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INTERNATIONAL DT 466
Navistar INTERNATIONAL DT 466 User Manual
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7
ELECTRONIC
CONTROL
SYSTEMS
DIAGNOSTICS
473
To
o
l
s
•
EST
with
MasterDiagnosti
cs®
software
•
EZ-T
ech®
interface
cabl
e
•
Digital
Multimeter
(DMM)
EGES-270-1
Read
all
safety
instructions
in
the
"Safety
Information"
section
of
this
manual
before
doing
any
procedures.
Follow
all
warnings,
cautions,
and
notes.
©
August
2008
Navistar
,
Inc.
476
478
Table of Contents
Diagnostic/Troubleshooting Manual I
3
Table of Contents
3
Foreword
5
Service Diagnosis
6
Safety Information
7
Table of Contents
9
Engine Identification
11
Engine Serial Number
11
Engine Emission Label
11
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
57
Engine Brake Components
57
Engine Brake Control
58
Operation of Diamond Logic® Engine Brake in Braking Mode
60
3 Diagnostic Software Operation 65
69
Diagnostic Software Operation
70
Diagnostic Trouble Code Detection
71
Continuous Monitor
72
Diagnostic Trouble Codes
73
Using EST
73
Accessing Diagnostic Trouble Codes (Dtcs)
73
Reading Dtcs
73
Clearing Dtcs
73
Using Cruise Switches
73
Accessing Dtcs
73
Reading Dtcs
74
Clearing Dtcs
74
Diagnostic Tests
75
Key-On Engine-Off Tests
75
Standard Test
75
Standard Test Using EST
75
Standard Test Using Cruise Switches
76
Injector Test
76
Continuous Monitor Test
77
Output State Low Test
78
Output State High Test
79
Glow Plug/Inlet Air Heater Output State Test
80
Key-On Engine-Running Tests
81
Standard Test
81
Continuous Monitor Test
82
Air Management Test
83
VGT Test
87
Injector Disable Tests
89
Automatic Test
89
Manual Test - Engine Cold
91
Manual Test - Engine Hot
92
Relative Compression
95
Reset Change Engine Oil Interval Message
97
Using EST
97
Using Cruise Switches
101
4 Engine Symptoms Diagnostics 99
103
Problems and Conditions
105
Combustion Leaks to Coolant
106
Aerated Fuel
108
Aerated Fuel Inspection
108
Alternate Fuel Source Supply to Fuel Pump
110
Alternate Fuel Source Supply to Fuel Filter Housing
111
Combustion Leaks to Fuel
112
Coolant in Lube Oil
113
Coolant System Inspection
113
Engine Symptoms Diagnostics
114
Air Compressor Leak Test
114
Front Cover Inspection
115
Cylinder Head Leak Test
116
ECM Reset / IDM Reset (Intermittent Engine Stumble)
117
Excessive Fuel Consumption
118
Fuel in Coolant
119
Coolant Leak to Exhaust
121
Coolant Over-Temperature
123
Coolant System Inspection
123
Temperature Sensor Validation Test
124
Cooling System Operating Pressure Test
125
Lube Oil in Coolant
126
Fuel in Lube Oil
128
Low Oil Pressure
132
Oil Inspection
132
Oil Pressure Regulator Inspection
133
Oil and Crankcase Inspection
133
Oil Pump Inspection
134
Front Cover Inspection
135
Priming Fuel System
136
Rough Idle
139
Smoke
141
Black Smoke
141
White Smoke
141
Low Power (Turbocharger Assembly and Actuator)
143
Table of Contents
145
Default Chapter
146
Hard Start and no Start Diagnostics
146
Description
147
Diagnostic Form Information
147
Test Procedures
148
1 Initial Ignition Switch on (Do Not Start)
148
2 Engine Cranking
150
3 Diagnostic Trouble Codes
152
Vehicle Information for Form Heading
152
Entering Vehicle Information Without Using the EST
152
Entering Vehicle Information Using the EST
153
Accessing Dtcs
155
Reading Dtcs
156
4 KOEO Standard Test
157
5 KOEO Injector Test
159
6 EST Data List
161
Monitoring Engine Systems Using an EST
161
Monitoring ICP Using VC Gasket Breakout Harness
163
Monitoring BCP Using VC Gasket Breakout Harness
165
Monitoring EOP at EOT Sensor Port
167
Monitoring Engine Systems Using Breakout Box
168
7 Fuel
170
8 Engine Systems
174
9 Engine Oil
175
10 Intake and Exhaust Restriction
176
11 Main Power Relay to ECM
178
Voltage Measurement with Breakout Harness at Main Power Relay
178
Voltage Measurement at ECM with Breakout Box
179
12 Main Power Relay to IDM
181
Voltage Measurement at 12-Pin Connection with Breakout Harness
181
Voltage Measurement with Breakout Harness at Main Power Relay
183
13 Fuel Pressure and Aerated Fuel
184
Fuel Pressure
184
Checking for Aerated Fuel Using Spare Fuel Line
187
Operation of Fuel Pump
189
14 Low ICP System Pressure
190
14.1 - System Function
190
Oil Reservoir Level
192
14.3 - IPR and High-Pressure Pump Operation
192
Under Valve Cover Leak Test
195
14.5 - IPR Function
198
15 Inlet Air Heater System
201
15.1 - Current Amperage Draw
201
15.2 - Voltage at Element Terminal
202
15.3 - Element Terminal Continuity
203
15.4 - Wiring Harness Continuity and Resistance
204
15.5 - Relay Operation
204
Table of Contents
207
Default Chapter
208
Performance Diagnostics
208
Description
209
Diagnostic Form Information
209
Test Procedures
211
1 Diagnostic Trouble Codes
211
Vehicle Information for Form Heading
211
Entering Vehicle Information Without Using the EST
211
Entering Vehicle Information Using the EST
212
Accessing Dtcs
215
Reading Dtcs
216
2 KOEO Standard Test
217
3 KOEO Injector Test
219
4 Engine Oil
221
5 Fuel
222
6 Fuel Pressure and Aerated Fuel
226
Fuel Pressure
226
Checking for Aerated Fuel Using Spare Fuel Line
230
Operation of Fuel Pump
232
7 Intake Restriction
233
8 Exhaust Restriction
235
Monitoring EBP Using EST
235
Monitoring EBP Using Pressure Sensor Breakout Harness
237
9 KOER Standard Test
238
10 Injection Control Pressure
240
Monitoring ICP and BCP Using EST
240
Monitoring ICP Using VC Gasket Breakout Harness
243
Monitoring BCP Using VC Gasket Breakout Harness
246
11 Injector Disable Test
248
Automatic Test - Auto Run
248
Manual Test
250
12 Relative Compression
252
13 Air Management
255
14 VGT Test
257
15 Torque Converter Stall (Automatic Only)
259
16 Crankcase Pressure
260
17 Test Drive (Full Load, Rated Speed)
262
Monitoring Engine Parameters Using EST and Fuel Pressure Gauge
262
Fuel Inlet Restriction
270
Monitoring Boost Pressure Using Pressure Sensor Breakout Harness
272
Monitoring ICP Using VC Gasket Breakout Harness
273
Monitoring BCP Using VC Gasket Breakout Harness
276
18 Valve Lash and Brake Lash
278
Adjusting Valve Lash
278
Brake Lash
281
Table of Contents
283
Description
287
Section Information
287
Electronic Control System Diagnostics Form
288
EGED-285 Diagnostic Form Example
288
Sensor and Actuator Locations
289
Engine Mounted Components
289
Vehicle Mounted Components
292
Diagnostic Procedures for Sensors and Actuators
292
Pin Grip Inspection
292
Operational Diagnostics
293
Tests Using Masterdiagnostics
293
Vref
293
Temperature Sensor Tests Using Masterdiagnostics
293
Pin-Point Diagnostics
294
Connector Voltage Checks to Ground
294
Connector Resistance Checks to ECM Chassis Ground
294
Connector Resistance Checks to Chassis Ground
295
Harness Resistance Checks
296
Operational Voltage Checks
296
Circuit Diagnostics
297
AMS (Air Management System)
297
AMS Operation
298
APS/IVS (Accelerator Position Sensor and Idle Validation Switch)
304
APS/IVS Circuit Operation
305
APS/IVS Operational Diagnostics
308
APS/IVS Pin-Point Diagnostics
310
ATA Datalink (American Trucking Association)
313
ATA Circuit Operation
314
ATA Pin-Point Diagnostics
316
BAP Sensor (Barometric Absolute Pressure)
318
BAP Circuit Operation
319
BAP Pin-Point Diagnostics
320
BCP Sensor (Brake Control Pressure)
322
BCP Circuit Operation
324
BCP Operational Diagnostics
326
BCP Pin-Point Diagnostics (ECM to Valve Cover Gasket Connector)
332
BCP Pin-Point Diagnostics (ECM to BCP Sensor- Valve Cover Removed)
337
Brake Shut-Off Valve
338
Brake Shut-Off Valve Circuit Operation
340
Brake Shut-Off Valve Pin-Point Diagnostics (ECM to Valve Cover Gasket Connector)
342
Brake Shut-Off Valve Pin-Point Diagnostics
342
Removed)
348
Brake Switch Circuit
351
Brake Switch Operation
351
CAN Communications (Controller Area Network)
352
CAN Pin-Point Diagnostics
353
CKP Sensor (Crankshaft Position)
355
CKP Circuit Operation
356
CKP Pin-Point Diagnostics
357
CMP Sensor (Camshaft Position)
359
CMP Circuit Operation
360
CMP Pin-Point Diagnostics
361
EBP Sensor (Exhaust Back Pressure)
363
EBP Circuit Operation
364
EBP Operational Diagnostics
365
EBP Pin-Point Diagnostics
368
ECI System (Engine Crank Inhibit)
370
ECI Circuit Diagnostics
372
ECL Sensor (Engine Coolant Level)
374
ECL Circuit Operation
375
ECL Pin-Point Diagnostics
376
ECM / IDM Communications (Electronic Control Module / Injector Driver Module)
377
ECM / IDM Circuit Operation
378
ECM / IDM Pin-Point Diagnostics
380
ECM PWR (Electronic Control Module Power)
385
ECM PWR Circuit Operation
386
ECM PWR Pin-Point Diagnostics
388
ECM Self Diagnostics (Electronic Control Module)
392
ECM Self Diagnostic Trouble Codes (Dtcs)
393
ECT Sensor (Engine Coolant Temperature)
395
ECT Circuit Operation
397
ECT Operational Diagnostics
398
ECT Pin-Point Diagnostics
400
EFAN Control (Engine Fan Control)
402
Fan Clutch Circuit Operation
403
Fan Clutch Pin-Point Diagnostics
404
Fan Air Solenoid Circuit Operation
407
Fan Air Solenoid Pin-Point Diagnostics
408
EFP Sensor (Engine Fuel Pressure - Optional)
410
EFP Circuit Operation
411
EFP Operational Diagnostics
412
EFP Pin-Point Diagnostics
414
EGR Actuator (Exhaust Gas Recirculation)
417
EGR Circuit Operation
418
EGR Pin-Point Diagnostics
421
EOP Sensor (Engine Oil Pressure)
430
EOP Circuit Operation
431
EOP Operational Diagnostics
432
EOP Pin-Point Diagnostics
435
EOT Sensor (Engine Oil Temperature)
437
EOT Circuit Operation
438
EOT Operational Diagnostics
440
EOT Pin-Point Diagnostics
442
EWPS (Engine Warning and Protection System)
444
EWPS Operational Diagnostics
445
IAH System (Inlet Air Heater)
448
IAH Circuit Operation
449
IAH Pin-Point Diagnostics
451
IAT Sensor (Intake Air Temperature)
455
IAT Circuit Operation
456
IAT Operational Diagnostics
457
IAT Pin-Point Diagnostics
459
ICP Sensor (Injection Control Pressure)
461
ICP Circuit Operation
462
ICP Operational Diagnostics
464
ICP Pin-Point Diagnostics (ECM to Valve Cover Gasket Connector)
469
ICP Pin-Point Diagnostics (ECM to ICP Sensor- Valve Cover Removed)
473
ICP System (Injection Control Pressure)
476
ICP System Operation
476
IDM PWR (Injection Driver Module Power)
483
IDM PWR Circuit Operation
484
IDM PWR Pin-Point Diagnostics
486
INJ Circuits (Injector Drive)
493
INJ Circuit Operation
493
INJ Pin-Point Diagnostics
494
IPR (Injection Pressure Regulator)
498
IPR Circuit Operation
499
IPR Pin-Point Diagnostics
500
IST System (Idle Shutdown Timer)
501
IST Operation
501
MAP Sensor (Manifold Absolute Pressure)
504
MAP Circuit Operation
505
MAP Operational Diagnostics
507
MAP Pin-Point Diagnostics
509
MAT Sensor (Manifold Air Temperature)
512
MAT Circuit Operation
513
MAT Operational Diagnostics
514
MAT Pin-Point Diagnostics
516
RSE (Radiator Shutter Enable)
518
RSE Circuit Operation
519
RSE Pin-Point Diagnostics
520
SCCS (Speed Control Command Switches)
523
SCCS Circuit Operation
523
Tachometer Output Circuit
526
Tachometer Pin-Point Diagnostics
527
VGT Actuator (Variable Geometry Turbocharger)
528
VGT Circuit Operation
530
VGT Pin-Point Diagnostics
532
(Reference Voltage)
543
Ref
543
Circuit Operation
544
Ref
544
Pin-Point Diagnostics
546
VSS (Vehicle Speed Sensor)
548
VSS Circuit Operation (Manual and Allison Transmissions)
549
VSS Pin-Point Diagnostics (Manual Transmissions)
551
VSS Pin-Point Diagnostics (Allison Transmissions)
553
8 Diagnostic Tools and Accessories 555
559
Diagnostic Tools and Accessories
561
Tools and Accessories
561
EZ-Tech® Electronic Service Tool (EST)
561
EZ-Tech® Interface Kit
561
Masterdiagnostics® Software
561
Digital Multimeter (Fluke 88)
562
Amp Clamp
562
96-Pin Breakout Box - DLC II
563
Breakout Harness Kit
563
3-Banana Plug Harness
564
VC Gasket Breakout Harness
564
UVC Sensor Breakout Harness
564
4-Pin Injector Harness
564
12-Pin Breakout Harness
565
500 Ohm Resistor Harness
565
Actuator Breakout Harness
565
APS/IVS Sensor Breakout Harness
565
Pressure Sensor Breakout Harness
566
Relay Breakout Harness
566
Temperature Sensor Breakout Harness
566
Temperature Sensor Breakout Harness
567
Turbo Breakout Harness
567
EGR Valve Breakout Harness
567
Terminal Test Adapter Kit
568
Gauge Bar Tool
568
Fuel Pressure Gauge
569
Slack Tube Manometer
569
Fuel Pressure Test Kit
570
Fuel/Oil Pressure Test Coupler
570
Fuel Test Fitting
571
ICP System Test Adapter
571
ICP Test Kit
571
Inline Shut-Off Valve
572
Vacuum Pump and Gauge
572
Charge Air Cooler Test Kit
572
Crankcase Pressure Test Adapter
573
UV Leak Detection Kit
573
Electronic Circuit Testing
574
Electrical Theory
574
Voltage
574
Ohm's Law
574
Using the Digital Multimeter
575
Test Meters
575
Jumper Wires
576
Voltmeter
576
Ammeter
578
Ohmmeter
579
Measuring Duty Cycle with FLUKE 88
580
Troubleshooting
582
Abbreviations and Acronyms
585
Terminology
589
11 Appendix A: Dt 466 Performance Specifications 2004 593 Model Year
597
11 Appendix A: Dt 466 Performance Specifications 2004 593
599
DT 466 (Standard and High Torque - All Ratings)
599
Temperature, Fuel, and Lubrication
599
Appendix A: DT 466 Performance Specifications 2004 Model Year
600
DT 466 (Standard Torque)
601
Hp @ 2300 Rpm (12NPL)
601
Hp @ 2300 Rpm (12NPM)
603
Hp @ 2300 Rpm (12NPN)
605
Hp @ 2300 Rpm (12NPP)
607
DT 466 (High Torque)
609
Hp @ 2300 Rpm (12NPR)
609
Hp @ 2300 Rpm (12NPS)
611
Hp @ 2300 Rpm (12NPT)
613
Hp @ 2300 Rpm (12NPU)
615
Hp @ 2300 Rpm (12NPV)
617
Hp @ 2300 Rpm (12NPX)
619
Table of Contents
621
Appendix B: DT 570 and HT 570 Performance Specifications 2004 Model Year
622
DT 570 and HT 570 (All Ratings)
623
12 Appendix B: Dt 570 and Ht 570 Performance
623
Temperature, Fuel, and Lubrication
623
DT 570 (Standard Torque)
625
12NPW (285 Hp @ 2000 Rpm)
625
12NPZ (310 Hp @ 2000 Rpm)
627
12NRB (330 Hp @ 2000 Rpm)
629
HT 570 (High Torque)
631
12NRC (295 Hp @ 2000 Rpm)
631
12NRD (295 Hp @ 2000 Rpm)
633
12NRE (310 Hp @ 2000 Rpm)
635
12NRA 300 Hp @ 2000 Rpm
637
12NRG (310 Hp @ 2000 Rpm)
639
12NRH (330 Hp @ 2000 Rpm)
641
12NRZ (340 Hp @ 2000 Rpm)
643
Appendix C: Diagnostic Trouble Code Index
647
Appendix D: Technical Service Information (TSI)
653
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Navistar INTERNATIONAL DT 466 Specifications
General
Brand
Navistar
Model
INTERNATIONAL DT 466
Category
Engine
Language
English
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