Navistar International DT466 DT530 DT570 Full 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

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Navistar International DT466 DT530 DT570 Full Service & Repair Manual

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