2000-2008 Navistar International DT466/DT466E/DT530/DT530E/HT530 Diesel Engines OEM Service & Repair Manual

© 2006 International Truck and Engine Corporation Printed in the United States of America SERVICE MANUAL INTERNATIONAL® DT 466E, 530E, 466, 530, and HT 530 DIESEL ENGINE Model Year 2000 and Up EGES-210-1 SERVICE MANUAL INTERNATIONAL® DT 466E, 530E, 466, 530, and HT 530 DIESEL ENGINE EGES-210-1 Model Year 2000 and Up

ENGINE SERVICE MANUAL I Table of Contents Foreword...................................................................................................................1 Service Diagnosis ........................................................................................................2 Safety Information........................................................................................................3 Introduction................................................................................................................5 Mounting Engine on Stand............................................................................................33 Turbochargers...........................................................................................................39 Manifolds..................................................................................................................59 Cylinder Head and Valves..............................................................................................69 Rocker Arm Assembly, Camshaft Assembly, Tappets, and Push Rods......................................113 Power Cylinders........................................................................................................133 Vibration Damper, Crankshaft, Main Bearings, Flywheel, and Crankcase...................................165 Timing Gear Train and Front Cover.................................................................................221 Lubricating Oil Pump, Oil Filter, and Cooler......................................................................243 Water Pump and Thermostat........................................................................................259 Engine Electrical.......................................................................................................277 High-pressure Lube Oil System.....................................................................................299 Fuel System.............................................................................................................309 Terminology.............................................................................................................319 Speciﬁcations..........................................................................................................327 Torque Information....................................................................................................341 Special Tools............................................................................................................351 EGES-210-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © 2006 International Truck and Engine Corporation

II ENGINE SERVICE MANUAL EGES-210-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©2006 International Truck and Engine Corporation

ENGINE SERVICE MANUAL 1 Foreword This manual is part of a series of publications intended to assist service technicians in maintaining International® diesel engines. Due to a commitment of continuous research and development, some procedures, speciﬁcations, and parts may be altered to improve International® products and introduce technological advances. Periodic revisions may be made to these publications and mailed automatically to “Revision Service” subscribers. When ordering publications, the latest revision will be supplied. NOTE: International® diesel engines are installed in many different applications. It is not always possible to illustrate the exact surroundings of the working area in photographs. When ordering additional copies of this publication or any other International Truck and Engine Corporation publication, refer to the following contact information: International Truck and Engine Corporation Printing and Distribution Services C/O Moore Wallace North America 1750 Wallace Avenue St. Charles, IL 60174 Telephone: 630-313-7507 Technical Service Literature 1171734R7 DT 466E, 1999, 2003 Model Year Operations and Maintenance Manual 1171735R5 International 530E, 1999-2003 Model Year Operations and Maintenance Manual EGES 210-1 Engine Service Manual EGES 175-1 Diagnostic Manual EGES 180-1 Hard Starting No Starting Diagnostic Form EGED 185-1 Electronic Control System Diagnostic Form EGES-210-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © 2006 International Truck and Engine Corporation

2 ENGINE SERVICE MANUAL Service Diagnosis Service diagnosis is an investigative procedure that must be followed to locate and correct an engine problem. The engine is ﬁrst considered as a complete unit. If it is determined that the problem is application related, see application speciﬁc manuals for further diagnostic information. If the problem is determined to be within the engine, the problem can then be localized to components or systems. Testing procedures will then help analyze the source of the problem. Prerequisites for effective diagnosis: Knowledge of the principles of operation for both engine and application systems. Knowledge to perform and understand all procedures in the diagnostic and service publications. Availability of and the ability to use diagnostic test equipment, such as gauges. Availability of the most current information for the engine application. Effective service diagnosis requires use of the following references: Engine Service Manual Engine Diagnostic Manual Diagnostics Forms Electronic Control Systems Diagnostics Forms Technical Service Information (TSI) letters Technical Services Frequently Asked Questions (FAQ) NOTE: Metric values precede English values for test procedures and reference. Examples: 96 kPa (14 psi), 20 °C (68 °F) EGES-210-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©2006 International Truck and Engine Corporation

ENGINE SERVICE MANUAL 3 Safety Information This manual provides general and specific service procedures 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. Disregard for warnings, cautions, and instructions can lead to injury, death, or damage to the engine or vehicle. Read safety instructions before doing any service and test procedures for the engine or vehicle. See related application manuals for more information. Most accidents that involve operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. Read and follow OSHA regulations. SAFETY TERMINOLOGY Three terms are used to stress your safety and safe operation of the engine: Warning, Caution, and Note Warning: Signals conditions, hazards, and unsafe practices that can cause injury or death Caution: Signals conditions and practices that can cause damage to the engine or vehicle 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 or park, the parking brake is set, and the wheels are blocked before doing any work or diagnostic procedures on the engine or vehicle. Work area The engine and its components must be kept clean during service or maintenance. Contamination of the engine or components will cause premature wear. • 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 appropriate protective apparel when working with or around hot liquid, hot engines, or hot engine components • 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. • To prevent fire and hazardous fumes, clean and wipe dry all engine surfaces where fluids may have spilled. 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. • Use suitable eye protection. • Do not expose batteries to open flames or sparks. • Do not smoke in workplace. EGES-210-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © 2006 International Truck and Engine Corporation

4 ENGINE SERVICE MANUAL 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. • Make sure all standard electrical tools are grounded. • Check for frayed power cords before using power tools, lights, or extension cords. 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 fuel 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-210-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©2006 International Truck and Engine Corporation

INTRODUCTION 5 Table of Contents Component Location.....................................................................................................7 Front View........................................................................................................7 Left View..........................................................................................................8 Rear View.........................................................................................................9 Right View.......................................................................................................10 Engine Identification....................................................................................................11 Engine Serial Numbers.......................................................................................11 Engine Serial Number Chart.................................................................................12 Engine Component Identification....................................................................................13 Turbocharger (Non-Wastegate)..............................................................................13 Turbocharger (Wastegate)....................................................................................14 Features...................................................................................................................15 General Features...............................................................................................15 Chassis Features........................................................................................................16 Chassis-Mounted Charge Air Cooler.......................................................................16 Cooling System..........................................................................................................17 Description......................................................................................................17 Thermostat Operation ........................................................................................18 Lubrication System.....................................................................................................19 Description......................................................................................................20 Location.........................................................................................................20 Oil Flow..........................................................................................................20 Oil Pressure Regulator Valve and Oil Pressure Relief Valve...........................................21 Air Induction and Exhaust Systems.................................................................................23 Description......................................................................................................24 Air Flow..........................................................................................................24 Fuel System..............................................................................................................25 Location.........................................................................................................25 Description......................................................................................................26 Negative Pressure (Vacuum).......................................................................26 Fuel Supply Pump Pressure........................................................................26 Supply Manifold......................................................................................26 Injection Control Pressure (ICP)...................................................................27 Fuel Injector Assembly.......................................................................................29 Description............................................................................................29 Solenoid................................................................................................30 Poppet Valve..........................................................................................30 Intensifier Piston and Plunger.....................................................................30 EGES-210-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. © 2006 International Truck and Engine Corporation

6 INTRODUCTION Nozzle Assembly.....................................................................................30 Fuel Injector Operation.......................................................................................30 Fill Cycle...............................................................................................30 Injection................................................................................................30 End Of Injection - Drain Cycle......................................................................31 EGES-210-1 Read all safety instructions in the "Safety Information" section of this manual before doing any procedures. Follow all warnings, cautions, and notes. ©2006 International Truck and Engine Corporation

2000-2008 Navistar International DT466/DT466E/DT530/DT530E/HT530 Diesel Engines OEM Service & Repair Manual

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