Need factory-spec rebuild data for your International D-155, D-179, D-206, D-239, D-246, D-268, D-310, D-358, DT-239, DT-358, or DT-402 diesel? This is the original 1980 IH source document (OEM #1091624R2), 108 pages of it. High-detail exploded views cover every major assembly, while service diagnosis charts trace each failure mode, from chronic knocks and excessive smoke to outright bearing failure. Step-by-step procedures walk through disassembly, inspection, and reassembly: camshaft, crankshaft, pistons, cylinder sleeves, injection-pump timing, and valve lash. Torque the cylinder-head cap screws to 14+15 daNm (101+109 Lbf-ft) and the nozzle union nut to 6-8 daNm. Every hour your machine sits idle costs money. Search any spec by keyword, jump by bookmark, and get back to work.
What's Inside This International D-155 & variants Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 4 | - |
| Service Diagnosis | 9-14 | Work Safely - Follow Those Rules, Gaskets and Seals, Service Tools, Service Parts, Serial Numbers, Priming Lubricating System, Engine Run-In Schedule, Start |
| Specifications | 15-17 | Valves Sticking, Piston and Cylinder Sleeve Wear, Improper Fuel Pressure, Low Engine RPM, Low Fuel Pressure, High Fuel Pressure, Engine Runs Unevenly and Vibrates, Type |
| Longitudinal and Cross Section | 18-19 | Longitudinal Section of Engine, Illust. 3 Typical Dt-358 Engine, Cross Section of Engine, Illust. 4 Typical Dt-358 Engine, Valve Lever Springs, Removal and Disassembly, Cleaning |
| Valve Lever Assy | 20-22 | Valve Lever, Shaft, Valve Lever Springs, Removal, Disassembly, Reassembly |
| Camshaft and Idler Gear | 23-28 | General, Removal and Disassembly, Cleaning, Inspection and Repair, Procedure for Line Boring Camshaft Bushings, Camshaft Gear, Thrust Plate and Idler Gear |
| Cylinder Head Valves and Valve Guides | 29-40 | Idler Gear Carrier and Needle Bearings, Reassembly and Installation, General, Oversize Valve Seat Insert Counterbore Chart, Valve Timing, Valve Dimensional Chart |
| Manifolds | 41 | Intake Manifold, Exhaust Manifold, Turbocharger Installation, Air Hose, Fuel Lines, Gaskets |
| Fan - V-Belts | 42 | General, Cleaning, Inspection and Repair, Installation |
| Crankshaft Pulley and Vibration Damper | 43-44 | General, Removal and Disassembly, Cleaning, Inspection and Repair, Installation, Removal |
| Crankcase Front Cover and Plate | 45-46 | Reassembly and Installation, General, Removal and Disassembly |
| Crankcase | 47-50 | Cleaning, Inspection and Repair, Reassembly and Installation, Installation of the Front Oil Seal, Crankcase Front Cover in Place, General, Removal and Disassembly |
| Crankshaft | 51-64 | Grinding the Cutter, General, Hardening Processes, Straightening, Crankshaft Rear End Sealing Flange, Re-Hardening Processes for Nitrided Crankshafts |
| Pistons Cylinder Sleeves - Connecting Rods | 65-73 | General, Groove Diameter, Piston Versions, Piston Ring Gap, Piston Pin Dia, Removal and Disassembly, Checking Cylinder Sleeve Wear, Cleaning |
| Balancer (4-Cyl. Only) | 74-78 | General, Removal and Disassembly, Repair, Reassembly |
| Flywheel | 79-81 | Installation, Removal and Disassembly, Cleaning, Inspection and Repair |
| Oil Pump | 84-87 | Body Gears, Relief Valve, Idler Gear, Drive Gear, Crankshaft Pinion, Roller Bearing |
| Water Pump | 88-90 | Idler Gear Fastening with Self-Locking Nut, Idler Gear Shaft Replacement, General, Removal and Disassembly, Cleaning, Inspection and Repair, Reassembly |
| Thermostat and Coolant Manifold | 91-92 | Thermostat, Removal and Disassembly, Inspection and Repair |
| Injection Pump Ep/Va-Ve | 93-97 | Removal and Disassembly, Repair, Installation, General, A. Checking Static Timing, B. Removal, C. Installing and Timing the Pump to the Engine |
| Injection Nozzle Holder | 98 | Fuel Feed Pump, Installation, A. Flange Mounted Holder, B. Crab Mounted Holder |
| Timing Gear Train | 99-100 | Adjustment, Illust. 212, Illust. 212 Shows the Gear Train of a 6-Cyl.-Engine with Piston Number One on Compression TDC, Timing Chart for Injection Pump Gear Illust. 212 |
| Valve Lash Adjustment | 101-102 | Valve Lever, Feeler Gauge, Adjusting Screw, Lock Nut, Adjusting Valve Lash |
| Engine Testing | 103-108 | Valve Timing, Compression, Lubricating Oil Pressure, Air Cleaner Restriction, Boost Pressure, Crankcase Pressure Orificed Restrictor |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cylinder-head cap screws with collar torque | 14+15 daNm (101+109 Lbf-ft) | p. 17 |
| Valve cover screws (sheet metal) torque | 0.5+0.7 daNm (3.6+5 Lbf-ft) | p. 17 |
| Valve cover screws (gray iron) torque | 1.5+1.7 daNm (11+12.3 Lbf-ft) | p. 17 |
| Nozzle holder stud nuts (flange mounted) torque | 1.3+1.8 daNm (9.4+13 Lbf-ft) | p. 17 |
| Nozzle union nut (nozzle holder) torque | 6-8 daNm (44-58 Lbf-ft) | p. 17 |
| Injection pump flange nut torque | 2.2+2.5 daNm (16+18 Lbf-ft) | p. 17 |
| Injection pump gear bolt (3 radial lines) torque | 2.2+2.5 daNm (16+18 Lbf-ft) | p. 17 |
| Fuel feed pump replacement | Install a new feed pump if the diaphragm is damaged or the operating mechanism is defective. | p. 97 |
| Oil pump idler gear end play | 0.0 - 0.05 mm (0.0 - .002 in.) | p. 84 |
| Oil pump drive gear end play | 0.10 mm (.004 in.) | p. 84 |
| Water pump bearing assembly replacement | Replace bearing assembly (1) Illust. 186 with a new one, if pump has been running rough and/or noisy. | p. 88 |
| Thermostat (5) opening temperature | 78 - 82°C (172 - 180 °F) | p. 91 |
International D-155 & variants Common Problems This Manual Covers
International D-239 cranks without firing or hard to start in cold weather p. 9
Check the troubleshooting chart on page 9. Bleed the fuel system at the filter and injection pump; air on the suction side is the most common cause after sitting. Verify the lift pump delivers fuel freely; replace the diaphragm per page 97 if flow is weak or the mechanism is defective. Compression at starting speed should reach 2.2-2.4 MPa (313-341 PSI).
Manual Section: Service DiagnosisEngine burns oil, crankcase blow-by is excessive, or blue smoke pours from exhaust p. 65
Inspect cylinder sleeves and piston rings per page 65. Measure ring gap; compression rings should read 0.35-0.55 mm (0.014-0.022 inch) per page 66. Replace rings as a complete set only per page 69. Check valve guides for wear on page 29. Persistent blow-by with acceptable ring gap points to worn cylinder sleeves requiring replacement.
Manual Section: Pistons Cylinder Sleeves - Connecting RodsEngine overheats, coolant boils over, or temperature climbs and won't come down p. 91
Test the thermostat; it should begin opening at 78-82°C (172-180°F) and be fully open by 88-92°C (190-198°F) per page 91. Inspect the water pump bearing assembly on page 88 and replace if running rough or noisy. Check for a slipping fan belt on page 42 and verify coolant passages are clear of scale throughout.
Manual Section: Thermostat and Coolant ManifoldEngine loses power under load, black smoke at the stack, won't pull rated RPM p. 9
Examine the air filter first; a clogged element robs power faster than anything else. Check injection pump timing and governor linkage on page 93. Test compression per page 103; all cylinders must read 2.2-2.4 MPa (313-341 PSI). Pull and bench-test injection nozzles per page 98 if timing and compression both check out.
Manual Section: Service DiagnosisLow oil pressure light comes on, bearing knock audible, or rattle on startup p. 84
Verify oil level and grade first. Measure pressure at the main gallery; minimum at rated speed is 0.30 MPa (44 PSI) per page 14. Pressure that holds cold but drops hot points to worn main or rod bearings. Inspect the oil pump on page 84; idler gear end play must not exceed 0.05 mm (0.002 inch).
Manual Section: Oil PumpFuel system bleeds normally but engine misfires, runs rough, or smokes white p. 98
Remove and inspect injection nozzles per page 98. Incorrect injection timing is a common root cause; verify static timing on page 93 and cross-reference the gear timing chart on page 99. Adjust valve lash to 0.30 mm (0.012 inch) with the engine hot per page 101. White smoke commonly clears once timing and nozzle condition are both corrected.
Manual Section: Injection Nozzle HolderFrequently Asked Questions
How to reset a D-358 after injector pump service?
With injector-pump service done, set the engine to static timing position. Line the timing pointer up with the scribed mark on the face cam, and the pump is timed. On a D-358 (6-cylinder), see Illust. 56 for the cylinder-head bolt torque sequence and page 39 for general reassembly, including the valve-clearance check.
How to reset International D-239 engine after fuel system service
Once fuel-system work is finished, you need to vent the system. Work the fuel feed pump by hand with lever (6), Illust. 209, to fill or bleed it. Then confirm injection-pump timing by aligning the timing pointer with the timing mark on the front pulley.
Torque specs for International D-358 head bolts
Cylinder-head cap screws with collars get a final torque of 14 + 15 daNm (101 + 109 Lbf-ft), brought up in three steps per the Illust. 56 sequence on 6-cylinder engines. The full "Special Nut and Bolt Torque Data" sits on page 17 for the exact values.
What format is this manual in?
A 108-page Service Manual in searchable PDF format, available the moment you complete checkout. View on computer, tablet, or phone, with no shipping wait.
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Document Quality
This is a scanned document with an OCR layer, allowing you to search the full text. The text is generally readable, though some smaller fonts appear slightly blurry or faded in places. Diagrams and illustrations are scanned images, with labels mostly legible for understanding. Pages show minor scan artifacts and some background discoloration, and page 2 is a notable blank page.
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