V8 Engine Service Manuals (Table 6)

G.

V6 Engine Diagnostic Manuals (Table 7)

H.

V6 Engine Diagnostic Forms (Table 8)

I.

V6 Engine Service Manuals (Table 9)

1
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.

Description (cont.)
Engine Service Publication Numbering
System

translations are always one whole number higher


than the English version base number as follows:
English base number ends in 0, Spanish base number
ends in 1
English base number ends in 5, Spanish base number
ends in 6
French translations are assigned base numbers
that are two whole numbers higher than the English
version base number as follows:
English base number ends in 0, French base number
ends in 2
English base number ends in 5, French base number
ends in 7

Language Translation Availability and


Identification (1999 MY and earlier)
Translations for early engine publications were
identified by adding an alphabetic suffix to the base
manual number and revision level. Examples include:

Figure 1 Explanation of service publication


numbering (arrow indicates base number variable
column)
1.
2.
3.
4.
5.
6.
7.

EGES-175-S - Spanish version of EGES-175

ES = Either an Engine Service or Diagnostic manual,


ED = Engine Diagnostics form
Base publication number
Revision of base number, applies only to that specific
publication
Base number ends in either 0 or 5 = English version
Base number ends in either 1 or 6 = Spanish version
Base number ends in either 2 or 7 = French version
Example: VT 365 Service Manual, Spanish version,
no revision

EGES-190-SP - Spanish version of EGES-190


EGES-160-1-S - First revision of Spanish version of
EGES-160

Publication Revisions
Revisions are indicated by an additional digit after
the 3-digit base number. The higher the digit, the
higher the level of revision. Absence of a revision
digit indicates the publication is at its original base
(non-revision) level.

Language Translation Availability and


Identification (2000 MY and later)

Revision levels can be out of phase for a particular


publication series having English, Spanish and
French versions. Therefore, the existence of a
revised English version does not imply that there is a
corresponding revised Spanish or French version.

By knowing the English base number of a particular


service publication or diagnostic form, the Spanish or
French version can be determined.
When searching for a V8 service manual for
the International VT 365 in Spanish, first look
through table 6 to find the English EGES-235-2.
This publications base number is 235. Spanish

TSI091207

Occasionally, revisions are available only on ISIS.


This occurs when recent corrections or changes are
made but they are not yet available in print.

Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.

Navistar Diesel Engine Service


Publications
Table 1
Model
Years

Navistar Inline Engine Diagnostic Manuals


Navistar Engine
Model(s)

1987-1992 DT/DTI 466 A and B


series

Navistar Engine
Serial No. Info

Distinguishing Features

143536-567491

UTDS Model 100 pump

CGES-450-3

Robert Bosch PES6MW or


PES6A in-line pump

DT/DTI/DTA 466 C
series

Service
Publication

1993-1994 DT 408/466 and 530


series

850676-1193209

Robert Bosch PES6P


in-line pump

EGES-110

1995-1997 DT 466E and 530E

931164-1075288

Chassis mounted ECM /


IDM or engine mounted
Diamond Logic Controller
(Navpak)

EGES-145

1997-2000 DT 466E and 530E

1075289-1194038

Diamond Logic Controller


(Navpak)

EGES-175-1

2000-2004 DT 466E and DT


530E

1194039-above

Front mounted ECM / Air


induction (vertical) at top of
valve cover

EGES-215

2001-2004 DT 466 and DT 530

1273511-above

Rear mounted ECM / Air


induction at left side of
valve cover

EGES-215

2004-2006 DT 466, DT 570 and


HT 570

2000001-above

EGR system / VGT


turbocharger / 4 valves
per cylinder

EGES-270

2007-2009 MaxxForce DT, 9,


and 10

3000001-above

Dual EGR coolers / VGT


turbocharger / exhaust
aftertreatment / 4 valves
per cylinder

EGES-370-1

2008-2009 MaxxForce 11 and


13

4000001-above

CAC on top of engine


/ dual turbocharger /
exhaust aftertreatment / 4
valves per cylinder

EGES 420-1

United Technologies Diesel Systems

TSI091207

Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.

Navistar Diesel Engine Service


Publications (cont.)
Table 2
Model
Years

Navistar Inline Engine Diagnostic Forms


Navistar Engine
Model

Navistar Engine
Serial No. Info

Publication No. and Form Type

not available

CGED-390-2, Diagnostic Analysis Guide

DT/DTI/DTA 466 C
series

0436665-0690519

CGED-365-5, Engine Performance Analysis


1
Guide

DT 408/466 and 530


series

850017-1193209

EGED-115, Performance Analysis Guide

931164-1075288

EGED-150-1, Performance Diagnostics

1987-1992 DT/DTI 466 A and B


series

1993

1995-1997 DT 466E and 530E

EGED-155-1, Electronic Control Diagnostics


1997-2000 DT 466E and 530E

1075289-1194038

EGED-180-2, Hard Start / No Start Diagnostics


EGED-185-1, Electronic Control Diagnostics

2000-2004 DT 466E and 530E

1194039-above

EGED-220, Mechanical Diagnostics


EGED-225, Electronic Control Diagnostics

2001-2004 DT 466 and DT 530

1273511-above

EGED-220, Mechanical Diagnostics


EGED-225, Electronic Control Diagnostics

2004-2006 DT 466, DT 570 and


HT 570

2000001-above

2007-2009 MaxxForce DT, 9,


and 10

3000001-above

EGED-285, Electronic Control Diagnostics


EGED-290, Mechanical Diagnostics
EGED-375, Hard Start / No Start Diagnostics
EGED-380, Performance Diagnostics
EGED-385, Electronic Control Diagnostics

2008-2009 MaxxForce 11 and


13

4000001- above

EGED-425, Engine Performance Form


EGED-430-2, Engine Wiring Diagram
EGED-435, Signal Values

Available on ISIS only.

TSI091207

Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.

Navistar Diesel Engine Service


Publications (cont.)
Table 3
Model
Years

Navistar Inline Engine Service Manuals


Navistar
Engine Model /
Component

Navistar Engine
Serial No. Info

Manual Type /
Distinguishing Features

Service
Publication

1987-1994 Robert Bosch


PES6A fuel injection
pump

0003108-5788494

Service manual for pump

CGES-480

1979-1989 312, 360, 414, 436,


466, 466B, 466C

0003108-6151766

Engine / UTDS Model 100


pump or

CGES-185-5

Robert Bosch PES6MW


in-line pump

1987-1992 DT/DTA 360

30001-112787

Engine / Robert Bosch


PES6A or PES6MW in-line
pump

CGES-430-3

1982-1994 DT 466

400001-0691240

Engine / Robert Bosch


PES6A or PES6MW in-line
pump

CGES-415-3

DTA 466

463568-7681608

1993-1999 DT 408/466 and 530


series

850676-1193209

Engine / Robert Bosch


PES6P in-line pump

EGES-105-2

1995-2000 DT 466E and 530E

931164-1205049

Engine / Chassis mounted


ECM / Engine mounted
Diamond Logic Controller
(Navpak)

EGES-160-2

2000-2004 DT 466E and 530E

1194039-above

Engine / Front mounted


ECM / Air induction at top
(vertical) of valve cover

EGES-210-1

2001-2004 DT 466 and DT 530

1273511-above

Engine / Rear mounted


ECM / Air induction at side
of valve cover

EGES-2101

2004-2006 DT 466, DT 570 and


HT 570

2000001-above

EGR system / VGT


turbocharger / 4 valves
per cylinder

EGES-265-2

2007-2009 MaxxForce DT, 9,


and 10

3000001-above

Dual EGR coolers / VGT


turbocharger / exhaust
aftertreatment / 4 valves
per cylinder

EGES-335

2008-2009 MaxxForce 11 and


13

4000001- above

CAC on top of engine / dual


turbocharger / exhaust
aftertreatment / 4 valves
per cylinder

EGES-415-1

EGES-210-1 has combined the EGES-210 service manual with the now obsolete EGES-230 supplement.

TSI091207

Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.

Navistar Diesel Engine Service


Publications (cont.)
Table 4
Model
Years

Navistar V8 Engine Diagnostic Manuals


Navistar Engine
Model

Navistar Engine
Serial No. Info

Distinguishing Features

Service
Publication

1983-1986 9.0 L

0005565-above

Dual oil filters (L.S.) / In-line


injection pump

CGES-240-4

1982-1987 6.9 L

1001-445179

Stanadyne DB-2 injection


pump

CGES-455

1987-1994 7.3 L

500079-1260423

Stanadyne DB-2 injection


pump

CGES-460-4

1993-1997 T 444E

000500-634233

Chassis mounted ECM /


IDM configuration

EGES-125-1

1997-2003 T 444E

634234-above

Engine mounted Diamond


Logic Controller (Navpak)

EGES-190

2002-2003 VT 365

0000082-112359

EGR system / VGT


turbocharger / intake
manifold has crossover at
rear / 4 valves per cylinder

EGES-240

2004-2006 VT 365

112360-above

EGR system / VGT


turbocharger / intake
manifold does not have
crossover at rear / 4 valves
per cylinder

EGES-240

2007-2009 MaxxForce 7

424243-above

Dual fuel filters / VGT


turbocharger / exhaust
aftertreatment / 4 valves
per cylinder

EGES-350-1

TSI091207

Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.

Navistar Diesel Engine Service


Publications (cont.)
Table 5

Navistar V8 Engine Diagnostic Forms

Model Years

Navistar Engine Model

Navistar Engine Serial


No. Info

Publication No. and Form Type

1982-1987

6.9 L

1001-445179

CGED-355-5, 6.9 L Engine


1
Performance Analysis Guide

1987-1994

7.3 L

500079-1260423

CGED-440-5, 7.3 L Diesel


1
Performance Analysis Guide
CGED-470-4, 7.3 L Solid State
1
Glow Plug Troubleshooting Guide

1993-1997

T 444E

000500-634233

EGED-130-1, Hard Start / No Start


& Performance Diagnostics
EGED-135-1, Electronic Control
System Diagnostics

1997-2003

T 444E

634234-above

EGED-195-1, Hard Start / No Start


& Performance Diagnostics
EGED-200-1, Electronic Control
System Diagnostics

2002-2003

VT 365

0000082-112359

EGED-245, Hard Start / No Start


Diagnostics
EGED-250, Engine Performance
Diagnostics
EGED-255, Electronic Control
System Diagnostics

2004-2006

VT 365

112360-above

EGED-245, Hard Start / No Start


Diagnostics
EGED-250, Engine Performance
Diagnostics
EGED-255, Electronic Control
System Diagnostics

2007-2009

MaxxForce 7

424243-above

EGED-3551, Hard Start / No Start


and Performance Diagnostics
EGED-365, Engine Control
Diagnostics

Available on ISIS only.

TSI091207

Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.

Navistar Diesel Engine Service


Publications (cont.)
Table 6

Navistar V8 Engine Service Manuals

Model Years

Navistar
Engine Model /
Component

Navistar Engine
Serial No. Info

Manual Type /
Distinguishing Features

Service
Publication

1983-1986

9.0 L

0005565-above

Engine / Dual oil filters


(L.S.), in-line injection
pump

CGES-205-1

1982-1987

6.9 L

1001-445179

Engine / Stanadyne DB-2


injection pump

CGES-340-3

1987-1994

7.3 Liter

500079-1260423

Engine / Stanadyne DB-2


injection pump

CGES-435-1

1987-1994

7.3 L / Stanadyne
Model DB-2
injection pump

500079-1260423

Component / Service
manual for pump

CGES-475

1993-1997

T 444E

000500-634233

Chassis mounted ECM /


IDM configuration

EGES- 120-1

1997-2003

T 444E

634234-above

Engine / Engine Mounted


Diamond Logic Controller
(Navpak)

EGES- 205

2002-2003

VT 365

0000082-112359

Engine / Intake manifold


has a crossover at rear

EGES-235-2

2004-2006

VT 365

112360-above

Engine / Intake manifold


does not have a crossover
at rear

EGES-295-2

2007-2009

MaxxForce 7

424243-above

Dual fuel filters / VGT


turbocharger / exhaust
aftertreatment / 4 valves
per cylinder

EGES-345

TSI091207

Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.

Navistar Diesel Engine Service


Publications (cont.)
Table 7

Navistar V6 Engine Diagnostic Manuals

Model
Years

Navistar Engine
Serial No. Info

Manual Type /
Distinguishing Features

Service
Publication

2005-2006 VT 275

0143815-above

EGR system / dual


turbochargers / 4 valves
per cylinder

EGES-305-1

2007-2009 MaxxForce 5

563958-above

Intake throttle valve / dual


turbochargers / exhaust
aftertreatment / 4 valves
per cylinder

EGES-395

Table 8

Navistar
Engine Model /
Component

Navistar V6 Engine Diagnostic Forms

Model Years

Navistar Engine Model /


Component

Navistar Engine Serial


No. Info

Publication No. and Form Type

2005-2006

VT 275

0143815-above

EGED-140 Supplemental Coolant


1
Level Reference Chart
EGED-3101, Electronic Control
Diagnostics
EGED-315, Hard Start / No Start
and Performance Diagnostics

2007-2009

MaxxForce 5

563958-above

EGED-400, Hard Start / No Start


Diagnostics
EGED-410, Electronic Control
Diagnostics

Available on ISIS only.

Table 9
Model
Years

Navistar V6 Engine Service Manuals


Navistar
Engine Model /
Component

Navistar Engine
Serial No. Info

Manual Type /
Distinguishing Features

Service
Publication

2005-2006 VT 275

0143815-above

EGR system / dual


turbochargers / 4 valves
per cylinder

EGES-300-1

2007-2009 MaxxForce 5

563958-above

Intake throttle valve / dual


turbochargers / exhaust
aftertreatment / 4 valves
per cylinder

EGES-390

TSI091207

Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
2009 Navistar, Inc.