Navistar International DT466/DT530/DT570 Engine Service & Repair Manual

SERVICE MANUAL ENGINE SERVICE MANUAL DT 466 / DT 570 / HT 570 Service Manual - 2004 Emissions with EGR Engine Family: DT 466 Engine Family: DT 570 Engine Family: HT 570 EGES-265-1, FORMERLY EGES-265-1 03/30/2004 EGES-265-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©03/30/2004 International Truck and Engine Corporation

ENGINE SERVICE MANUAL I Table of Contents Foreword...................................................................................................................1 Service Diagnosis ........................................................................................................2 Safety Information........................................................................................................3 Engine Systems...........................................................................................................5 Mounting Engine on Stand............................................................................................59 EVRT® Electronically Controlled Turbocharger...................................................................67 Intake, Inlet, and Exhaust Manifolds.................................................................................75 EGR Cooler and Tubing................................................................................................87 Cylinder Head and Valve Train........................................................................................99 Front Cover and Related Components.............................................................................141 Oil Pan and Oil Suction Tube........................................................................................181 Power Cylinders........................................................................................................191 Crankcase, Crankshaft, and Camshaft.............................................................................221 Oil System Module Assembly and Secondary Filtration........................................................253 Engine Electrical.......................................................................................................273 Fuel System.............................................................................................................309 Flywheel and Flywheel Housing.....................................................................................335 Diamond Logic™ Engine Brake.....................................................................................359 Air Compressor and Power Steering Pump.......................................................................375 Abbreviations and Acronyms........................................................................................383 Terminology.............................................................................................................387 Appendix A — Specifications........................................................................................395 Appendix B — Torques...............................................................................................407 EGES-265-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©03/30/2004 International Truck and Engine Corporation

II ENGINE SERVICE MANUAL Appendix C — Special Service Tools...............................................................................417 EGES-265-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©03/30/2004 International Truck and Engine Corporation

ENGINE SERVICE MANUAL 1 Foreword This publication provides general and specific service procedures and repair methods essential for reliable engine operation and your safety. Since many variations in procedures, tools, and service parts are involved, advice for all possible safety conditions and hazards cannot be stated. Departure from instructions in this publication or disregard of warnings and cautions can lead to injury or death, or both and damage to the engine or vehicle. Read safety instructions below before doing service or test procedures in this publication for the engine or vehicle. See related engine manuals for more information. Periodic revisions may be made to publications. When ordering publications, the latest revision will be supplied. The following literature supporting International® Diesel Engines is available from: International Truck and Engine Corporation Moore Wallace North America 1750 Wallace Avenue St. Charles, IL 60174 630-313-7507 Technical Service Literature 1171809R1 DT 466, DT 570 and HT 570 Engine Operation and Maintenance Manual EGES-265 DT 466, DT 570 and HT 570 Service Manual EGES-270 DT 466, DT 570 and HT 570 Diagnostic Manual EGED-285 DT 466, DT 570 and HT 570 Electronic Control Systems Diagnostic Form (Pad of 50) EGED-290 DT 466, DT 570 and HT 570 Diagnostic Form (Pad of 50) EGES-265-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©03/30/2004 International Truck and Engine Corporation

2 ENGINE SERVICE MANUAL Service Diagnosis Service diagnosis is a systematic procedure of investigation to be followed in order to locate and correct an engine problem. The engine is first considered as a complete unit in its specific application and then the problem is localized to components or systems; intake, exhaust, cooling, lubrication or injection. Testing procedures will then help analyze the source of the problem. PREREQUISITES FOR EFFECTIVE DIAGNOSIS: • Knowledge of the principles of operation for both the engine and application systems • Knowledge to perform and understand all procedures in the diagnostic and service publications • Availability of and the ability to use gauges and diagnostic test equipment • Availability of the most current information for the engine application Although the cause of an engine failure may be apparent, very often the real cause is not found until a repeat failure occurs. This can be prevented if specific diagnostic action is taken before, during and after engine disassembly and during engine assembly. It is also very important that specific diagnostic tests follow engine assembly before and after the engine is placed back into service. Identification of the symptoms which lead to engine failure is the result of proper service diagnosis. Effective service diagnosis requires use of the following references: • Engine Service Manual • Hard Start and No Start Diagnostics • Performance Diagnostics • Electronic Control Systems Diagnostics • Service Bulletins NOTE: Metric values precede English values for test procedures and reference. Examples: 96 kPa (14 psi), 20°C (68°F) EGES-265-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©03/30/2004 International Truck and Engine Corporation

ENGINE SERVICE MANUAL 3 Safety Information This manual provides general and specific service procedures and repair methods essential for reliable engine operation and your safety. Since many variations in procedures, tools, and service parts are involved, advice for all possible safety conditions and hazards cannot be stated. Departure from instructions in this manual or disregard of warnings and cautions can lead to injury or death, or both and damage to the engine or vehicle. Read safety instructions below before doing service and test procedures in this manual for the engine or vehicle. See related application manuals for more information. SAFETY TERMINOLOGY Three terms are used in this manual to stress your safety and safe operation of the engine: Warning, Caution, and Note. Warning: This symbol is used to make you aware of an unsafe condition, hazard, or practice that can result in personal injury or death. Caution: This symbol is used to alert you to a condition or practice that can cause damage to the engine or vehicle, or both. Note: Signals a key point or procedure that must be followed for correct, efficient engine operation. SAFETY INSTRUCTIONS Vehicle • Make sure the vehicle is in neutral, the parking brake is set, and the wheels are blocked before doing any work or diagnostic procedures on the engine or vehicle. Work area • Keep work area clean, dry, and organized. • Keep tools and parts off the floor. • Make sure the work area is ventilated and well lit. • Make sure a First Aid Kit is available. Safety equipment • Use correct lifting devices. • Use safety blocks and stands. Protective measures • Wear protective glasses and safety shoes (do not work in bare feet, sandals, or sneakers.) • Wear appropriate hearing protection • Wear correct work clothing. • Do not wear rings, watches, or other jewelry. • Restrain long hair. Fire prevention • Make sure charged fire extinguishers are in the work area. NOTE: Check the classification of each fire extinguisher to ensure that the following fire types can be extinguished. 1. Type A — Wood, paper, textiles, and rubbish 2. Type B — Flammable liquids 3. Type C — Electrical equipment Batteries Batteries produce highly flammable gas during and after charging. • Always disconnect the main negative battery cable first. • Always connect the main negative battery cable last. • Avoid leaning over batteries. • Protect your eyes. • Do not expose batteries to open flames or sparks. • Do not smoke in workplace. Compressed air • Limit shop air pressure for blow gun to 207 kPa (30 psi). • Use approved equipment. • Do not direct air at body or clothing. • Wear safety glasses or goggles. • Wear hearing protection • Use shielding to protect others in the work area. Tools • Make sure all tools are in good condition. EGES-265-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©03/30/2004 International Truck and Engine Corporation

4 ENGINE SERVICE MANUAL • Make sure all standard electrical tools are grounded. • Check for frayed power cords before using power tools. Fluids under pressure • Use extreme caution when working on systems under pressure. • Follow approved procedures only. Fuel • Do not over fill the fuel tank. Over fill creates a fire hazard. • Do not smoke in the work area. • Do not refuel the tank when the engine is running. Removal of tools, parts, and equipment • Reinstall all safety guards, shields, and covers after servicing the engine. • Make sure all tools, parts, and service equipment are removed from the engine and vehicle after all work is done. EGES-265-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©03/30/2004 International Truck and Engine Corporation

ENGINE SYSTEMS 5 Table of Contents Engine Identification.....................................................................................................7 Engine Serial Number..........................................................................................7 Engine Emission Label.........................................................................................7 Engine Description..............................................................................................9 Engine Component Locations ..............................................................................12 Engine Systems.........................................................................................................18 Engine System Diagram......................................................................................18 Air Management System...............................................................................................19 Air Management Components and Air Flow..............................................................19 Charge Air Cooler (CAC).....................................................................................20 Variable Geometry Turbocharger (VGT)...................................................................21 Exhaust Gas Recirculation (EGR) System................................................................24 Exhaust System................................................................................................25 Fuel Management System.............................................................................................26 Fuel Management Components.............................................................................26 Injection Control Pressure (ICP) System Components and High Pressure Oil Flow..............27 Fuel Injectors...................................................................................................30 Fuel Supply System.....................................................................................................34 Fuel System Components and Fuel Flow.................................................................34 Fuel Flow Schematic..........................................................................................35 Engine Lubrication System ...........................................................................................37 Lubrication System Components and Oil Flow..........................................................37 Cooling System..........................................................................................................41 Cooling System Components and Coolant Flow.........................................................41 Electronic Control System.............................................................................................44 Electronic Control System Components..................................................................44 Injection Drive Module (IDM).................................................................................46 Engine and Vehicle Sensors.................................................................................48 Diamond Logic™ Engine Brake......................................................................................54 Engine Brake Components...................................................................................54 Engine Brake Control.........................................................................................55 Operation of Diamond Logic™ Engine Brake in Braking Mode.......................................57 EGES-265-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©03/30/2004 International Truck and Engine Corporation

6 ENGINE SYSTEMS EGES-265-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©03/30/2004 International Truck and Engine Corporation

Navistar International DT466/DT530/DT570 Engine Service & Repair Manual

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