Page 1 SERVICE MANUAL INTERNATIONAL® DT 466, DT 570, HT 570 DIESEL ENGINE SERVICE MANUAL FORM EGES-265-2 © 2009 Navistar. Inc. Printed in the United States of America...
Page 3: Table Of Contents
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.
Page 4 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.
Page 5: Foreword
ENGINE SERVICE MANUAL Foreword Navistar, Inc. is committed to continuous research and development to improve products and introduce Navistar, Inc. is committed to continuous research technological advances. Procedures, speciﬁcations, and development to improve products and introduce and parts deﬁned in published technical service technological advances.
Page 6: Service Diagnosis
Service Bulletins • Availability of current information for engine application and engine systems 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.
Page 7: Safety Information
• Protect your eyes. • Do not wear rings, watches or other jewelry. 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.
Page 8 Make sure all tools, parts, and service equipment are removed from the engine and vehicle after all work is done. 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.
Page 9: Engine Systems
Operation of Diamond Logic® Engine Brake in Braking Mode........56 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.
Page 10 ENGINE SYSTEMS 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.
Page 11: Engine Identiﬁcation
• The engine serial number is also on the engine emission label. 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.
Page 12: Engine Emission Label
Figure 3 Engine emission label (Example) 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.
Page 13: Engine Description
* Base rating shown. See Appendix A in the Engine Diagnostics Manual. **Base rating shown. See Appendix B in the Engine Diagnostics Manual. 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.
Page 14 The rear oil seal carrier is part of the ﬂywheel housing. The open crankcase breather 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.
Page 15 ﬁlter assembly heats the fuel for improved warms the intake air entering the cylinder head. performance. 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.
Page 16: Engine Component Locations
Inlet and EGR mixer duct sensor EGR cooler assembly EGR control valve Valve cover Breather assembly 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.
Page 17 Water inlet elbow 12. Flat idler pulley assembly Front cover (front half) Water pump pulley 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.
Page 18 12. Engine Oil Temperature (EOT) (one) three wire connector sensor for the brake valve. 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.
Page 19 11. Power steering pump 17. High-pressure oil pump Lifting eye 12. Oil pan assembly assembly 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.
Page 20 11. Turbocharger control module Water supply housing (Freon® 12. Coolant drain plug (underneath compressor bracket) location) 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.
Page 21 Crankcase EGR cooler return tube Rear engine mount brackets (2) assembly Flywheel housing 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.
Page 22: Engine Systems
• The Coolant System provides heat transfer for EGR gases and lubrication oil. 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.
Page 23: Air Management System
– single or dual element 12. Exhaust manifold Intake manifold 13. EGR cooler 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.
Page 24: Charge Air Cooler (Cac)
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.
Page 25: Variable Geometry Turbocharger (Vgt)
Pressure (EBP) sensor to provide feedback to the ECM. The ECM uses the EBP sensor to continuously 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.
Page 26 ECM decreases the duty cycle to the control module. Figure 15 VGT control 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.
Page 27: Exhaust Gas Recirculation (Egr) System
Integrated Circuit (IC). The IC has three Hall effect position sensors to monitor valve movement. The 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.
Page 28: Exhaust System
CDPF, depending on application, and out the discharge pipe to the atmosphere. 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.
Page 29: Fuel Management System
Injection Control Pressure (ICP) system • Lubrication system • Fuel supply system • Electronic control system 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.
Page 30: Injection Control Pressure (Icp) System Components And High-Pressure Oil Flow
High-pressure oil inlet (pump) Oil exhaust port (2) Fuel injector High-pressure oil hose Fuel inlet (4) 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.
Page 31 IPR valve will operate from programmed default values. This is called Open Loop operation. 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.
Page 32 The ICP sensor is installed under the valve cover, forward of the No. 6 fuel injector in the high-pressure oil rail. 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.
Page 33: Fuel Injectors
19. CLOSE coil Nozzle assembly 13. Edge ﬁlter 20. Spool valve (control valve) 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.
Page 34 Low-pressure fuel ﬁlls the four ports and enters through the edge ﬁlter on its way to the chamber 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.
Page 35 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.
Page 36 High-pressure oil is deadheaded against the spool valve. 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.
Page 37: Fuel Supply System
14. Fuel inlet (4) assembly assembly Low-pressure fuel supply pump 10. Fuel ﬁlter access cap 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.
Page 38: Fuel Flow Schematic
Primer pump assembly • Engine Fuel Pressure (EFP) sensor (optional) • Fuel ﬁltering element 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.
Page 39 Plug or EFP sensor (optional) 15. Water drain valve assembly 23. Stand pipe 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.
Page 40 ﬁlter housing. Another drain valve in the bottom of the housing drains strainer cavity. 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.
Page 41: Engine Lubrication System
Pick-up tube crankcase 26. Air compressor Unﬁltered oil gallery 16. Oil pan assembly 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.
Page 42 Unﬁltered oil (under pressure) ﬂows through the header of the oil cooler. The oil is then internally 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.
Page 43 (if equipped). 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.
Page 44: Cooling System
EGR coolant return tube 15. Water inlet to front cover and assembly water pump 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.
Page 45 The EGR cooler receives coolant from the front cover. Coolant ﬂows from the front of the cooler and exits the 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.
Page 46 Coolant out to radiator Coolant ﬂow to heater port Coolant in from engine 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.
Page 47: Electronic Control System
A supplies 5 volts to engine sensors • Controls actuators • B supplies 5 volts to vehicle sensors 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.
Page 48 • Engine warning and protection modes 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.
Page 49: Injection Drive Module (Idm)
The IDM uses information from the ECM to determine the timing and quantity of fuel for each injector. 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.
Page 50 OPEN coil, then the CLOSE coil. The low side 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.
Page 51: Engine And Vehicle Sensors
20. Exhaust Back Pressure (EBP) Crankshaft Position (CKP) 14. Driveline Disengagement Switch Camshaft Position (CMP) (DDS) 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.
Page 52 • out of range. The ECT sensor is installed in the water • 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.
Page 53 The ECM monitors the EOP signal, and uses this information for the instrument panel pressure gauge • Signal ground 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.
Page 54 ﬁeld. 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.
Page 55 A remote accelerator or throttle device can be used in addition to the accelerator pedal. 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.
Page 56 A voltage input switch supplies the ECM with a voltage when it is closed. A grounding 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.
Page 57: Diamond Logic® Engine Brake System
High-pressure oil rail sensor Turbocharger control module Brake Control Pressure (BCP) Front of engine sensor 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.
Page 58: Engine Brake Control
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.
Page 59 A gallery. brake shutoff valve, mounted in the high-pressure oil 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.
Page 60: Operation Of Diamond Logic® Engine Brake In Braking Mode
The engine brake is activated once the ABS event is • Operator input switches (On/Off) (power selection over. – Low, Med, High) 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.
Page 61 Figure 50 Brake pressure relief valve in high-pressure oil rail Front of engine Brake pressure relief valve 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.
Page 62 ENGINE SYSTEMS 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.
Page 63: Mounting Engine On Engine Stand
Special Service Tools....................65 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.
Page 64 MOUNTING ENGINE ON ENGINE STAND 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.
Page 65: Engine Preparation
Wash or discard clothing and rags contaminated with engine ﬂuids. 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.
Page 66: Component Removal
1. Remove four nuts (M10 ﬂange head) securing bolt (M8 x 16) at crankcase. turbocharger assembly to exhaust manifold ﬂange. 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.
Page 67: Oil Filter
The oil cooler drain tube is trapped between the oil system module and the front cover. 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.
Page 68: Engine
5. Slowly release tension from engine hoist. 6. remove hoist safety chain hooks from engine lifting eyes. 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.
Page 69: Special Torque
Special Service Tools Table 4 Special Tools Engine Mounting Plate ZTSE4649 Engine Stand OTC1750A 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.
Page 70 MOUNTING ENGINE ON ENGINE STAND 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.
Page 71: Evrt® Electronically Controlled Turbocharger
Special Torque......................75 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.
Page 72 EVRT® ELECTRONICALLY CONTROLLED TURBOCHARGER 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.
Page 73: Description
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.
Page 74 10. Turbocharger control module Compressor outlet Oil drain port 11. VGT linkage Compressor housing Compressor inlet 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.
Page 75: Removal
4. Disconnect electrical harness from VGT actuator. and rags contaminated with engine ﬂuids. 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.
Page 76: Cleaning
4. Clean remaining gasket material from mounting manifold. surface of the turbine housing and exhaust manifold. 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.
Page 77: Inspection
6. Lift VGT assembly onto engine and insert VGT under spring tension (Table 5). mounting studs into the exhaust manifold ﬂange. 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.
Page 78 ﬂange located on top of the VGT central housing. 16. Connect electrical harness to VGT actuator. 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.
Page 79: Speciﬁcations
Table 6 VGT Special Torques VGT Spiralock® nuts (M10) 71 N·m (52 lbf·ft) 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.
Page 80 EVRT® ELECTRONICALLY CONTROLLED TURBOCHARGER 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.
Page 81: Intake, Inlet, And Exhaust Manifolds
Special Torque......................89 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.
Page 82 INTAKE, INLET, AND EXHAUST MANIFOLDS 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.
Page 83 ﬂange head bolt, M12 x 120 (1) 11. Intake manifold to mixer gasket 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.
Page 84: Removal
EBP tubing nut ﬂames and sparks. 1. Disconnect the EBP tubing nut at exhaust manifold. 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.
Page 85: Inlet And Egr Mixer Duct
(M12 x 120) securing the three-piece exhaust manifold to the cylinder head. 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.
Page 86: Aluminum Air Inlet Adapter And Inlet Air Heater Option
Inlet and EGR mixer support bolt, M10 x 90 Inlet mixer bolt, M8 x 60 (4) 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.
Page 87: Cleaning And Inspection
3. Check manifold for cracks and damage. Replace special torque value (Table 8). intake manifold as necessary. 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.
Page 88: Installation
4. Torque the exhaust manifold bolts in the following the exhaust manifold gasket over these two bolts. three step sequence. 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.
Page 89 Torque all bolts in sequence 1 through 12 to 109 N·m (80 lbf·ft). 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.
Page 90: Intake Manifold
Figure 80 Installing EBP tubing nut EBP tubing nut 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.
Page 91: Inlet And Egr Mixer Duct
3. Thread the inlet and EGR mixer duct support bolt (M10 x 90) ﬁnger tight. Figure 83 Inlet and EGR mixer gasket 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.
Page 92 7. Install intake plug assemblies, if removed (M12) and tighten to the special torque value (Table 8). 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.
Page 93: Speciﬁcations
Intake manifold mounting bolts 40 N·m (30 lbf·ft) Intake plug assembly 25 N·m (18 lbf·ft) 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.
Page 94 INTAKE, INLET, AND EXHAUST MANIFOLDS 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.
Page 95: Egr Cooler And Tubing
Special Service Tools....................114 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.
Page 96 EGR COOLER AND TUBING 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.
Page 97: Description
EGR cooler return conﬁgurations: • Deeper O-ring location in EGR coolant return tube plus retaining clip 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.
Page 98: Egr System Components (Beginning Model Year 2004)
M8 x 16 19. EGR valve assembly O-ring (3) 13. Gasket, hot side 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.
Page 99 Wash or discard clothing and rags contaminated with engine ﬂuids. 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.
Page 100 EGR cooler and the rear half of the front cover. 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.
Page 101 11. Remove two bolts (M8 x 30) retaining the EGR cooler to the exhaust manifold. 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.
Page 102: Cleaning Egr System Components
14. Remove the EGR cooler assembly by pulling out from EGR cooler supply tube and discard O-ring gasket. 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.
Page 103: Installation Egr System Components
EGR cooler mounting bracket port in rear half of front cover. Bolt, M12 x 120 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.
Page 104 (M8 x 16) ﬁnger tight. Figure 107 EGR cooler return tube O-rings 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.
Page 105 13. Secure EGR valve assembly with four bolts (M8 x 35) ﬁnger tight. 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.
Page 106 16. Position a new gasket between the EGR tube assembly and EGR cooler. Figure 115 EGR tube assembly at EGR cooler 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.
Page 107: Modiﬁcation 1 - Deeper O-Ring Location Into Egr Coolant Return Tube Plus Retaining Clip
Retain bolt for reuse with new EGR cooler return tube assembly. 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.
Page 108 3. Using P-80 or equivalent, lubricate both O-rings on the EGR cooler elbow. 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.
Page 109 8. Install EGR return tube mounting bolt (M8 x 25) into cylinder head (ﬁnger tight). 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.
Page 110 Guidelines, page445 ). Figure 123 Seating the EGR cooler elbow and retaining clip 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.
Page 111 Figure 125 Installing the EGR elbow bracket and mounting hardware Bracket M10 x 25 Bolt and 3/8 ﬂat washer 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.
Page 112: Modiﬁcation 2 - Egr Coolant Return Tube Adapter And Egr Coolant Hose
Discard O-ring. lubricants. 2. Using P-80 or equivalent, lubricate O-ring on adapter. 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.
Page 113 9. Retighten constant tension EGR hose clamps to the special torque (Table 10). Figure 129 EGR upper hose clamp details 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.
Page 114: Modiﬁcation 3 - Round Egr Cooler And Egr Return Hose
EGR tube assembly and exhaust manifold. 6. Remove EGR rear mounting bolts. 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.
Page 115: Installation
8. Tighten EGR rear mounting bolts (M8 x 30) to the standard torque (General Torque Guidelines, page445 ). 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.
Page 116: Egr Coolant Return Kits (Conversion From Egr Cooler Return Tube To Hose)
(Table 10). 2. Put O-ring seal on new EGR coolant return adapter tube. 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.
Page 117 EGR tube bracket Flat washer, 3/8 in Bolt, M10 x 1.5 x 25 mm 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.
Page 118: Special Torque
Table 11 EGR System Special Service Tools EGR cooler pressure test plates ZTSE4636 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.
Page 119: Cylinder Head And Valve Train
Assembly....................142 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.
Page 120 Special Service Tools....................156 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.
Page 121: Description
The valve guides and valve seats are replaceable. 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.
Page 122 14. Intake valve Valve guide inserts 10. Rear lifting eye 15. Valve assemblies 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.
Page 123 Lower support washer (6) 14. Rocker shaft plug (2) (12) 10. Roller tappets (12) 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.
Page 124: Removal
(Crankcase Ventilation Limit compressed air pressure to 207 kPa (30 psi). System, page253 ). 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.
Page 125: Removing Rocker Arm Assembly
Make sure that you have these washers for installing the rocker arm shaft. 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.
Page 126: Measuring Camshaft Lift
(base circle), then “zero” indicator. Figure 140 Measuring cam lobes with micrometer 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.
Page 127: Removing Rocker Arms
Oil Rail Assembly, page346 ). 1. Remove and discard 26 cylinder head mounting bolts (M15 x 180). 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.
Page 128: Roller Tappets
NOTE: Place the cylinder head on wood blocks to protect the valves and bottom deck surface. 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.
Page 129: Cleaning
1. Thoroughly clean each push rod using a suitable solvent and dry rods using ﬁltered compressed air 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.
Page 130: Rocker Arms
Replace the adjuster screw if excessive wear is replace the rocker arm. Be sure to inspect the found. 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.
Page 131: Cylinder Head Warpage
NOTE: If leakage occurs, the valves must be reconditioned. 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.
Page 132: Cylinder Head Cracking
2. Spray dye penetrant on the gasket surface of the cylinder head. Leave the dye penetrant on for 1-10 minutes. 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.
Page 133: Pressure Check Cylinder Head
If leakage is observed at any port or the upper and lower deck, replace the cylinder head. 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.
Page 134: Reconditioning
1. After removing valves, use soap, water, and a nylon brush to clean valve guides. 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.
Page 135: Replacing Valve Guides
NOTE: Chilling the valve guide inserts ﬁrst may facilitate installation. 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.
Page 136: Inspecting Valves
NOTE: If the valves are in serviceable condition, they may be refaced to the speciﬁed angles, as required. 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.
Page 137: Valve Stem Tip
Figure 169 Valve face angles Intake margin Intake valve angle Exhaust margin Exhaust valve angle 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.
Page 138: Checking Valve Face-To-Valve Seat Contact
Figure 172 Applying Prussian Blue® to valve face 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.
Page 139: Resurfacing Valve Seats
15 degree or smaller angle stone. 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.
Page 140: Replacing Valve Seats
Figure 179 Grinding groove in valve seat 2. Position the appropriate size extractor in the valve seat. 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.
Page 141 4. Unlock the collet by loosening the threaded shaft. from cylinder head. Discard valve seat insert. 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.
Page 142: Installation
5. Grind new valve seats to the speciﬁed angles and misalignment. widths, see Cylinder Head Speciﬁcations (Table 15) in this section. 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.
Page 143: Inspecting Valve Springs
If the cutoff end has worn a notch in the adjacent coil, replace the spring. 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.
Page 144: Inspecting Valve Rotators
Replace any valve rotator that does not turn. 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.
Page 145: Inspecting Valve Spring Retainer Keys
See cylinder head and valve special service tools (Table 17). Figure 188 Cleaning fuel injector bore 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.
Page 146: Installing Valves
Make sure that the and insert into the valve guides. 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.
Page 147 (Table 17). Compress the valve spring. 6. Install the valve spring retainer keys. 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.
Page 148: Installation
4. Install a new cylinder head gasket over the alignment dowels. 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.
Page 149 Carefully lower the cylinder head onto the crankcase. Figure 197 Lowering cylinder head onto crankcase 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.
Page 150: Torque-To-Yield Procedure For Cylinder Head Bolts
B. in both sequence A and B to obtain uniform head bolt torque. 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.
Page 151 ﬂats). The marks on the head bolt socket, head mark. (Figure 200) Item 4 bolt, and cylinder head surface should align. 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.
Page 152: Valve Train Components
4. Install plastic washer (assembly aid) onto each intake rocker arm retaining bolt. 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.
Page 153: Installing The Rocker Arm Assembly
Torque rocker arm clamp assembly bolts to 27 N·m (20 lbf·ft) for the ﬁrst pass. 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.
Page 154: Valve Lash For Intake And Exhaust Valves
(page151 ) and do steps 4 and 5 for cylinders 1, 3, time. and 5. 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.
Page 155 Valve and brake lash adjustments with piston 6 at TDC compression Figure 206 Valve lash adjustment 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.
Page 156: High-Pressure Oil Rail Assembly
5. Once valve lash is set, tighten valve adjustment screw locknut to Special Torque (Table 55) and 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.
Page 157 (General Torque Guidelines, page445 ). 7. Add any necessary brackets to the appropriate studs. 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.
Page 158: Speciﬁcations
Intake valve seat insert counterbore diameter Standard: 33.50 ± 0.03 mm (1.319 ± 0.001 in) 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.
Page 159: Special Torque
Rocker arm bolts torque and sequence (Installing Rocker Arms, page148 ) Valve adjustment locknut 27 N·m (20 lbf·ft) 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.
Page 160: Special Service Tools
Valve spring compressor ZTSE1846 Valve spring compressor jaws ZTSE4652 Water supply housing pressure adapter ZTSE4648 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.
Page 161: Front Cover And Related Components
Front Engine Mount................... 187 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.
Page 162 Special Service Tools....................202 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.
Page 163: Description
10 lobe gerotor oil pump are the same as for the 8 lobe gerotor oil pump. 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.
Page 164 9 10 11 45 46 H06086 Figure 209 Front cover related components (less gear train) 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.
Page 165 42. Front engine mount locations (Figure 228) 43. Cover, front half (PTO equipped) 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.
Page 166: Checking Gear Train Timing Without Removing
82.5 mm (3.25 in) or a straight line distance of 81 mm (3.188 in) clockwise from 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.
Page 167: Dt 570 And Ht 570 Engines Only
(clockwise) until the intake valve starts to lift and the feeler gauge becomes tight. The mark should 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.
Page 168: Removal
Limit compressed air pressure to 207 kPa (30 psi). 4. Remove alternator bracket. 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.
Page 169: Flat Idler Pulley And Automatic Belt Tensioner
Figure 216 Water inlet elbow Figure 214 Water supply housing bolts Bolt, M10 x 25 (4) 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.
Page 170: Fan Drive Hub
Figure 220 Fan hub assembly (typical) 5. Lift thermostat out of cylinder head. Bolt, M8 x 65 (4) 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.
Page 171: Water Pump Assembly
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.
Page 172: Vibration Damper, Damper Hub, And Wear Sleeve
5. Tighten H-bar center shaft to pull damper hub off of crankshaft and remove damper hub. 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.
Page 173: Gerotor Assembly Oil Pump And Front Oil Seal
2. Remove two bolts (M8 x 60) retaining the oil pump housing cover. 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.
Page 174 Mark will indicate rotor turning direction and orientation to front cover. 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.
Page 175: Front Engine Mount
(spline) (Crankshaft Disassembly, page 256 ) for 3. Remove front engine mounting bracket. procedure relating to oil pump drive. 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.
Page 176: Front Cover (Front Half)
(M8). 3. Remove four hex ﬂange bolts (M8 x 30) and nuts (M8). 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.
Page 177: Generation 2 (Mounting Bolts)
3. Remove six M8 x 50 special bolts and nuts. 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.
Page 178: Idler Gears
2. Remove lower idler gear. Crankshaft gear Figure 236 Removing the lower idler gear 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.
Page 179 267 ) after removing the upper idler gear. Figure 238 Removing the upper idler gear 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.
Page 180: Front Cover (Rear Half)
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.
Page 181: Inspection
If the backlash exceeds speciﬁcations, replace upper idler gear. 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.
Page 182: Checking Camshaft Gear Backlash
If the backlash Oil pump and rotor housing exceeds speciﬁcations, replace camshaft gear. Outer rotor 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.
Page 183: Measuring Oil Pump End Clearance
Figure 244 Oil pump end clearance measurement Straightedge Feeler gauge Outer rotor Inner rotor 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.
Page 184: Installation
2. Install a new coolant gasket onto the crankcase the front cover (rear half). side of the front cover (rear half). 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.
Page 185: Mounting Bolts (Rear Half)
Crankshaft, and Camshaft” section in this manual the special torque value (Table 20). for removal procedure. 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.
Page 186: Idler Gears
2. Tighten the M20 x 70 bolt to the special torque value (Table 20) using Lower Idler Gear Socket (Table 21). 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.
Page 187 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.
Page 188: Front Cover (Front Half)
2. Install a new O-ring seal into the front half of the the front half of the front cover. front cover 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.
Page 189: Generation 1 (Mounting Bolts)
(General a guide. Torque Guidelines, page445 ). 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.
Page 190: Generation 2 (Mounting Bolts)
(General Torque Guidelines, page445 ) . 4. Install six M8 x 50 special bolts and nuts ﬁnger tight. 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.
Page 191: Front Engine Mount
Vibration damper key Washer seal the crankshaft, (Crankshaft Assembly, page268 ). Inner rotor 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.
Page 192 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.
Page 193 13. Lightly coat the inside sealing surface of the front oil seal with clean engine oil. 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.
Page 194: Pose Dust Seal And Wear Sleeve
POSE dust seal) must be installed as a set for engines equipped with a 10 lobe oil pump. 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.
Page 195: Vibration Damper Hub And Damper Retaining Plate
6. Tighten three M12 x 40 damper bolts to special torque (Table 20). Figure 264 Installation of vibration damper hub 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.
Page 196: Vibration Damper Assembly
M10 x 16 bolts ﬁnger tight. 2. Torque bolts to special torque (Table 20). 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.
Page 197: Fan Drive
(General Torque Guidelines, page 445 ), unless otherwise noted (Table 20). 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.
Page 198 Bolt, M10 x 20 3. Install the fan pulley and spacer as required for application. 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.
Page 199: Horton Drivemaster
4. Tighten bearing retainer nut to the special torque (Table 20). 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.
Page 200: Water Pump Assembly
Tighten bolts to the standard torque value (General Torque Guidelines, page445 ) . 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.
Page 201: Water Supply Housing
2. Install the two remaining bolts (M8 x 100) and hex ﬂange nuts (M8) ﬁnger tight. 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.
Page 202: Flat Idler Pulley And Automatic Belt Tensioner
Flat idler pulley assembly mounting bolt, M10 x 80 Automatic belt tensioner assembly mounting bolt, M10 x 80 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.
Page 203 (Table 20). Figure 281 Water outlet tube assembly Bolt, M8 x 25 (2) 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.
Page 204: Speciﬁcations
465 (18.3) 201.2 (7.92) 466 mid-mount, (spin-on) 411 (16.2) 201.2 (7.92) 1.08 : 1 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.
Page 205: Special Torque
Water outlet tube assembly at front cover 33 N·m (24 lbf·ft) Wear plate (water pump) 7 N·m (60 lbf·in) 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.
Page 206: Special Service Tools
Thermo-melt crayon, 100 °C (212 °F) Obtain locally 16 mm 12 point impact socket Obtain locally 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.
Page 207: Oil Pan And Oil Suction Tube
Special Service Tools....................211 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.
Page 208 OIL PAN AND OIL SUCTION TUBE 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.
Page 209 Bolt, M8 x 24 (18) Oil drain plug (typical) Heater element gasket Oil drain plug gasket 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.
Page 210: Removal
Wash or discard clothing and rags contaminated with engine ﬂuids. 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.
Page 211: Removing The Oil Suction Tube
1. Remove two (M8 x 35) mounting bolts from the oil suction tube. 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.
Page 212: Cleaning And Inspection
3. Torque both bolts (M8 x 35) to the special torque value (Table 23). 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.
Page 213: Installing The Oil Pan
ﬂywheel housing. 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.
Page 214: Watt Oil Pan Heater (Optional)
See (1171848R1 300 Watt Oil Pan Heater Kit, page495 ) for installation procedure. Figure 294 Installing the oil pan 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.
Page 215: Speciﬁcations
Special Service Tools Table 24 Special Tools Wacker T – 442 RTV sealant Obtain locally 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.
Page 216 OIL PAN AND OIL SUCTION TUBE 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.
Page 217: Power Cylinders
New Piston Cooling Tubes................242 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.
Page 218 Special Service Tools....................247 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.
Page 219: Description
New piston cooling tubes were released for service. • New connecting rod assemblies were released for service. 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.
Page 220 Bearing shells (2) 13. Connecting rod bolt (2) Piston crown (570) 10. Connecting rod 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.
Page 221: Removal
ﬂuids. 1. Remove M6 x 16 patch type bolt from piston cooling tubes. 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.
Page 222: New Piston Cooling Tubes
4. Rotate the engine to a vertical position with the and bolts. front end up. 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.
Page 223: Disassembling Piston And Connecting Rod Assembly
Figure 305 Removing piston pin retaining rings 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.
Page 224: Cylinder Sleeve Removal
Remove the piston skirt from the crown. Figure 309 Removing cylinder sleeve from crankcase 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.
Page 225: Cleaning
CAUTION: To prevent engine damage, do not clean the fractured mating surfaces of the connecting rods. 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.
Page 226: Top And Intermediate Compression Ring Grooves
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.
Page 227: Piston-To-Cylinder Sleeve Running Clearance
Discard any piston ring that does not meet speciﬁcation for the one-piece piston, replace the speciﬁcations. 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.
Page 228: Piston Pins
3. Tighten the connecting rod cap bolts to the special torque value (Table 33). 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.
Page 229: Connecting Rod Bearing Bore
Figure 317 Measuring connecting rod bearing bore taper 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.
Page 230: Bearing Running Clearance
Check running clearance Rod Assembly (page237 ). again before condemning the crankshaft. 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.
Page 231: Connecting Rod Side Clearance
The result is the cylinder sleeve taper. If the result exceeds the speciﬁcation, replace the cylinder sleeve. 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.
Page 232 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.
Page 233: Checking Counterbore Depth
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.
Page 234 ﬂange to the surface of the crankcase. Record the cylinder sleeve protrusion reading on the dial indicator. 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.
Page 235 Top surface of crankcase 0.51 0.020 Cylinder sleeve ﬂange 0.81 0.032 Shim to suit Counterbore 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.
Page 236: Reconditioning
Push the tool bit out until it touches the 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.
Page 237 NOTE: Do not remove more than 0.05 mm (0.002 in) of material at any one attempt. 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.
Page 238: Installation
If the cylinder sleeve is not measuring up to speciﬁcations, check for an improperly aligned crevice seal. 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.
Page 239: Assembling Piston And Connecting Rod Assembly
NOTE: New piston skirts may be oriented in either direction due to piston skirt symmetry. 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.
Page 240 (protrusion points to front of engine) 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.
Page 241: Installing Piston And Connecting Rod Assembly
Do not scratch the cylinder wall. Figure 343 Installing piston pin retaining rings 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.
Page 242 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.
Page 243 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.
Page 244 M12 connecting rod cap bolts, depending on connecting rod version, ﬁnger tight. Figure 350 Installing the connecting rod cap 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.
Page 245: Torque Procedure For Connecting Rods With M12 Bolts
Connecting rod bolt with permanent marker spot (after torque-to-yield) Permanent marker spot on connecting rod cap 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.
Page 246: Piston Cooling Tubes
The knurled piston cooling tube is required for DT 570 and HT 570 engines. 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.
Page 247 If new pistons or piston rings have been installed, do the following engine run-in procedure: 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.
Page 248 Air leaks 5. Return to idle and check for leaks. • Excessive exhaust smoke 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.
Page 249 Top ring – keystone cross section Intermediate – rectangular cross section 466 and 570 piston speciﬁcations 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.
Page 250 46.352 - 46.357 mm (1.8249 - 1.8251 in) Length 96.57 - 96.82 mm (3.802 - 3.812 in) 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.
Page 251 Piston ring gauge pins (set of 3) ZTSE4653 Telescoping gauge set Obtain locally 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.
Page 252 POWER CYLINDERS 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.
Page 253: Crankcase, Crankshaft, And Camshaft
Special Service Tools....................278 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.
Page 254 CRANKCASE, CRANKSHAFT, AND CAMSHAFT 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.
Page 255 CRANKCASE, CRANKSHAFT, AND CAMSHAFT H06087 Figure 359 Crankcase, Crankshaft, and Camshaft 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.
Page 256 16. Bolt, M8 x 35 (2) 31. Bolt, M10 x 25 (10) 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.
Page 257: Removal
WARNING: To prevent personal injury or death, shift transmission to park or neutral, set 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.
Page 258 Allow tube and reducer hose to drain. Reconnect reducer hose and clamp. 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.
Page 259: Oil Level Gauge
2. Remove the tube clamp at the crankcase and discard oil dipstick tube seal. 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.
Page 260: Crankcase Ladder (Dt 466 Series - 225 Hp And 245 Hp @ 2600 Rpm) And All 570 Ratings
Figure 365 Removing the main bearings Figure 363 Removing the crankcase ladder 3. Remove the crankcase ladder. 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.
Page 261: Cam Gear From Camshaft
Figure 367 Removing oil pump drive spline 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.
Page 262: Camshaft Disassembly
NOTE: Use this procedure to remove the cam gear and camshaft as a unit. Figure 370 Removing camshaft thrust plate bolts 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.
Page 263: Camshaft Bushings
It is recommended that the intermediate bushings be removed according to the following illustration. 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.
Page 264: Coolant Heater (If Equipped)
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.
Page 265: Cleaning And Inspection
Use a nylon brush (Table 40) with soap and water to clean oil galleries. 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.
Page 266: Crankshaft And Main Bearings
If the thrust plate is too worn or damaged, replace the thrust plate. 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.
Page 267: Checking Camshaft Lobes And Journals
Orient electrical connector so that it is facing downward (6 o’clock position). 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.
Page 268 Cam bearings oil holes must align with oil holes in cylinder block. Figure 378 Marking oil hole location on bushing 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.
Page 269 Figure 380 Paint marks indicating oil hole alignment 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.
Page 270: Camshaft Assembly
4. Install the two camshaft thrust plate bolts (M8 x 20). Tighten the bolts to the special torque value (Table 39). 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.
Page 271: Cam Gear On Camshaft
Repeat the procedure. Figure 385 Installing cam gear on camshaft 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.
Page 272: Crankshaft Assembly
11. Rotate the crankshaft 180 degrees (1/2 turn). 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.
Page 273: Bearing Fitting Procedure
15. Using an appropriate lifting sling, carefully lower the crankshaft onto the main bearings. 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.
Page 274: Main Bearings And Caps
5. Align and seat each of the main bearing caps. Figure 393 Measuring widest point of ﬂattened Plastigage® 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.
Page 275: Torque Procedure For Torque-To-Yield Main Bearing Bolts
(130 lbf·ft) using the recommended torque sequence. Figure 396 Checking crankshaft end play 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.
Page 276: Crankcase Ladder (Dt 466 Series - 225 Hp And 245 Hp @ 2600 Rpm) And All 570 Ratings
3. Install 10 crankcase ladder bolts (M10 x 25) to the 10 outboard bolt holes ﬁnger tight. 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.
Page 277 Figure 401 Torquing the crankcase ladder bolts 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.
Page 278: Oil Level Gauge
2. Install a new O-ring onto breather assembly and at the fuel ﬁlter bracket. push into valve cover grommet. 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.
Page 279 (General Torque Guidelines, page445 ) and move ﬁnger tight. clamps into their sealing positions. 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.
Page 280: Speciﬁcations
Standard size to 0.51 mm (0.020 in) undersized 34.404 ± 0.03 mm (1.3545 ± 0.010 in) 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.
Page 281 63.01 - 63.04 mm (2.481 - 2.482 in) Rear 65.51 - 63.55 mm (2.501 - 2.502 in) 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.
Page 282: Special Torque
Tap, cylinder head bolt holes ZTSE4671 Tap set ZTSE4386 Stiff nylon brush ZTSE4392 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.
Page 283: Oil System Module Assembly And Secondary Filtration
Special Service Tools....................299 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.
Page 284 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION 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.
Page 285 13. Lube adapter (not serviceable) 19. Plug assembly, M12 Coolant seal 14. Bolt, M8 x 25 (3) 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.
Page 286 Figure 405 Secondary ﬁlter components Stud assembly O-ring Cover O-ring gasket Filter element Filter header 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.
Page 287: Removal
Wash or discard clothing and rags contaminated with engine ﬂuids. 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.
Page 288 Figure 409 VGT oil supply tubing O-ring 10. Remove the VGT oil supply tube O-ring and discard. 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.
Page 289 O-ring. 13. Remove eight oil system module assembly bolts (M8 x 30). 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.
Page 290: Secondary Filtration Assembly
Oil in secondary ﬁlter drains back into crankcase, therefore no additional draining procedures are required. 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.
Page 291: Disassembling The Oil System Module
3. Remove the oil thermal valve from the oil system Oil cooler housing base module. Remove O-ring and discard. 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.
Page 292 Figure 418 Lube adapter assembly and gaskets 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.
Page 293: Disassembling The Secondary Filtration Filter
1. Remove stud assembly from the top of the secondary ﬁltration ﬁlter and O-ring. 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.
Page 294: Cleaning And Inspection
2. Fasten Oil Cooler Test Plate (Table 43) to cooler heat exchanger. 3. Make sure oil port valve is closed. 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.
Page 295 Replace the cooler heat exchanger. Replace the cooler heat exchanger. 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.
Page 296: Internal
Test plate set Air pressure regulator Coolant port (open) Oil port 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.
Page 297: Installation
Only lubricate the bottom O-ring thoroughly seated. with clean engine oil. 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.
Page 298 5, 6, 7, 8, 1, 2. Figure 430 Oil and coolant seals Oil seal Coolant seal (2) 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.
Page 299: Assembling The Secondary Filtration Filter
ﬁlter cover and tighten to the special torque value (Table 42). 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.
Page 300: Secondary Filtration Assembly
Tighten bolts to the special torque torque value (Table 42). value (Table 42). 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.
Page 301 (Table 42). 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.
Page 302: Priming The Lubrication System
CMP sensor connector and (M18) and tighten to the special torque (Table 42). start engine. 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.
Page 303: Speciﬁcations
Oil Cooler Test Plate ZTSE4654 Oil Filter Wrench ZTSE1879 Slide Hammer Puller Set Obtain locally 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.
Page 304 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION 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.
Page 305: Engine Electrical
Special Torque......................334 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.
Page 306 ENGINE ELECTRICAL 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.
Page 307: Sensor Identiﬁcation
MAP sensor in the housing. intake manifold. 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.
Page 308 EFP sensor is installed in the rear of the fuel ﬁlter valve in the high-pressure rail. assembly (crankcase side). 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.
Page 309 EBP sensor is installed in a bracket mounted on the water supply housing (Freon® compressor bracket). 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.
Page 310: Removal
ﬁnd the problem and free connectors or clips. 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.
Page 311 Figure 455 Disconnecting the EOT sensor 6. Disconnect the wiring harness connector from the EOT sensor. 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.
Page 312 8. Disconnect the wiring harness connector from the MAT sensor. 10. Disconnect the wiring harness connector from the EOP sensor. 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.
Page 313 WIF sensor. 12. Disconnect the wiring harness connector from the fuel heater (optional). 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.
Page 314 20. Disconnect two ECM engine connectors. These are the two connectors towards the rear of the ECM. 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.
Page 315 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.
Page 316: Injector Wiring Harness
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.
Page 317: Ecm, Idm, Egr Drive Module, And Intake Air Heater
Figure 469 ECM, IDM, EGR drive module, and 7. Disconnect two ECM engine connectors. tube assembly overview 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.
Page 318 See (TSI-05-12-35 New 1500 Watt Single Grid Intake Air Heater Production Option, page466 ). 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.
Page 319 Figure 476 ECM, IDM, and EGR drive module assembly 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.
Page 320 ECM / IDM bracket and lift off. 23. Both IDM and ECM modules can now be separated. 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.
Page 321: Valve Cover Gasket With Pass-Through Connectors
Brake shutoff valve (optional). 1. Disconnect the wiring harness connector from the ICP sensor. 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.
Page 322 6. Release valve cover harness by unclipping from the high-pressure oil manifold. Figure 484 Injector connector 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.
Page 323: Cleaning And Inspection
Repair or worn, install new grommets. replace each wiring harness as necessary. 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.
Page 324: Installation
2. Install valve cover gasket. 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.
Page 325: Ecm, Idm, Egr Drive Module, And Intake Air Heater
It will be assembled here on a workbench for illustrative purposes. 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.
Page 326 40 (4) Vibration isolation bushing (4) ECM / IDM bracket Nut, M8 (4) 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.
Page 327 IDM / ECM bracket assembly assembled 2. Lay the IDM / ECM bracket assembly over the IDM. 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.
Page 328 (General Torque (General Torque Guidelines, page445 ). Guidelines, page445 ). 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.
Page 329 Inlet and EGR mixer Intake air heater cable locations Intake air heater element 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.
Page 330 21. Connect two ECM chassis connectors. 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.
Page 331: Injector Wiring Harness
2. Slide ground eyelet over injector shielded ground stud (Figure 471). Install nut and tighten. 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.
Page 332: Sensor Wiring Harness
Figure 502 Intake air heater relay connectors (2) Injector ground stud Top relay connector Bottom relay connector 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.
Page 333 14. Connect the wiring harness to the CKP sensor. 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.
Page 334 Figure 509 Connecting to the block heater sensor (optional). 18. Install the block heater cable connections (optional). 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.
Page 335 22. Connect the wiring harness connector to the MAP sensor. 20. Connect wiring harness connector to the IPR valve solenoid. 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.
Page 336 24. Connect the wiring harness connector at the EGR 26. Connect the wiring harness connector to the CMP control valve. sensor. 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.
Page 337 27. Connect the wiring harness connector to the ECT sensor. 28. Connect the VGT harness at the VGT. 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.
Page 338 10-20 N·m (88-176 lbf·in) Intake Manifold Air Temperature (MAT) sensor 10-20 N·m (88-176 lbf·in) 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.
Page 339: Fuel System
Special Service Tools....................364 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.
Page 340 FUEL SYSTEM 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.
Page 341: Description
(if necessary) and passes through the fuel head and is delivered to each fuel injector. 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.
Page 342: High-Pressure Oil System
High-pressure pump assembly manifold Oil inlet from front cover reservoir Oil outlet (2) 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.
Page 343 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.
Page 344: Periodic Service
6. Coat fuel bowl threads and a new O-ring with clean fuel. Thread fuel bowl into fuel ﬁlter header 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.
Page 345: Fuel Filter
7. Thread fuel ﬁlter and housing cover in as an suitable container. assembly. Torque to the special value (Table 47). 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.
Page 346: Removal
2. Remove the transfer pump inlet tube assembly. for cracks, burrs and straightness. Replace low-pressure fuel supply pump if necessary. 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.
Page 347: Fuel Filter Header Assembly And Intake Manifold
4. Remove three mounting bolts (M8 x 100) and fuel ﬁlter assembly from intake manifold. 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.
Page 348 Discard O-ring seal. Figure 534 Removing the fuel rail plug assembly 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.
Page 349: High-Pressure Hose Assembly - Generation 1
Figure 538 High-pressure oil elbow (typical) O-ring seal (#14) (2) Back-up ring Elbow jam nut Elbow 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.
Page 350: High-Pressure Pump And Ipr Valve
Remove O-rings and discard. cylinder head. 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.
Page 351 7. Remove and discard backup ring and injector inlet seal from injector oil inlet adapters in the high-pressure oil rail. 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.
Page 352: Fuel Injector Assemblies
ﬁlled closeable plastic container; this prevents contamination or oxidation damage. 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.
Page 353 Remove gaskets and discard. injector into an oil ﬁlled plastic container and close container. 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.
Page 354: Disassembly
Plug or EFP sensor (optional) 15. Water drain valve assembly 23. Stand pipe 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.
Page 355 • Contaminated fuel has been introduced to the engine, resulting in poor performance. 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.
Page 356: Installation
Fuel inlet port O-ring recess 4. Align injector assembly slot with hold down clamp assembly. 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.
Page 357: High-Pressure Oil Rail Assembly
Figure 555 Injector connector 6. Connect each injector harness connector to each injector. 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.
Page 358 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.
Page 359 Tighten bolts to the special torque value 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.
Page 360: High-Pressure Oil Pump And Ipr Valve Assembly
Figure 564 Installing the high-pressure pump assembly Figure 563 Installing the IPR valve 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.
Page 361: High-Pressure Hose Assembly - Generation 1
1. Install a new O-ring seal onto the high-pressure pump assembly before installing 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.
Page 362 Use one wrench to hold 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.
Page 363: Fuel Filter Header Assembly And Intake Manifold
(air bleed and pressure test port) bolts (M8 x 100) to the intake manifold. 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.
Page 364: Low-Pressure Fuel Supply Pump And Tubing
7. Coat fuel bowl threads and a new O-ring with clean fuel. Thread fuel bowl into fuel ﬁlter header 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.
Page 365 Low Sulfur Diesel (LSD) fuel could leak after changing to Ultra Low Sulfur Diesel (ULSD) fuel. 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.
Page 366: Priming Fuel System After Out Of Fuel
Limit compressed air pressure to 207 kPa (30 psi). 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.
Page 367: Speciﬁcations
5 N·m (41 lbf·in) Water In Fuel (WIF) sensor 1.7 N·m (15 lbf·in) 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.
Page 368: Special Service Tools
Fuel injector remover tool (#40 Torx®) ZTSE4524 IPR removal / installation tool ZTSE4666 Loctite® 246 Threadlocker Obtain locally 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.
Page 369: Flywheel And Flywheel Housing
Special Service Tools....................387 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.
Page 370 FLYWHEEL AND FLYWHEEL HOUSING 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.
Page 371: Description
Starter location will work only with a 148 tooth ring gear. Standard SAE #2 side mount locations. 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.
Page 372 Bolt, M6 x 16 (2) Bolt, M6 x 16 Hollow dowel (2) Flywheel housing Flywheel housing seal 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.
Page 373: Flywheel And Flexplate Applications
Figure 584 14 inch ﬂywheel - for multiple plate clutch applications, 800 lbf·ft and below Crankshaft timing disk Flywheel assembly Bolt, M12 x 40 (12) 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.
Page 374 Figure 585 15.5 inch ﬂywheel - for multiple plate clutch applications, 800 lbf·ft and above Crankshaft timing disk Flywheel assembly Bolt, M12 x 40 (12) 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.
Page 375 Figure 586 Pot type ﬂywheel – for multiple plate clutch applications, 800 lbf·ft and above Flywheel assembly Bolt, M12 x 40 (12) Crankshaft timing disk 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.
Page 376: Automatic Transmissions
Bolt, M12 x 45 (12) Reinforcement ring (Allison Crankshaft timing disk transmissions only) Flexplate adapter 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.
Page 377 Flexplate adapter Flexplate assembly Bolt, M12 x 45 (12) Crankshaft timing disk Reinforcement ring 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.
Page 378 Plate assembly, Allison AT Adapter hub, AT transmissions Hex ﬂange nut, M10 x 1.5 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.
Page 379: Removal
3. Install two guide pins (made locally) in place of the two ﬂywheel mounting bolts. 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.
Page 380: Flexplate (Automatic Transmissions)
Damage to the rear oil hub off guide pins. seal could occur resulting in a leak. 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.
Page 381 Discard oil seal assembly. Figure 595 Drilling holes in the rear oil seal 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.
Page 382: Inspection
Place the tip of the dial indicator against the crankshaft pilot. 2. Zero the dial indicator. 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.
Page 383: Removing Flywheel Housing
ﬂywheel after resurfacing for any cracks or heat checks. Flywheel resurfacing information is provided for guidance only. Navistar, Inc. assumes no responsibility either for the results of any work performed in accordance with this information or for the ability of service personnel to detect heat cracks.
Page 384: Ring Gear Replacement
B. Make sure the ring gear is seated properly against the ﬂywheel shoulder. 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.
Page 385: Rear Oil Seal
(2). transmission) and start seal onto oil seal installer base. 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.
Page 386: Crankshaft Timing Disk
NOTE: Alignment dowel pin convex end must protrude out of crankshaft (Figure 583). 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.
Page 387: Flywheel Assembly
148 tooth ring gears to the special torque value (Table 51). Figure 612 Installing guide pins 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.
Page 388: Checking Flywheel Surface Runout
ﬂexplate is offset (not centered) toward the transmission. 3. Install the ﬂexplate assembly on the guide pins. 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.
Page 389: Md-3000 And Hd-4000 Series World Transmissions
NOTE: Make sure that the paint mark, part number or XMSN SIDE on the ﬂexplate is facing outward (towards the transmission). 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.
Page 390: Speciﬁcations
ﬂywheel after resurfacing for any cracks or heat checks. Flywheel resurfacing information is provided for guidance only. Navistar, Inc. assumes no responsibility either for the results of any work performed in accordance with this information or for the ability of service personnel to detect heat cracks.
Page 391: Special Torque
Guide pins Obtain locally Rear seal installer ZTSE4637 Slide hammer puller set ZTSE1879 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.
Page 392 FLYWHEEL AND FLYWHEEL HOUSING 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.
Page 393: Diamond Logic® Engine Brake
Special Tools......................405 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.
Page 394 DIAMOND LOGIC® ENGINE BRAKE 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.
Page 395 Injection Control Pressure (ICP) assembly (6) 15. Brake actuator piston locknut (6) sensor Back-up ring (6) 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.
Page 396: Periodic Service
Wash or discard clothing and rags contaminated with engine ﬂuids. 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.
Page 397 Brake and valve lash adjustments with piston 6 at TDC compression Figure 620 Brake lash adjustment 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.
Page 398: Reconditioning
(page393 ) and do steps 4 and 5 for cylinders 2, 4, and 6. 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.
Page 399: Brake Shutoff Valve
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.
Page 400: Bcp Sensor
3. Install new O-ring on new ICP sensor, and lubricate O-ring with clean engine oil. 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.
Page 401: M12 Plug Assembly
Polished surfaces are acceptable. Figure 631 Rail end plug assembly 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.
Page 402 152 ) in the “Cylinder Head and Valve Train” section of this manual. Figure 634 Removing brake actuator piston 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.
Page 403: Removal
NOTE: The ICP and BCP sensors are identical and Pressure (ICP) sensor electrical connector from share the same part number. 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.
Page 404: High-Pressure Oil Rail
Figure 641 Oil inlet O-ring 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.
Page 405: Installation
6. Coat backup rings and injector oil inlet seals with clean engine oil. 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.
Page 406 1. Lift high-pressure oil rail up and place on engine. Align injector oil inlet adaptors with injector inlets. 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.
Page 407: Electrical Connections
(rear) and clip harness to high-pressure oil rail. Figure 648 Injector electrical connector 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.
Page 408 ) in the “Cylinder Head and Valve Train” section of this manual. 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.
Page 409: Speciﬁcations
Special Tools Table 56 Engine Brake Special Service Tools Feeler gauge (long) Obtain locally 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.
Page 410 DIAMOND LOGIC® ENGINE BRAKE 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.
Page 411: Air Compressor, Power Steering Pump, And Power Take-Off
Special Torques....................415 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.
Page 412 AIR COMPRESSOR, POWER STEERING PUMP, AND POWER TAKE-OFF 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.
Page 413: Description
International Service Information Solutions - ISIS® and then select manufacturer from suppliers tab. 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.
Page 414: Air Compressor
M10 x 25 (2) Fitting (NPTF), 3/8 x 1/2 M12 x 80 (2) 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.
Page 415: Power Steering Pump
Guidelines, page445 ) and need to be oriented to the 5. Remove gasket and discard. correct angle (Figure 652) upon installation. 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.
Page 416: Power Steering Pump With Air Compressor
Power steering pump gasket Hex ﬂange bolt, M10 x 35 Power steering pump assembly 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.
Page 417 2. Install two power steering pump mounting bolts (M10 x 35) and tighten to the special torque value (Table 57). 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.
Page 418: Power Steering Pump Without Air Compressor
(M10 x 90) and nuts (M10) and tighten to the standard torque value (General Torque Guidelines, page445 ). 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.
Page 419: Special Torques
57 N·m (42 lbf·ft) Power steering pump drive nut 90 N·m (66 lbf·ft) 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.
Page 420 AIR COMPRESSOR, POWER STEERING PUMP, AND POWER TAKE-OFF 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.
Page 421: Abbreviations And Acronyms
Abbreviations and Acronyms..................419 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.
Page 422 ABBREVIATIONS AND ACRONYMS 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.
Page 423 EPA – Environmental Protection Agency N – Newton EPR – Engine Pressure Regulator 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.
Page 424 ABBREVIATIONS AND ACRONYMS NEG – Negative SCCS – Speed Control Command Switches NETS – Navistar Electronics Technical Support SID – Subsystem Identiﬁer N•m – Newton meter – Sulfur Dioxide NO – Nitrogen Oxide SYNC – Synchronization – Nitrogen Oxides TACH – Tachometer output signal NSBU –...
Page 425: Terminology
Terminology......................423 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.
Page 426 TERMINOLOGY 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.
Page 427 (cavities) in the ﬂuid. ﬂuctuations resulting in a decrease of acoustic energy. 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.
Page 428 (SAE J1004 SEP81) down the circuit being measured. 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.
Page 429 EGR cooler or out the exhaust data communication. system. 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.
Page 430 International Tool Utilized Next Generation Electronics (INTUNE) – 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.
Page 431 (SAE J1995 JUN90) 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.
Page 432 ) – Sulfur dioxide is caused by intake air to charge air. oxidation of sulfur contained in fuel. 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.
Page 433 Vehicle Retarder Enable/Engage – Output from the cab heat. ECM to a vehicle retarder. 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.
Page 434 TERMINOLOGY 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.
Page 435: Appendix A - Speciﬁcations
Speciﬁcations......................433 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.
Page 436 APPENDIX A – SPECIFICATIONS 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.
Page 437 Valve stem-to-valve guide clearance (max.) Intake: 0.10 mm (0.004 in) Exhaust: 0.11 mm (0.005 in) 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.
Page 438 Exhaust: 1.40 mm (0.055 in) Valve seat angles Intake: 59.75 - 60° Exhaust: 44.75 - 45° 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.
Page 439 201.2 (7.92) DriveMaster) 466 high-mount, (spin-on) 465 (18.3) 201.2 (7.92) 1.08 : 1 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.
Page 440 0.05 mm (0.002 in) Table 66 Piston Speciﬁcations 466 piston conﬁguration Piston material Aluminum alloy 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.
Page 441 0.080 - 0.030 mm (0.0031 - Oil control ring, side clearance, 570 0.0012 in) 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.
Page 442 107.19 ± 0.0152 mm (4.220 ± 0.0006 in) Damper mounting area runout (maximum) 0.03 mm (0.001 in) 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.
Page 443 Standard size to 0.51 mm (0.020 in) undersized 34.404 ± 0.03 mm (1.3545 ± 0.010 in) 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.
Page 444 63.01 - 63.04 mm (2.481 - 2.482 in) Rear 65.51 - 63.55 mm (2.501 - 2.502 in) 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.
Page 445 0.48 mm (0.019 in) Engine exhaust valve lash (cold) Refer to (Adjusting Valve Lash, page150 ) 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.
Page 446 APPENDIX A – SPECIFICATIONS 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.
Page 447: Appendix B - Torques
Special Torque......................448 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.
Page 448 APPENDIX B – TORQUES 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.
Page 449 Values listed are 80% of proof load. Figure 655 Classiﬁcation and Identiﬁcation – Metric and Special Use Fasteners 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.
Page 450 (engine oil) to be considered lubricated. application. 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.
Page 451 = 43.3 lbf·ft or 58.9 N·m • L – Length through which force is applied to fastener 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.
Page 452 Rocker arm bolts torque and sequence (Installing Rocker Arms, page148 ) Valve adjustment locknut 27 N·m (20 lbf·ft) 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.
Page 453 13 N·m (115 lbf·in) Piston cooling tube bolts, M6 x 16 13 N·m (115 lbf·in) 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.
Page 454 10-20 N·m (88-176 lbf·in) Intake Manifold Air Temperature (MAT) sensor 10-20 N·m (88-176 lbf·in) 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.
Page 455 136 N·m (100 lbf·ft) Rear engine mounting bracket bolts 108 N·m (80 lbf·ft) 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.
Page 456 57 N·m (42 lbf·ft) Power steering pump drive nut 90 N·m (66 lbf·ft) 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.
Page 457 Photos of Essential Tools....................459 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.
Page 458 APPENDIX C – SPECIAL SERVICE TOOLS 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.
Page 459 Table 93 EGR System Special Service Tools EGR cooler pressure test plates ZTSE4636 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.
Page 460 Valve spring compressor ZTSE1846 Valve spring compressor jaws ZTSE4652 Water supply housing pressure adapter ZTSE4648 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.
Page 461 Piston ring gauge pins (set of 3) ZTSE4653 Telescoping gauge set Obtain locally 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.
Page 462 ZTSE1879 Table 102 Engine Brake Special Service Tools Feeler gauge (long) Obtain locally 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.
Page 463 Figure 662 Injector sleeve remover, ZTSE4643 Figure 659 Valve seat remover (collet), ZTSE4640 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.
Page 464 Figure 666 Engine mounting plate, ZTSE4649 Figure 664 Thermostat opening pressure adapter– cylinder head, ZTSE4647 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.
Page 465 Figure 670 Head bolt and main bolt thread gauge, ZTSE4667 Figure 668 Piston gauge pins (set of three), ZTSE4653 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.
Page 466 Figure 674 IPR valve removal and installation tool, ZTSE4666 Figure 672 Sleeve protrusion hold down clamps, ZTSE4672 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.
Page 467 TSI-09-12-02 High-pressure Pump Assembly Inlet Filter Service Kit......... . . 483 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.
Page 468 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS 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.
Page 469: Tsi-05-12-28 New High-Pressure Oil Rails
APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS TSI-05-12-28 New High-pressure Oil Rails 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.
Page 470: Tsi-05-12-35 New 1500 Watt Single Grid Intake Air Heater Production Option
APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS TSI-05-12-35 New 1500 Watt Single Grid Intake Air Heater Production Option 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.
Page 471 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS 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.
Page 472: Tsi-06-12-15 Sensor O-Ring Kit For Cmp Or Ckp Applications
APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS TSI-06-12-15 Sensor O-ring Kit for CMP or CKP Applications 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.
Page 473: Tsi-06-12-14 Update Valve Train Components - Push Rod And Tappet Compatibility
APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS TSI-06-12-14 Update Valve Train Components – Push Rod and Tappet Compatibility 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.
Page 474 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS 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.
Page 475 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS 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.
Page 476 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS 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.
Page 477 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS 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.
Page 478: Tsi-06-12-21 Update Valve Train Components - Adjuster Screws
APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS TSI-06-12-21 Update Valve Train Components – Adjuster Screws 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.
Page 479: Tsi-06-12-27 New Piston And Piston Ring Assemblies
APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS TSI-06-12-27 New Piston and Piston Ring Assemblies 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.
Page 480 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS 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.
Page 481: Tsi-07-12-12 Egr Coolant Return Kit
APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS TSI-07-12-12 EGR Coolant Return Kit 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.
Page 482 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS 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.
Page 483 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS 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.
Page 484: Tsi-08-12-20 Rubber Vibration Damper Replacement Kits
APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS TSI-08-12-20 Rubber Vibration Damper Replacement Kits 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.
Page 485 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS 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.
Page 486 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS 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.
Page 487: Tsi-09-12-02 High-Pressure Pump Assembly Inlet Filter Service Kit
APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS TSI-09-12-02 High-pressure Pump Assembly Inlet Filter Service Kit 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.
Page 488 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) BULLETINS 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.
Page 489 1171915R2 Turbocharger Actuator Flange and Pivot Shaft Kit..........508 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.
Page 490 APPENDIX E – INSTRUCTION SHEETS 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.
Page 491: 1171813R1 Front Cover Pto Adaptation Kit
APPENDIX E – INSTRUCTION SHEETS 1171813R1 Front Cover PTO Adaptation 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.
Page 492 APPENDIX E – INSTRUCTION SHEETS 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.
Page 493: 1171836R1 Air Compressor Bracket Kit
APPENDIX E – INSTRUCTION SHEETS 1171836R1 Air Compressor Bracket Kit 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.
Page 494 APPENDIX E – INSTRUCTION SHEETS 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.
Page 495 APPENDIX E – INSTRUCTION SHEETS 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.
Page 496: 1171846R1 Aluminum Air Inlet Adapter
APPENDIX E – INSTRUCTION SHEETS 1171846R1 Aluminum Air Inlet Adapter 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.
Page 497 APPENDIX E – INSTRUCTION SHEETS 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.
Page 498 APPENDIX E – INSTRUCTION SHEETS 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.
Page 499: 1171848R1 300 Watt Oil Pan Heater Kit
APPENDIX E – INSTRUCTION SHEETS 1171848R1 300 Watt Oil Pan Heater Kit 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.
Page 500 APPENDIX E – INSTRUCTION SHEETS 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.
Page 501: 1171855R1 Turbo Actuator Service Kit (Sra)
APPENDIX E – INSTRUCTION SHEETS 1171855R1 Turbo Actuator Service Kit (SRA) 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.
Page 502 APPENDIX E – INSTRUCTION SHEETS 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.
Page 503: 1171908R1 Turbocharger Vgt Linkage Kit
APPENDIX E – INSTRUCTION SHEETS 1171908R1 Turbocharger VGT Linkage 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.
Page 504 APPENDIX E – INSTRUCTION SHEETS 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.
Page 505 APPENDIX E – INSTRUCTION SHEETS 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.
Page 506 APPENDIX E – INSTRUCTION SHEETS 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.
Page 507: 1171913R1 Turbine Vane Assembly Cleaning Kit
APPENDIX E – INSTRUCTION SHEETS 1171913R1 Turbine Vane Assembly Cleaning Kit 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.
Page 508 APPENDIX E – INSTRUCTION SHEETS 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.
Page 509 APPENDIX E – INSTRUCTION SHEETS 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.
Page 510 APPENDIX E – INSTRUCTION SHEETS 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.
Page 511 APPENDIX E – INSTRUCTION SHEETS 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.
Page 512: 1171915R2 Turbocharger Actuator Flange And Pivot Shaft Kit
APPENDIX E – INSTRUCTION SHEETS 1171915R2 Turbocharger Actuator Flange and Pivot Shaft Kit 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.
Page 513 APPENDIX E – INSTRUCTION SHEETS 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.
Page 514 APPENDIX E – INSTRUCTION SHEETS 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.
Page 515 APPENDIX E – INSTRUCTION SHEETS 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.
Page 516 APPENDIX E – INSTRUCTION SHEETS 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.
Page 517 APPENDIX E – INSTRUCTION SHEETS 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.
Page 518 APPENDIX E – INSTRUCTION SHEETS 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.
Page 520 Printed in the United States of America...

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International dt 570 International ht 570

Navistar INTERNATIONAL DT 466 Service Manual

Engine Service Manual I

Table of Contents

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

Table of Contents

Oil Pan and Oil Suction Tube 203

Power Cylinders 213

Crankcase, Crankshaft, and Camshaft 249

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