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INTERNATIONAL DT 466
Navistar INTERNATIONAL DT 466 Service Manual
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© 2009 Navistar. Inc.
Printed in the United States of America
SER
VICE MANUAL
INTERNATIONAL® DT 466, DT 570, HT 570
DIESEL ENGINE
SERVICE MANUAL
FORM EGES-265-2
SER
VICE MANUAL
INTERNATIONAL® DT 466, DT 570, HT 570
DIESEL ENGINE (S/N 2000001 AND ABOVE)
FORM EGES-265-2
2004 MODEL YEAR AND ABOVE
2
Table of Contents
Engine Service Manual I
3
Table of Contents
3
Foreword
5
Service Diagnosis
6
Safety Information
7
Table of Contents
9
Engine Systems
9
Engine Identification
11
Engine Serial Number
11
Engine Emission Label
12
Engine Description
13
Engine Component Locations
16
Engine Systems
22
Engine System Diagram
22
Air Management System
23
Air Management Components and Air Flow
23
Charge Air Cooler (CAC)
24
Variable Geometry Turbocharger (VGT)
25
Exhaust Gas Recirculation (EGR) System
27
Exhaust System
28
Fuel Management System
29
Fuel Management Components
29
Injection Control Pressure (ICP) System Components and High-Pressure Oil Flow
30
Fuel Injectors
33
Fuel Supply System
37
Fuel System Components and Fuel Flow
37
Fuel Flow Schematic
38
Engine Lubrication System
41
Lubrication System Components and Oil Flow
41
Cooling System
44
Cooling System Components and Coolant Flow
44
Electronic Control System
47
Electronic Control System Components
47
Injection Drive Module (IDM)
49
Engine and Vehicle Sensors
51
Diamond Logic® Engine Brake System
57
Engine Brake Components
57
Engine Brake Control
58
Operation of Diamond Logic® Engine Brake in Braking Mode
60
Mounting Engine on Engine Stand 59
63
Engine Preparation
65
Cleaning the Engine
65
Draining Engine Fluids
65
Component Removal
66
Turbocharger Oil Inlet Tube
66
Turbocharger
66
Oil Filter
67
Oil System Module
67
Mounting Adapter Plate and Engine
67
Adapter Plate
67
Engine
68
Special Service Tools
69
Special Torque
69
Evrt® Electronically Controlled Turbocharger 67
71
Description
73
Removal
75
Variable Geometry Turbocharger (VGT) Assembly
75
Cleaning
76
Turbocharger and Related Parts
76
Inspection
77
Checking Turbine and Compressor
77
Checking Rotation of Actuator Shaft
77
Installation
77
Variable Geometry Turbocharger (VGT) Assembly
77
Special Torque
79
Specifications
79
Intake, Inlet, and Exhaust Manifolds 77
81
Removal
84
Exhaust Manifold
84
Inlet and EGR Mixer Duct
85
Aluminum Air Inlet Adapter and Inlet Air Heater Option
86
Intake Manifold
86
Cleaning and Inspection
87
Exhaust Manifold
87
Intake Manifold
87
Installation
88
Exhaust Manifold
88
Intake Manifold
90
Inlet and EGR Mixer Duct
91
Special Torque
93
Specifications
93
Egr Cooler and Tubing 91
95
Description
97
EGR Coolant System
97
EGR System Components (Beginning Model Year 2004)
98
Removal of EGR System Components
98
Cleaning EGR System Components
102
Inspection of EGR Cooler
102
Installation EGR System Components
103
Modification 1 - Deeper O-Ring Location into EGR Coolant Return Tube Plus Retaining Clip
107
Removal of EGR Coolant Return Tube and Elbow
107
Installation of EGR Coolant Return Tube and Elbow
107
Modification 2 - EGR Coolant Return Tube Adapter and EGR Coolant Hose
112
Removal of EGR Coolant Return Tube Adapter and EGR Coolant Hose
112
Installation of EGR Coolant Return Tube Adapter and EGR Coolant Hose
112
Modification 3 - Round EGR Cooler and EGR Return Hose
114
Removal
114
Installation
115
EGR Coolant Return Kits (Conversion from EGR Cooler Return Tube to Hose)
116
Removal of EGR Coolant Return
116
Installation of EGR Coolant Return Kit
116
Special Service Tools
118
Special Torque
118
Cylinder Head and Valve Train 115
119
Description
121
Removal
124
Valve Cover
124
Removing Rocker Arm Assembly
125
Measuring Camshaft Lift
126
Removing Rocker Arms
127
Removing Cylinder Head
127
Roller Tappets
128
Cleaning
129
Cylinder Head
129
Inspection
129
Valve Train Components
129
Push Rods
129
Rocker Shaft
129
Rocker Arms
130
Cylinder Head Warpage
131
Cylinder Head Thickness
131
Valve Seat Leakage
131
Cylinder Head Cracking
132
Pressure Check Cylinder Head
133
Reconditioning
134
Removing Valves from Cylinder Head
134
Inspecting Valve Guides
134
Replacing Valve Guides
135
Inspecting Valves
136
Refacing Valves
136
Valve Face
136
Valve Stem Tip
137
Checking Valve Face-To-Valve Seat Contact
138
Resurfacing Valve Seats
139
Replacing Valve Seats
140
Removal
140
Installation
142
Inspecting Valve Springs
143
Inspecting Valve Rotators
144
Inspecting Valve Spring Retainer Keys
145
Replacing Fuel Injector Sleeves
145
Removal
145
Installation
145
Installing Valves
146
Cleaning
146
Assembly
146
Installation
148
Roller Tappets
148
Installing the Cylinder Head
148
Torque-To-Yield Procedure for Cylinder Head Bolts
150
Valve Train Components
152
Installing Rocker Arms
152
Installing the Rocker Arm Assembly
153
Valve Lash for Intake and Exhaust Valves
154
Adjusting Valve Lash
154
High-Pressure Oil Rail Assembly
156
Valve Cover
156
Specifications
158
Special Torque
159
Special Service Tools
160
Table of Contents
161
Front Cover and Related Components
161
Description
163
Front Cover Assemblies
163
Gerotor Oil Pump Assembly
163
Checking Gear Train Timing Without Removing
166
DT 466 Engines Only
166
Method One - Using a Feeler Gauge
166
Method Two - Using a Dial Indicator
166
DT 570 and HT 570 Engines Only
167
Method One - Using a Feeler Gauge
167
Method Two - Using a Dial Indicator
167
Removal
168
Alternator Bracket
168
Flat Idler Pulley and Automatic Belt Tensioner
169
Water Supply Housing
169
Water Inlet Elbow, Water Outlet Tube, and Thermostat
169
Fan Drive Hub
170
Water Pump Assembly
171
Vibration Damper, Damper Hub, and Wear Sleeve
172
Gerotor Assembly Oil Pump and Front Oil Seal
173
Front Engine Mount
175
Front Cover (Front Half)
176
Generation 1 (Mounting Bolts)
176
Generation 2 (Mounting Bolts)
177
Idler Gears
178
Front Cover (Rear Half)
180
Inspection
181
Checking Lower Idler Gear Backlash
181
Checking Upper Idler Gear Backlash
181
Checking Camshaft Gear Backlash
182
Gerotor Oil Pump Clearance
182
Measuring Oil Pump Side Clearance
182
Measuring Oil Pump End Clearance
183
Installation
184
Front Cover
184
Gaskets
184
Mounting Bolts (Rear Half)
185
Idler Gears
186
Front Cover (Front Half)
188
Gaskets
188
Generation 1 (Mounting Bolts)
189
Generation 2 (Mounting Bolts)
190
Front Engine Mount
191
Gerotor Oil Pump Assembly and Front Oil Seal
191
POSE Dust Seal and Wear Sleeve
194
Vibration Damper Hub and Damper Retaining Plate
195
Vibration Damper Assembly
196
Fan Drive
197
Horton Drivemaster
199
Water Pump Assembly
200
Water Supply Housing
201
Alternator Bracket
201
Flat Idler Pulley and Automatic Belt Tensioner
202
Water Inlet Elbow, Water Outlet Tube, and Thermostat
202
Specifications
204
Special Torque
205
Special Service Tools
206
Oil Pan and Oil Suction Tube 203
207
Removal
210
Removing the Oil Pan
210
Removing the Oil Suction Tube
211
Cleaning and Inspection
212
Oil Pan
212
Installation
212
Installing the Oil Suction Tube
212
Installing the Oil Pan
213
Watt Oil Pan Heater (Optional)
214
Special Service Tools
215
Special Torque
215
Specifications
215
Power Cylinders 213
217
Description
219
Removal
221
Piston Cooling Tubes
221
Old Piston Cooling Tubes
221
New Piston Cooling Tubes
222
Removing Piston and Connecting Rod Assembly
222
Disassembling Piston and Connecting Rod Assembly
223
Cylinder Sleeve Removal
224
Cleaning
225
Pistons and Related Components
225
Inspection
225
Pistons
225
Top and Intermediate Compression Ring Grooves
226
Oil Control Ring Groove
226
Piston-To-Cylinder Sleeve Running Clearance
227
Piston Rings
227
Piston Pins
228
Connecting Rods
228
Piston Pin Bushing
228
Connecting Rod Cap Bolts
228
Connecting Rod Bearing Bore
229
Bend and Twist
229
Bearing Fitting Procedures and Bearing Running Clearance
229
Bearing Running Clearance
230
Connecting Rod Side Clearance
231
Checking Cylinder Sleeves
231
Checking Counterbore Depth
233
Surface Gauge Method
233
Depth Micrometer Method
233
Checking Cylinder Sleeve Protrusion
233
Reconditioning
236
Resurfacing the Counterbore
236
Installation
238
Cylinder Sleeve Installation
238
Assembling Piston and Connecting Rod Assembly
239
Installing Piston and Connecting Rod Assembly
241
Torque Procedure for Connecting Rods with M12 Bolts
245
Torque-To-Yield Procedure for New Connecting Rod with M11 Bolts
245
Piston Cooling Tubes
246
Old Piston Cooling Tubes
246
New Piston Cooling Tubes
246
Crankcase, Crankshaft, and Camshaft 249
253
Removal
257
Crankcase Ventilation System
257
Oil Level Gauge
259
Crankcase Ladder (DT 466 Series - 225 Hp and 245 Hp @ 2600 Rpm) and All 570 Ratings
260
Crankshaft Disassembly
260
Cam Gear from Camshaft
261
Camshaft Disassembly
262
Camshaft Bushings
263
Coolant Heater (if Equipped)
264
Cleaning and Inspection
265
Cleaning the Crankcase
265
Crankcase Ventilation
265
Crankshaft and Main Bearings
266
Checking Camshaft Assembly
266
Checking Camshaft Lobes and Journals
267
Installation
267
Coolant Heater (if Equipped)
267
Camshaft Bushings
267
Camshaft Assembly
270
Cam Gear on Camshaft
271
Checking Camshaft End Play
271
Crankshaft Assembly
272
Bearing Fitting Procedure
273
Main Bearings and Caps
274
Torque Procedure for Torque-To-Yield Main Bearing Bolts
275
Crankcase Ladder (DT 466 Series - 225 Hp and 245 Hp @ 2600 Rpm) and All 570 Ratings
276
Oil Level Gauge
278
Crankcase Ventilation System
278
Specifications
280
Special Service Tools
282
Special Torque
282
Oil System Module Assembly and Secondary Filtration 279
283
Removal
287
Oil System Module
287
Secondary Filtration Assembly
290
Disassembling the Oil System Module
291
Disassembling the Secondary Filtration Filter
293
Cleaning and Inspection
294
Cleaning the Oil System Module
294
Checking the Cooler Heat Exchanger for Leakage
294
External
294
Internal
296
Installation
297
Assembling the Oil System Module
297
Assembling the Secondary Filtration Filter
299
Secondary Filtration Assembly
300
Oil System Module
300
Priming the Lubrication System
302
Alternate Method
302
Special Service Tools
303
Special Torque
303
Specifications
303
Engine Electrical 301
305
Sensor Identification
307
Removal
310
Sensor Wiring Harness
310
Injector Wiring Harness
316
ECM, IDM, EGR Drive Module, and Intake Air Heater
317
Valve Cover Gasket with Pass-Through Connectors
321
Cleaning and Inspection
323
Checking Wiring Harness and Electrical Connectors
323
Installation
324
Valve Cover Gasket with Pass-Through Connectors
324
ECM, IDM, EGR Drive Module, and Intake Air Heater
325
Injector Wiring Harness
331
Sensor Wiring Harness
332
Fuel System 335
339
Description
341
Low-Pressure Fuel System
341
High-Pressure Oil System
342
Periodic Service
344
Fuel Strainer
344
Fuel Filter
345
Removal
346
Low-Pressure Fuel Supply Pump and Tubing
346
Fuel Filter Header Assembly and Intake Manifold
347
High-Pressure Hose Assembly - Generation 1
349
High-Pressure Hose Assembly with 70 and 90 Degree Elbows - Generation 2
349
High-Pressure Pump and IPR Valve
350
High-Pressure Oil Rail Assembly
350
Fuel Injector Assemblies
352
Disassembly
354
Fuel Filter Header Assembly
354
Installation
356
Fuel Injectors
356
High-Pressure Oil Rail Assembly
357
High-Pressure Oil Pump and IPR Valve Assembly
360
IPR Valve Assembly
360
High-Pressure Oil Pump
360
High-Pressure Hose Assembly - Generation 1
361
High-Pressure Hose Assembly with 70 and 90 Degree Elbows - Generation 2
361
Fuel Filter Header Assembly and Intake Manifold
363
Low-Pressure Fuel Supply Pump and Tubing
364
Priming Fuel System after out of Fuel
366
Special Torque
367
Specifications
367
Special Service Tools
368
Flywheel and Flywheel Housing 365
369
Description
371
Flywheel and Flexplate Applications
373
Manual Transmissions
373
Automatic Transmissions
376
Removal
379
Flywheel Assembly
379
Flexplate (Automatic Transmissions)
380
Allison 2000 Series Transmissions
380
MD-3000 and HD-4000 Series Transmissions
380
Crankshaft Timing Disk and Rear Oil Seal
380
Inspection
382
Flywheel Housing Face Runout
382
Flywheel Housing Bore Concentricity
382
Crankshaft Pilot Concentricity
382
Removing Flywheel Housing
383
Flywheel Reconditioning
383
Cleaning
383
Inspection
383
Flywheel Resurfacing
383
Ring Gear Replacement
384
Installation
384
Flywheel Housing
384
Rear Oil Seal
385
Crankshaft Timing Disk
386
Flywheel Assembly
387
Checking Flywheel Surface Runout
388
Flexplate (Automatic Transmissions)
388
Allison 2000 Series Transmissions
388
MD-3000 and HD-4000 Series World Transmissions
389
Specifications
390
Special Service Tools
391
Special Torque
391
Diamond Logic® Engine Brake 389
393
Periodic Service
396
Engine Brake Actuator Lash
396
Brake Lash Adjustment
396
Reconditioning
398
Diagnostic Tests Procedures and Service Parts
398
Reconditioning Procedures
398
Brake Shutoff Valve
399
BCP Sensor
400
ICP Sensor
400
M12 Plug Assembly
401
Rail End Plug Assembly
401
Oil Pressure Relief Valve
401
Brake Actuator Piston Assembly
401
Removal
403
Valve Cover
403
Electrical Connectors
403
High-Pressure Oil Rail
404
Installation
405
High-Pressure Oil Rail
405
Electrical Connections
407
Special Tools
409
Special Torque
409
Specifications
409
Air Compressor, Power Steering Pump, and Power 407 Take-Off
411
Air Compressor, Power Steering Pump, and Power Take-Off
411
Description
413
Air Compressor
413
Power Steering Pump
413
Power Take-Off
413
Removal
413
Air Compressor
414
Power Steering Pump
415
Installation
415
Air Compressor
415
Power Steering Pump with Air Compressor
416
Power Steering Pump Without Air Compressor
418
Special Torques
419
Abbreviations and Acronyms
421
Terminology
425
Appendix A - Specifications
435
Appendix A - Specifi Cations
447
Appendix B - Torques
447
Appendix D - Technical Service Information (Tsi) 463 Bulletins
467
Appendix D - Technical Service Information (Tsi)
469
TSI-05-12-28 New High-Pressure Oil Rails
469
TSI-05-12-35 New 1500 Watt Single Grid Intake Air Heater Production Option
470
TSI-06-12-15 Sensor O-Ring Kit for CMP or CKP Applications
472
TSI-06-12-14 Update Valve Train Components - Push Rod and Tappet Compatibility
473
TSI-06-12-21 Update Valve Train Components - Adjuster Screws
478
TSI-06-12-27 New Piston and Piston Ring Assemblies
479
TSI-07-12-12 EGR Coolant Return Kit
481
TSI-08-12-20 Rubber Vibration Damper Replacement Kits
484
TSI-09-12-02 High-Pressure Pump Assembly Inlet Filter Service Kit
487
Appendix E - Instruction Sheet S
491
1171813R1 Front Cover PTO Adaptation Kit
491
1171836R1 Air Compressor Bracket Kit
493
1171846R1 Aluminum Air Inlet Adapter
496
1171848R1 300 Watt Oil Pan Heater Kit
499
1171855R1 Turbo Actuator Service Kit (SRA)
501
1171908R1 Turbocharger VGT Linkage Kit
503
1171913R1 Turbine Vane Assembly Cleaning Kit
507
1171915R2 Turbocharger Actuator Flange and Pivot Shaft Kit
512
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Navistar INTERNATIONAL DT 466 Specifications
General
Brand
Navistar
Model
INTERNATIONAL DT 466
Category
Engine
Language
English
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