International DT466 / DT570 / HT570 Diesel Engine Service & Repair Manual

© 2009 Navistar. Inc. Printed in the United States of America SERVICE MANUAL INTERNATIONAL® DT 466, DT 570, HT 570 DIESEL ENGINE SERVICE MANUAL FORM EGES-265-2 SERVICE MANUAL INTERNATIONAL® DT 466, DT 570, HT 570 DIESEL ENGINE (S/N 2000001 AND ABOVE) FORM EGES-265-2 2004 MODEL YEAR AND ABOVE

ENGINE SERVICE MANUAL I Table of Contents Foreword.................................................................................................................. 1 Service Diagnosis ....................................................................................................... 2 Safety Information....................................................................................................... 3 Engine Systems......................................................................................................... 5 Mounting Engine on Engine Stand...................................................................................59 EVRT® Electronically Controlled Turbocharger...................................................................67 Intake, Inlet, and Exhaust Manifolds.................................................................................77 EGR Cooler and Tubing................................................................................................91 Cylinder Head and Valve Train........................................................................................ 115 Front Cover and Related Components.............................................................................. 157 Oil Pan and Oil Suction Tube.......................................................................................... 203 Power Cylinders......................................................................................................... 213 Crankcase, Crankshaft, and Camshaft.............................................................................. 249 Oil System Module Assembly and Secondary Filtration......................................................... 279 Engine Electrical......................................................................................................... 301 Fuel System.............................................................................................................. 335 Flywheel and Flywheel Housing...................................................................................... 365 Diamond Logic® Engine Brake....................................................................................... 389 Air Compressor, Power Steering Pump, and Power Take-off.................................................... 407 Abbreviations and Acronyms......................................................................................... 417 Terminology.............................................................................................................. 421 Appendix A – Speciﬁcations.......................................................................................... 431 Appendix B – Torques.................................................................................................. 443 EGES-265-2 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.

II ENGINE SERVICE MANUAL Appendix C – Special Service Tools................................................................................. 453 Appendix D – Technical Service Information (TSI) Bulletins.................................................... 463 Appendix E – Instruction Sheets..................................................................................... 485 EGES-265-2 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.

ENGINE SERVICE MANUAL 1 Foreword Navistar, Inc. is committed to continuous research and development to improve products and introduce technological advances. Procedures, specifications, and parts defined in published technical service literature may be altered. This Engine Service Manual provides a general sequence of procedures for out-of-chassis engine overhaul (removal, inspection, and installation). For in-chassis service of parts and assemblies, the sequence may vary. NOTE: Photo illustrations identify specific parts or assemblies that support text and procedures; other areas in a photo illustration may not be exact. See vehicle manuals and Technical Service Information (TSI) bulletins for additional information. Technical Service Literature 1171809R5 DT 466, DT 570 and HT 570 Engine Operation and Maintenance Manual EGES-265–2 DT 466, DT 570 and HT 570 Engine Service Manual EGES-270 DT 466, DT 570 and HT 570 Engine 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 Diagnostics Form (Pad of 50) Navistar, Inc. is committed to continuous research and development to improve products and introduce technological advances. Procedures, specifications, and parts defined in published technical service literature may be altered. This Engine Service Manual provides a general sequence of procedures for out-of-chassis engine overhaul (removal, inspection, and installation). For in-chassis service of parts and assemblies, the sequence may vary. NOTE: Photo illustrations identify specific parts or assemblies that support text and procedures; other areas in a photo illustration may not be exact. See vehicle manuals and Technical Service Information (TSI) bulletins for additional information. EGES-265-2 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.

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International DT466 / DT570 / HT570 Diesel Engine Service & Repair Manual

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