Navistar INTERNATIONAL DT 466 Manuals

Manuals and User Guides for Navistar INTERNATIONAL DT 466. We have 2 Navistar INTERNATIONAL DT 466 manuals available for free PDF download: Diagnostic/Troubleshooting Manual, Service Manual

Navistar INTERNATIONAL DT 466 Diagnostic/Troubleshooting Manual (658 pages)

Brand: Navistar | Category: Engine | Size: 29.96 MB

Diagnostic/Troubleshooting Manual I

3
- Table of Contents
  3
- Foreword
  5
- Service Diagnosis
  6
- Safety Information
  7
Table of Contents

9
- Engine Identification
  11
  - Engine Serial Number
    11
  - Engine Emission Label
    11
  - Engine Description
    13
  - Engine Component Locations
    16
  - Engine Systems
    22
  - Engine System Diagram
    22
- Air Management System
  23
- Fuel Management System
  29
- Fuel Supply System
  37
  - Fuel System Components and Fuel Flow
    37
  - Fuel Flow Schematic
    38
- Engine Lubrication System
  41
  - Lubrication System Components and Oil Flow
    41
- Cooling System
  44
  - Cooling System Components and Coolant Flow
    44
- Electronic Control System
  47
- Diamond Logic® Engine Brake
  57
3 Diagnostic Software Operation 65

69
- Diagnostic Software Operation
  70
- Diagnostic Trouble Code Detection
  71
  - Continuous Monitor
    72
- Diagnostic Trouble Codes
  73
  - Using EST
    73
    
    Accessing Diagnostic Trouble Codes (Dtcs)
    73
    
    Reading Dtcs
    73
    
    Clearing Dtcs
    73
  - Using Cruise Switches
    73
    
    Accessing Dtcs
    73
    
    Reading Dtcs
    74
    
    Clearing Dtcs
    74
- Diagnostic Tests
  75
  - Key-On Engine-Off Tests
    75
    
    Standard Test
    75
    
    Standard Test Using EST
    75
    
    Standard Test Using Cruise Switches
    76
    
    Injector Test
    76
    
    Continuous Monitor Test
    77
    
    Output State Low Test
    78
    
    Output State High Test
    79
    
    Glow Plug/Inlet Air Heater Output State Test
    80
  - Key-On Engine-Running Tests
    81
    
    Standard Test
    81
    
    Continuous Monitor Test
    82
    
    Air Management Test
    83
    
    VGT Test
    87
  - Injector Disable Tests
    89
    
    Automatic Test
    89
    
    Manual Test - Engine Cold
    91
    
    Manual Test - Engine Hot
    92
  - Relative Compression
    95
- Reset Change Engine Oil Interval Message
  97
  - Using EST
    97
  - Using Cruise Switches
    101
4 Engine Symptoms Diagnostics 99

103
- Problems and Conditions
  105
- Combustion Leaks to Coolant
  106
- Aerated Fuel
  108
- Coolant in Lube Oil
  113
  - Coolant System Inspection
    113
- Engine Symptoms Diagnostics
  114
  - Air Compressor Leak Test
    114
  - Front Cover Inspection
    115
  - Cylinder Head Leak Test
    116
- ECM Reset / IDM Reset (Intermittent Engine Stumble)
  117
- Excessive Fuel Consumption
  118
- Fuel in Coolant
  119
- Coolant Leak to Exhaust
  121
- Coolant Over-Temperature
  123
- Lube Oil in Coolant
  126
- Fuel in Lube Oil
  128
- Low Oil Pressure
  132
  - Oil Inspection
    132
  - Oil Pressure Regulator Inspection
    133
  - Oil and Crankcase Inspection
    133
  - Oil Pump Inspection
    134
  - Front Cover Inspection
    135
- Priming Fuel System
  136
- Rough Idle
  139
- Smoke
  141
  - Black Smoke
    141
  - White Smoke
    141
- Low Power (Turbocharger Assembly and Actuator)
  143
Table of Contents

145
- Hard Start and no Start Diagnostics
  146
- Description
  
  147
- Diagnostic Form Information
  
  147
- Test Procedures
  
  148
- 1 Initial Ignition Switch on (Do Not Start)
  
  148
- 2 Engine Cranking
  
  150
- 3 Diagnostic Trouble Codes
  
  152
  - Vehicle Information for Form Heading
    152
  - Entering Vehicle Information Without Using the EST
    152
  - Entering Vehicle Information Using the EST
    153
  - Accessing Dtcs
    155
  - Reading Dtcs
    156
- 4 KOEO Standard Test
  
  157
- 5 KOEO Injector Test
  
  159
- 6 EST Data List
  
  161
- 7 Fuel
  
  170
- 8 Engine Systems
  
  174
- 9 Engine Oil
  
  175
- 10 Intake and Exhaust Restriction
  
  176
- 11 Main Power Relay to ECM
  
  178
  - Voltage Measurement with Breakout Harness at Main Power Relay
    178
  - Voltage Measurement at ECM with Breakout Box
    179
- 12 Main Power Relay to IDM
  
  181
  - Voltage Measurement at 12-Pin Connection with Breakout Harness
    181
  - Voltage Measurement with Breakout Harness at Main Power Relay
    183
- 13 Fuel Pressure and Aerated Fuel
  
  184
  - Fuel Pressure
    184
  - Checking for Aerated Fuel Using Spare Fuel Line
    187
  - Operation of Fuel Pump
    189
- 14 Low ICP System Pressure
  
  190
  - 14.1 - System Function
    190
  - Oil Reservoir Level
    192
  - 14.3 - IPR and High-Pressure Pump Operation
    192
  - Under Valve Cover Leak Test
    195
  - 14.5 - IPR Function
    198
- 15 Inlet Air Heater System
  
  201
Table of Contents

207
- Performance Diagnostics
  208
- Description
  
  209
- Diagnostic Form Information
  
  209
- Test Procedures
  
  211
- 1 Diagnostic Trouble Codes
  
  211
  - Vehicle Information for Form Heading
    211
  - Entering Vehicle Information Without Using the EST
    211
  - Entering Vehicle Information Using the EST
    212
  - Accessing Dtcs
    215
  - Reading Dtcs
    216
- 2 KOEO Standard Test
  
  217
- 3 KOEO Injector Test
  
  219
- 4 Engine Oil
  
  221
- 5 Fuel
  
  222
- 6 Fuel Pressure and Aerated Fuel
  
  226
  - Fuel Pressure
    226
  - Checking for Aerated Fuel Using Spare Fuel Line
    230
  - Operation of Fuel Pump
    232
- 7 Intake Restriction
  
  233
- 8 Exhaust Restriction
  
  235
  - Monitoring EBP Using EST
    235
  - Monitoring EBP Using Pressure Sensor Breakout Harness
    237
- 9 KOER Standard Test
  
  238
- 10 Injection Control Pressure
  
  240
- 11 Injector Disable Test
  
  248
  - Automatic Test - Auto Run
    248
  - Manual Test
    250
- 12 Relative Compression
  
  252
- 13 Air Management
  
  255
- 14 VGT Test
  
  257
- 15 Torque Converter Stall (Automatic Only)
  
  259
- 16 Crankcase Pressure
  
  260
- 17 Test Drive (Full Load, Rated Speed)
  
  262
- 18 Valve Lash and Brake Lash
  
  278
  - Adjusting Valve Lash
    278
  - Brake Lash
    281
Table of Contents

283
- Description
  
  287
  - Section Information
    287
- Electronic Control System Diagnostics Form
  
  288
  - EGED-285 Diagnostic Form Example
    288
- Sensor and Actuator Locations
  
  289
  - Engine Mounted Components
    289
  - Vehicle Mounted Components
    292
- Diagnostic Procedures for Sensors and Actuators
  
  292
  - Pin Grip Inspection
    292
  - Operational Diagnostics
    293
    
    Tests Using Masterdiagnostics
    293
    
    Vref
    293
    
    Temperature Sensor Tests Using Masterdiagnostics
    293
  - Pin-Point Diagnostics
    294
    
    Connector Voltage Checks to Ground
    294
    
    Connector Resistance Checks to ECM Chassis Ground
    294
    
    Connector Resistance Checks to Chassis Ground
    295
    
    Harness Resistance Checks
    296
    
    Operational Voltage Checks
    296
- Circuit Diagnostics
  
  297
- CAN Communications (Controller Area Network)
  
  352
  - CAN Pin-Point Diagnostics
    353
- CKP Sensor (Crankshaft Position)
  
  355
  - CKP Circuit Operation
    356
  - CKP Pin-Point Diagnostics
    357
- CMP Sensor (Camshaft Position)
  
  359
  - CMP Circuit Operation
    360
  - CMP Pin-Point Diagnostics
    361
- EBP Sensor (Exhaust Back Pressure)
  
  363
  - EBP Circuit Operation
    364
  - EBP Operational Diagnostics
    365
  - EBP Pin-Point Diagnostics
    368
- ECI System (Engine Crank Inhibit)
  
  370
  - ECI Circuit Diagnostics
    372
- ECL Sensor (Engine Coolant Level)
  
  374
  - ECL Circuit Operation
    375
  - ECL Pin-Point Diagnostics
    376
- ECM / IDM Communications (Electronic Control Module / Injector Driver Module)
  
  377
  - ECM / IDM Circuit Operation
    378
  - ECM / IDM Pin-Point Diagnostics
    380
- ECM PWR (Electronic Control Module Power)
  
  385
  - ECM PWR Circuit Operation
    386
  - ECM PWR Pin-Point Diagnostics
    388
- ECM Self Diagnostics (Electronic Control Module)
  
  392
  - ECM Self Diagnostic Trouble Codes (Dtcs)
    393
- ECT Sensor (Engine Coolant Temperature)
  
  395
  - ECT Circuit Operation
    397
  - ECT Operational Diagnostics
    398
  - ECT Pin-Point Diagnostics
    400
- EFAN Control (Engine Fan Control)
  
  402
- EFP Sensor (Engine Fuel Pressure - Optional)
  
  410
  - EFP Circuit Operation
    411
  - EFP Operational Diagnostics
    412
  - EFP Pin-Point Diagnostics
    414
- EGR Actuator (Exhaust Gas Recirculation)
  
  417
  - EGR Circuit Operation
    418
  - EGR Pin-Point Diagnostics
    421
- EOP Sensor (Engine Oil Pressure)
  
  430
  - EOP Circuit Operation
    431
  - EOP Operational Diagnostics
    432
  - EOP Pin-Point Diagnostics
    435
- EOT Sensor (Engine Oil Temperature)
  
  437
  - EOT Circuit Operation
    438
  - EOT Operational Diagnostics
    440
  - EOT Pin-Point Diagnostics
    442
- EWPS (Engine Warning and Protection System)
  
  444
  - EWPS Operational Diagnostics
    445
  - IAH System (Inlet Air Heater)
    448
    
    IAH Circuit Operation
    449
    
    IAH Pin-Point Diagnostics
    451
  - IAT Sensor (Intake Air Temperature)
    455
    
    IAT Circuit Operation
    456
    
    IAT Operational Diagnostics
    457
    
    IAT Pin-Point Diagnostics
    459
  - ICP Sensor (Injection Control Pressure)
    461
    
    ICP Circuit Operation
    462
    
    ICP Operational Diagnostics
    464
    
    ICP Pin-Point Diagnostics (ECM to Valve Cover Gasket Connector)
    469
    
    ICP Pin-Point Diagnostics (ECM to ICP Sensor- Valve Cover Removed)
    473
  - ICP System (Injection Control Pressure)
    476
    
    ICP System Operation
    476
  - IDM PWR (Injection Driver Module Power)
    483
    
    IDM PWR Circuit Operation
    484
    
    IDM PWR Pin-Point Diagnostics
    486
  - INJ Circuits (Injector Drive)
    493
    
    INJ Circuit Operation
    493
    
    INJ Pin-Point Diagnostics
    494
  - IPR (Injection Pressure Regulator)
    498
    
    IPR Circuit Operation
    499
    
    IPR Pin-Point Diagnostics
    500
  - IST System (Idle Shutdown Timer)
    501
    
    IST Operation
    501
  - MAP Sensor (Manifold Absolute Pressure)
    504
    
    MAP Circuit Operation
    505
    
    MAP Operational Diagnostics
    507
    
    MAP Pin-Point Diagnostics
    509
  - MAT Sensor (Manifold Air Temperature)
    512
    
    MAT Circuit Operation
    513
    
    MAT Operational Diagnostics
    514
    
    MAT Pin-Point Diagnostics
    516
  - RSE (Radiator Shutter Enable)
    518
    
    RSE Circuit Operation
    519
    
    RSE Pin-Point Diagnostics
    520
  - SCCS (Speed Control Command Switches)
    523
    
    SCCS Circuit Operation
    523
  - Tachometer Output Circuit
    526
    
    Tachometer Pin-Point Diagnostics
    527
  - VGT Actuator (Variable Geometry Turbocharger)
    528
    
    VGT Circuit Operation
    530
    
    VGT Pin-Point Diagnostics
    532
  - (Reference Voltage)
    543
  - Ref
    543
    
    Circuit Operation
    544
    
    Ref
    544
    
    Pin-Point Diagnostics
    546
  - VSS (Vehicle Speed Sensor)
    548
    
    VSS Circuit Operation (Manual and Allison Transmissions)
    549
    
    VSS Pin-Point Diagnostics (Manual Transmissions)
    551
    
    VSS Pin-Point Diagnostics (Allison Transmissions)
    553
8 Diagnostic Tools and Accessories 555

559
- Diagnostic Tools and Accessories
  561
- Tools and Accessories
  561
  - EZ-Tech® Electronic Service Tool (EST)
    561
  - EZ-Tech® Interface Kit
    561
  - Masterdiagnostics® Software
    561
  - Digital Multimeter (Fluke 88)
    562
  - Amp Clamp
    562
  - 96-Pin Breakout Box - DLC II
    563
  - Breakout Harness Kit
    563
  - 3-Banana Plug Harness
    564
  - VC Gasket Breakout Harness
    564
  - UVC Sensor Breakout Harness
    564
  - 4-Pin Injector Harness
    564
  - 12-Pin Breakout Harness
    565
  - 500 Ohm Resistor Harness
    565
  - Actuator Breakout Harness
    565
  - APS/IVS Sensor Breakout Harness
    565
  - Pressure Sensor Breakout Harness
    566
  - Relay Breakout Harness
    566
  - Temperature Sensor Breakout Harness
    566
  - Temperature Sensor Breakout Harness
    567
  - Turbo Breakout Harness
    567
  - EGR Valve Breakout Harness
    567
  - Terminal Test Adapter Kit
    568
  - Gauge Bar Tool
    568
  - Fuel Pressure Gauge
    569
  - Slack Tube Manometer
    569
  - Fuel Pressure Test Kit
    570
  - Fuel/Oil Pressure Test Coupler
    570
  - Fuel Test Fitting
    571
  - ICP System Test Adapter
    571
  - ICP Test Kit
    571
  - Inline Shut-Off Valve
    572
  - Vacuum Pump and Gauge
    572
  - Charge Air Cooler Test Kit
    572
  - Crankcase Pressure Test Adapter
    573
  - UV Leak Detection Kit
    573
- Electronic Circuit Testing
  574
  - Electrical Theory
    574
    
    Voltage
    574
    
    Ohm's Law
    574
  - Using the Digital Multimeter
    575
    
    Test Meters
    575
    
    Jumper Wires
    576
    
    Voltmeter
    576
- Ammeter
  578
- Ohmmeter
  579
- Measuring Duty Cycle with FLUKE 88
  580
- Troubleshooting
  582
- Abbreviations and Acronyms
  585
- Terminology
  589
11 Appendix A: Dt 466 Performance Specifications 2004 593 Model Year

597
- 11 Appendix A: Dt 466 Performance Specifications 2004 593
  599
- DT 466 (Standard and High Torque - All Ratings)
  599
- Temperature, Fuel, and Lubrication
  599
- Appendix A: DT 466 Performance Specifications 2004 Model Year
  600
  - DT 466 (Standard Torque)
    601
    
    Hp @ 2300 Rpm (12NPL)
    601
    
    Hp @ 2300 Rpm (12NPM)
    603
    
    Hp @ 2300 Rpm (12NPN)
    605
    
    Hp @ 2300 Rpm (12NPP)
    607
  - DT 466 (High Torque)
    609
    
    Hp @ 2300 Rpm (12NPR)
    609
    
    Hp @ 2300 Rpm (12NPS)
    611
    
    Hp @ 2300 Rpm (12NPT)
    613
    
    Hp @ 2300 Rpm (12NPU)
    615
    
    Hp @ 2300 Rpm (12NPV)
    617
    
    Hp @ 2300 Rpm (12NPX)
    619
Table of Contents

621
- Appendix B: DT 570 and HT 570 Performance Specifications 2004 Model Year
  
  622
  - DT 570 and HT 570 (All Ratings)
    623
    
    12 Appendix B: Dt 570 and Ht 570 Performance
    623
    
    Temperature, Fuel, and Lubrication
    623
  - DT 570 (Standard Torque)
    625
    
    12NPW (285 Hp @ 2000 Rpm)
    625
    
    12NPZ (310 Hp @ 2000 Rpm)
    627
    
    12NRB (330 Hp @ 2000 Rpm)
    629
  - HT 570 (High Torque)
    631
    
    12NRC (295 Hp @ 2000 Rpm)
    631
    
    12NRD (295 Hp @ 2000 Rpm)
    633
    
    12NRE (310 Hp @ 2000 Rpm)
    635
    
    12NRA 300 Hp @ 2000 Rpm
    637
    
    12NRG (310 Hp @ 2000 Rpm)
    639
    
    12NRH (330 Hp @ 2000 Rpm)
    641
    
    12NRZ (340 Hp @ 2000 Rpm)
    643
- Appendix C: Diagnostic Trouble Code Index
  
  647
- Appendix D: Technical Service Information (TSI)
  
  653

Navistar INTERNATIONAL DT 466 Service Manual (520 pages)

Brand: Navistar | Category: Engine | Size: 23.51 MB

Engine Service Manual I

3
- Table of Contents
  3
- Foreword
  5
- Service Diagnosis
  6
- Safety Information
  7
Table of Contents

9
- Engine Systems
  9
- Engine Identiﬁcation
  11
  - Engine Serial Number
    11
  - Engine Emission Label
    12
  - Engine Description
    13
  - Engine Component Locations
    16
- Engine Systems
  22
  - Engine System Diagram
    22
- Air Management System
  23
- Fuel Management System
  29
- Fuel Supply System
  37
  - Fuel System Components and Fuel Flow
    37
  - Fuel Flow Schematic
    38
- Engine Lubrication System
  41
  - Lubrication System Components and Oil Flow
    41
- Cooling System
  44
  - Cooling System Components and Coolant Flow
    44
- Electronic Control System
  47
- Diamond Logic® Engine Brake System
  57
Mounting Engine on Engine Stand 59

63
- Engine Preparation
  65
  - Cleaning the Engine
    65
  - Draining Engine Fluids
    65
- Component Removal
  66
  - Turbocharger Oil Inlet Tube
    66
  - Turbocharger
    66
  - Oil Filter
    67
  - Oil System Module
    67
- Mounting Adapter Plate and Engine
  67
  - Adapter Plate
    67
  - Engine
    68
- Special Service Tools
  69
- Special Torque
  69
Evrt® Electronically Controlled Turbocharger 67

71
- Description
  73
- Removal
  75
  - Variable Geometry Turbocharger (VGT) Assembly
    75
- Cleaning
  76
  - Turbocharger and Related Parts
    76
- Inspection
  77
  - Checking Turbine and Compressor
    77
  - Checking Rotation of Actuator Shaft
    77
- Installation
  77
  - Variable Geometry Turbocharger (VGT) Assembly
    77
- Special Torque
  79
- Speciﬁcations
  79
Intake, Inlet, and Exhaust Manifolds 77

81
- Removal
  84
- Cleaning and Inspection
  87
  - Exhaust Manifold
    87
  - Intake Manifold
    87
- Installation
  88
  - Exhaust Manifold
    88
  - Intake Manifold
    90
  - Inlet and EGR Mixer Duct
    91
- Special Torque
  93
- Speciﬁcations
  93
Egr Cooler and Tubing 91

95
Cylinder Head and Valve Train 115

119
- Description
  121
- Removal
  124
  - Valve Cover
    124
  - Removing Rocker Arm Assembly
    125
  - Measuring Camshaft Lift
    126
  - Removing Rocker Arms
    127
  - Removing Cylinder Head
    127
  - Roller Tappets
    128
- Cleaning
  129
  - Cylinder Head
    129
- Inspection
  129
  - Valve Train Components
    129
  - Push Rods
    129
  - Rocker Shaft
    129
  - Rocker Arms
    130
  - Cylinder Head Warpage
    131
  - Cylinder Head Thickness
    131
  - Valve Seat Leakage
    131
  - Cylinder Head Cracking
    132
  - Pressure Check Cylinder Head
    133
- Reconditioning
  134
  - Removing Valves from Cylinder Head
    134
  - Inspecting Valve Guides
    134
  - Replacing Valve Guides
    135
  - Inspecting Valves
    136
  - Refacing Valves
    136
    
    Valve Face
    136
    
    Valve Stem Tip
    137
    
    Checking Valve Face-To-Valve Seat Contact
    138
  - Resurfacing Valve Seats
    139
  - Replacing Valve Seats
    140
    
    Removal
    140
    
    Installation
    142
  - Inspecting Valve Springs
    143
  - Inspecting Valve Rotators
    144
  - Inspecting Valve Spring Retainer Keys
    145
  - Replacing Fuel Injector Sleeves
    145
    
    Removal
    145
    
    Installation
    145
  - Installing Valves
    146
    
    Cleaning
    146
    
    Assembly
    146
- Installation
  148
  - Roller Tappets
    148
  - Installing the Cylinder Head
    148
  - Torque-To-Yield Procedure for Cylinder Head Bolts
    150
  - Valve Train Components
    152
  - Installing Rocker Arms
    152
  - Installing the Rocker Arm Assembly
    153
  - Valve Lash for Intake and Exhaust Valves
    154
  - Adjusting Valve Lash
    154
  - High-Pressure Oil Rail Assembly
    156
  - Valve Cover
    156
- Speciﬁcations
  158
- Special Torque
  159
- Special Service Tools
  160
Table of Contents

161
- Front Cover and Related Components
  161
- Description
  163
  - Front Cover Assemblies
    163
  - Gerotor Oil Pump Assembly
    163
- Checking Gear Train Timing Without Removing
  166
  - DT 466 Engines Only
    166
    
    Method One - Using a Feeler Gauge
    166
    
    Method Two - Using a Dial Indicator
    166
  - DT 570 and HT 570 Engines Only
    167
    
    Method One - Using a Feeler Gauge
    167
    
    Method Two - Using a Dial Indicator
    167
- Removal
  168
  - Alternator Bracket
    168
  - Flat Idler Pulley and Automatic Belt Tensioner
    169
  - Water Supply Housing
    169
  - Water Inlet Elbow, Water Outlet Tube, and Thermostat
    169
  - Fan Drive Hub
    170
  - Water Pump Assembly
    171
  - Vibration Damper, Damper Hub, and Wear Sleeve
    172
  - Gerotor Assembly Oil Pump and Front Oil Seal
    173
  - Front Engine Mount
    175
  - Front Cover (Front Half)
    176
    
    Generation 1 (Mounting Bolts)
    176
    
    Generation 2 (Mounting Bolts)
    177
  - Idler Gears
    178
  - Front Cover (Rear Half)
    180
- Inspection
  181
  - Checking Lower Idler Gear Backlash
    181
  - Checking Upper Idler Gear Backlash
    181
  - Checking Camshaft Gear Backlash
    182
  - Gerotor Oil Pump Clearance
    182
    
    Measuring Oil Pump Side Clearance
    182
    
    Measuring Oil Pump End Clearance
    183
- Installation
  184
  - Front Cover
    184
    
    Gaskets
    184
    
    Mounting Bolts (Rear Half)
    185
  - Idler Gears
    186
  - Front Cover (Front Half)
    188
    
    Gaskets
    188
    
    Generation 1 (Mounting Bolts)
    189
    
    Generation 2 (Mounting Bolts)
    190
  - Front Engine Mount
    191
  - Gerotor Oil Pump Assembly and Front Oil Seal
    191
  - POSE Dust Seal and Wear Sleeve
    194
  - Vibration Damper Hub and Damper Retaining Plate
    195
  - Vibration Damper Assembly
    196
  - Fan Drive
    197
  - Horton Drivemaster
    199
  - Water Pump Assembly
    200
  - Water Supply Housing
    201
  - Alternator Bracket
    201
  - Flat Idler Pulley and Automatic Belt Tensioner
    202
  - Water Inlet Elbow, Water Outlet Tube, and Thermostat
    202
- Speciﬁcations
  204
- Special Torque
  205
- Special Service Tools
  206
Oil Pan and Oil Suction Tube 203

207
- Removal
  210
  - Removing the Oil Pan
    210
  - Removing the Oil Suction Tube
    211
- Cleaning and Inspection
  212
  - Oil Pan
    212
- Installation
  212
  - Installing the Oil Suction Tube
    212
  - Installing the Oil Pan
    213
- Watt Oil Pan Heater (Optional)
  214
- Special Service Tools
  215
- Special Torque
  215
- Speciﬁcations
  215
Power Cylinders 213

217
- Description
  219
- Removal
  221
  - Piston Cooling Tubes
    221
    
    Old Piston Cooling Tubes
    221
    
    New Piston Cooling Tubes
    222
  - Removing Piston and Connecting Rod Assembly
    222
  - Disassembling Piston and Connecting Rod Assembly
    223
  - Cylinder Sleeve Removal
    224
- Cleaning
  225
  - Pistons and Related Components
    225
- Inspection
  225
  - Pistons
    225
    
    Top and Intermediate Compression Ring Grooves
    226
    
    Oil Control Ring Groove
    226
    
    Piston-To-Cylinder Sleeve Running Clearance
    227
  - Piston Rings
    227
  - Piston Pins
    228
  - Connecting Rods
    228
    
    Piston Pin Bushing
    228
    
    Connecting Rod Cap Bolts
    228
    
    Connecting Rod Bearing Bore
    229
    
    Bend and Twist
    229
  - Bearing Fitting Procedures and Bearing Running Clearance
    229
    
    Bearing Running Clearance
    230
    
    Connecting Rod Side Clearance
    231
  - Checking Cylinder Sleeves
    231
  - Checking Counterbore Depth
    233
    
    Surface Gauge Method
    233
    
    Depth Micrometer Method
    233
  - Checking Cylinder Sleeve Protrusion
    233
- Reconditioning
  236
  - Resurfacing the Counterbore
    236
- Installation
  238
Crankcase, Crankshaft, and Camshaft 249

253
- Removal
  257
  - Crankcase Ventilation System
    257
  - Oil Level Gauge
    259
  - Crankcase Ladder (DT 466 Series - 225 Hp and 245 Hp @ 2600 Rpm) and All 570 Ratings
    260
  - Crankshaft Disassembly
    260
  - Cam Gear from Camshaft
    261
  - Camshaft Disassembly
    262
  - Camshaft Bushings
    263
  - Coolant Heater (if Equipped)
    264
- Cleaning and Inspection
  265
  - Cleaning the Crankcase
    265
  - Crankcase Ventilation
    265
  - Crankshaft and Main Bearings
    266
  - Checking Camshaft Assembly
    266
  - Checking Camshaft Lobes and Journals
    267
- Installation
  267
  - Coolant Heater (if Equipped)
    267
  - Camshaft Bushings
    267
  - Camshaft Assembly
    270
  - Cam Gear on Camshaft
    271
  - Checking Camshaft End Play
    271
  - Crankshaft Assembly
    272
  - Bearing Fitting Procedure
    273
  - Main Bearings and Caps
    274
  - Torque Procedure for Torque-To-Yield Main Bearing Bolts
    275
  - Crankcase Ladder (DT 466 Series - 225 Hp and 245 Hp @ 2600 Rpm) and All 570 Ratings
    276
  - Oil Level Gauge
    278
  - Crankcase Ventilation System
    278
- Speciﬁcations
  280
- Special Service Tools
  282
- Special Torque
  282
Oil System Module Assembly and Secondary Filtration 279

283
- Removal
  287
- Cleaning and Inspection
  294
  - Cleaning the Oil System Module
    294
  - Checking the Cooler Heat Exchanger for Leakage
    294
    
    External
    294
    
    Internal
    296
- Installation
  297
  - Assembling the Oil System Module
    297
  - Assembling the Secondary Filtration Filter
    299
  - Secondary Filtration Assembly
    300
  - Oil System Module
    300
  - Priming the Lubrication System
    302
  - Alternate Method
    302
- Special Service Tools
  303
- Special Torque
  303
- Speciﬁcations
  303
Engine Electrical 301

305
- Sensor Identiﬁcation
  307
- Removal
  310
- Cleaning and Inspection
  323
  - Checking Wiring Harness and Electrical Connectors
    323
- Installation
  324
Fuel System 335

339
- Description
  341
- Low-Pressure Fuel System
  341
- High-Pressure Oil System
  342
- Periodic Service
  344
  - Fuel Strainer
    344
  - Fuel Filter
    345
- Removal
  346
- Disassembly
  354
  - Fuel Filter Header Assembly
    354
- Installation
  356
- Special Torque
  367
- Speciﬁcations
  367
- Special Service Tools
  368
Flywheel and Flywheel Housing 365

369
- Description
  371
- Flywheel and Flexplate Applications
  373
  - Manual Transmissions
    373
  - Automatic Transmissions
    376
- Removal
  379
- Inspection
  382
  - Flywheel Housing Face Runout
    382
  - Flywheel Housing Bore Concentricity
    382
  - Crankshaft Pilot Concentricity
    382
  - Removing Flywheel Housing
    383
- Flywheel Reconditioning
  383
  - Cleaning
    383
  - Inspection
    383
  - Flywheel Resurfacing
    383
  - Ring Gear Replacement
    384
- Installation
  384
  - Flywheel Housing
    384
  - Rear Oil Seal
    385
  - Crankshaft Timing Disk
    386
  - Flywheel Assembly
    387
  - Checking Flywheel Surface Runout
    388
  - Flexplate (Automatic Transmissions)
    388
    
    Allison 2000 Series Transmissions
    388
    
    MD-3000 and HD-4000 Series World Transmissions
    389
- Speciﬁcations
  390
- Special Service Tools
  391
- Special Torque
  391
Diamond Logic® Engine Brake 389

393
- Periodic Service
  396
  - Engine Brake Actuator Lash
    396
    
    Brake Lash Adjustment
    396
- Reconditioning
  398
  - Diagnostic Tests Procedures and Service Parts
    398
  - Reconditioning Procedures
    398
    
    Brake Shutoff Valve
    399
    
    BCP Sensor
    400
    
    ICP Sensor
    400
    
    M12 Plug Assembly
    401
    
    Rail End Plug Assembly
    401
    
    Oil Pressure Relief Valve
    401
    
    Brake Actuator Piston Assembly
    401
- Removal
  403
  - Valve Cover
    403
  - Electrical Connectors
    403
  - High-Pressure Oil Rail
    404
- Installation
  405
  - High-Pressure Oil Rail
    405
  - Electrical Connections
    407
- Special Tools
  409
- Special Torque
  409
- Speciﬁcations
  409
Air Compressor, Power Steering Pump, and Power 407 Take-Off

411
- Air Compressor, Power Steering Pump, and Power Take-Off
  411
- Description
  413
  - Air Compressor
    413
  - Power Steering Pump
    413
  - Power Take-Off
    413
- Removal
  413
  - Air Compressor
    414
  - Power Steering Pump
    415
- Installation
  415
  - Air Compressor
    415
  - Power Steering Pump with Air Compressor
    416
  - Power Steering Pump Without Air Compressor
    418
  - Special Torques
    419
- Abbreviations and Acronyms
  421
- Terminology
  425
- Appendix A - Speciﬁcations
  435
- Appendix A - Specifi Cations
  447
- Appendix B - Torques
  447
Appendix D - Technical Service Information (Tsi) 463 Bulletins

467

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Navistar INTERNATIONAL DT 466 Manuals

Navistar INTERNATIONAL DT 466 Diagnostic/Troubleshooting Manual (658 pages)

Table of Contents

Diagnostic/Troubleshooting Manual I

Table of Contents

3 Diagnostic Software Operation 65

4 Engine Symptoms Diagnostics 99

Table of Contents

Description

Diagnostic Form Information

Test Procedures

1 Initial Ignition Switch on (Do Not Start)

2 Engine Cranking

3 Diagnostic Trouble Codes

4 KOEO Standard Test

5 KOEO Injector Test

6 EST Data List

7 Fuel

8 Engine Systems

9 Engine Oil

10 Intake and Exhaust Restriction

11 Main Power Relay to ECM

12 Main Power Relay to IDM

13 Fuel Pressure and Aerated Fuel

14 Low ICP System Pressure

15 Inlet Air Heater System

Table of Contents

Description

Diagnostic Form Information

Test Procedures

1 Diagnostic Trouble Codes

2 KOEO Standard Test

3 KOEO Injector Test

4 Engine Oil

5 Fuel

6 Fuel Pressure and Aerated Fuel

7 Intake Restriction

8 Exhaust Restriction

9 KOER Standard Test

10 Injection Control Pressure

11 Injector Disable Test

12 Relative Compression

13 Air Management

14 VGT Test

15 Torque Converter Stall (Automatic Only)

16 Crankcase Pressure

17 Test Drive (Full Load, Rated Speed)

18 Valve Lash and Brake Lash

Table of Contents

Description

Electronic Control System Diagnostics Form

Sensor and Actuator Locations

Diagnostic Procedures for Sensors and Actuators

Circuit Diagnostics

CAN Communications (Controller Area Network)

CKP Sensor (Crankshaft Position)

CMP Sensor (Camshaft Position)

EBP Sensor (Exhaust Back Pressure)

ECI System (Engine Crank Inhibit)

ECL Sensor (Engine Coolant Level)

ECM / IDM Communications (Electronic Control Module / Injector Driver Module)

ECM PWR (Electronic Control Module Power)

ECM Self Diagnostics (Electronic Control Module)

ECT Sensor (Engine Coolant Temperature)

EFAN Control (Engine Fan Control)

EFP Sensor (Engine Fuel Pressure - Optional)

EGR Actuator (Exhaust Gas Recirculation)

EOP Sensor (Engine Oil Pressure)

EOT Sensor (Engine Oil Temperature)

EWPS (Engine Warning and Protection System)

8 Diagnostic Tools and Accessories 555

11 Appendix A: Dt 466 Performance Specifications 2004 593 Model Year

Table of Contents

Appendix B: DT 570 and HT 570 Performance Specifications 2004 Model Year

Appendix C: Diagnostic Trouble Code Index

Appendix D: Technical Service Information (TSI)

Navistar INTERNATIONAL DT 466 Service Manual (520 pages)

Table of Contents

Engine Service Manual I

Table of Contents