Navistar INTERNATIONAL DT 466 User manual

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

ENGINE SERVICE MANUAL I
Table of Contents
Foreword.................................................................................................................. 1
Service Diagnosis....................................................................................................... 2
Safety Information....................................................................................................... 3
Engine Systems......................................................................................................... 5
Mounting Engine on Engine Stand...................................................................................59
EVRT® Electronically Controlled Turbocharger...................................................................67
Intake, Inlet, and Exhaust Manifolds.................................................................................77
EGR Cooler and Tubing................................................................................................91
Cylinder Head and Valve Train........................................................................................115
Front Cover and Related Components...... .... ... .... ... .... ... . ... .... ... .... ... .... ... . ... .... ... .... ... .... ... .157
Oil Pan and Oil Suction Tube..........................................................................................203
Power Cylinders.........................................................................................................213
Crankcase, Crankshaft, and Camshaft..............................................................................249
Oil System Module Assembly and Secondary Filtration.... .....................................................279
Engine Electrical.........................................................................................................301
Fuel System..............................................................................................................335
Flywheel and Flywheel Housing......................................................................................365
Diamond Logic® Engine Brake.... ... ... ... .... ....... ... .... ... ... ... .... .......... .... ... ... ....... ... ....... .... ..389
Air Compressor, Power Steering Pump, and Power Take-off....................................................407
Abbreviations and Acronyms.........................................................................................417
Terminology..............................................................................................................421
Appendix A – Specifications..........................................................................................431
Appendix B – Torques..................................................................................................443
EGES-265-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.

II ENGINE SERVICE MANUAL
Appendix C – Special Service Tools.................................................................................453
Appendix D – Technical Service Information (TSI) Bulletins....................................................463
Appendix E – Instruction Sheets.....................................................................................485
EGES-265-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.

ENGINE SERVICE MANUAL 1
Foreword
Navistar, Inc. is committed to continuous research
and development to improve products and introduce
technological advances. Procedures, specifications,
and parts defined in published technical service
literature may be altered.
This Engine Service Manual provides a general
sequence of procedures for out-of-chassis engine
overhaul (removal, inspection, and installation). For
in-chassis service of parts and assemblies, the
sequence may vary.
NOTE: Photo illustrations identify specific parts or
assemblies that support text and procedures; other
areas in a photo illustration may not be exact.
See vehicle manuals and Technical Service
Information (TSI) bulletins for additional information.
Technical Service Literature
1171809R5 DT 466, DT 570 and HT
570 Engine Operation and
Maintenance Manual
EGES-265–2 DT 466, DT 570 and HT 570
Engine Service Manual
EGES-270 DT 466, DT 570 and HT 570
Engine Diagnostic Manual
EGED-285 DT 466, DT 570 and HT 570
Electronic Control Systems
Diagnostic Form (Pad of 50)
EGED-290 DT 466, DT 570 and HT 570
Diagnostics Form (Pad of 50)
Navistar, Inc. is committed to continuous research
and development to improve products and introduce
technological advances. Procedures, specifications,
and parts defined in published technical service
literature may be altered.
This Engine Service Manual provides a general
sequence of procedures for out-of-chassis engine
overhaul (removal, inspection, and installation). For
in-chassis service of parts and assemblies, the
sequence may vary.
NOTE: Photo illustrations identify specific parts or
assemblies that support text and procedures; other
areas in a photo illustration may not be exact.
See vehicle manuals and Technical Service
Information (TSI) bulletins for additional information.
EGES-265-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.

2ENGINE SERVICE MANUAL
Service Diagnosis
Service diagnosis is an investigative procedure that
must be followed to find and correct an engine
application problem or an engine problem.
If the problem is engine application, see specific
vehicle manuals for further diagnostic information.
If the problem is the engine, see specificEngine
Diagnostic Manual for further diagnostic information.
Prerequisites for Effective Diagnosis
• Availability of gauges, diagnostic test equipment,
and diagnostic software
• Availability of current information for engine
application and engine systems
• Knowledge of the principles of operation for
engine application and engine systems
• Knowledge to understand and do procedures in
diagnostic and service publications
Technical Service Literature required for Effective
Diagnosis
•Engine Service Manual
•Engine Diagnostic Manual
• Diagnostics Forms
• Electronic Control Systems Diagnostics Forms
• Service 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.

ENGINE SERVICE MANUAL 3
Safety Information
This manual provides general and specific
maintenance procedures essential for reliable engine
operation and your safety. Since many variations in
procedures, tools, and service parts are involved,
advice for all possible safety conditions and hazards
cannot be stated.
Read safety instructions before doing any service and
test procedures for the engine or vehicle. See related
application manuals for more information.
Disregard for Safety Instructions, Warnings, Cautions,
and Notes in this manual can lead to injury, death or
damage to the engine or vehicle.
Safety Terminology
Three terms are used to stress your safety and safe
operation of the engine: Warning, Caution, and Note
Warning: A warning describes actions necessary to
prevent or eliminate conditions, hazards, and unsafe
practices that can cause personal injury or death.
Caution: A caution describes actions necessary
to prevent or eliminate conditions that can cause
damage to the engine or vehicle.
Note: A note describes actions necessary for correct,
efficient engine operation.
Safety Instructions
Work Area
• Keep work area clean, dry, and organized.
• Keep tools and parts off the floor.
• Make sure the work area is ventilated and well lit.
• Make sure a First Aid Kit is available.
Safety Equipment
• Use correct lifting devices.
• Use safety blocks and stands.
Protective Measures
• Wear protective safety glasses and shoes.
• Wear correct hearing protection.
• Wear cotton work clothing.
• Wear sleeved heat protective gloves.
• Do not wear rings, watches or other jewelry.
• Restrain long hair.
Vehicle
• Make sure the vehicle is in neutral, the parking
brake is set, and the wheels are blocked before
servicing engine.
• Clear the area before starting the engine.
Engine
• The engine should be operated or serviced only
by qualified individuals.
• Provide necessary ventilation when operating
engine in a closed area.
• Keep combustible material away from engine
exhaust system and exhaust manifolds.
• Install all shields, guards, and access covers
before operating engine.
• Do not run engine with unprotected air inlets or
exhaust openings. If unavoidable for service
reasons, put protective screens over all openings
before servicing engine.
• Shutengineoffandrelieveallpressureinthe
system before removing panels, housing covers,
and caps.
• If an engine is not safe to operate, tag the engine
and ignition key.
Fire Prevention
• Make sure charged fire extinguishers are in the
work area.
NOTE: Check the classification of each fire
extinguisher to ensure that the following fire types
canbeextinguished.
1. Type A — Wood, paper, textiles, and rubbish
2. Type B — Flammable liquids
3. Type C — Electrical equipment
Batteries
• Always disconnect the main negative battery
cable first.
• Always connect the main negative battery cable
last.
• Avoid leaning over batteries.
• Protect your 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.

4ENGINE SERVICE MANUAL
• Do not expose batteries to open flames or sparks.
• Do not smoke in workplace.
Compressed Air
• Use an OSHA approved blow gun rated at 207
kPa (30 psi).
• Limit shop air pressure to 207 kPa (30 psi).
• Wear safety glasses or goggles.
• Wear hearing protection.
• Use shielding to protect others in the work area.
• Do not direct compressed air at body or clothing.
Tools
• Make sure all tools are in good condition.
• Make sure all standard electrical tools are
grounded.
• Check for frayed power cords before using power
tools.
Fluids Under Pressure
• Use extreme caution when working on systems
under pressure.
• Follow approved procedures only.
Fuel
• Do not over fill the fuel tank. Over fill creates a fire
hazard.
• Do not smoke in the work area.
• Do not refuel the tank when the engine is running.
Removal of Tools, Parts, and Equipment
• Reinstall all safety guards, shields, and covers
after servicing the engine.
• Make sure all tools, parts, and service equipment
are removed from the engine and vehicle after all
work is done.
EGES-265-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.

ENGINE SYSTEMS 5
Table of Contents
Engine Identification.................................................................................................... 7
Engine Serial Number......................................................................................... 7
Engine Emission Label....................................................................................... 8
Engine Description............................................................................................ 9
Engine Component Locations ... .... ... ... ... .......... .......... ... ... ... .... ... ... .... ... ... ... .... ... ...12
Engine Systems.........................................................................................................18
Engine System Diagram......................................................................................18
Air Management System...............................................................................................19
Air Management Components and Air Flow..............................................................19
Charge Air Cooler (CAC).....................................................................................20
Variable Geometry Turbocharger (VGT)...................................................................21
Exhaust Gas Recirculation (EGR) System................................................................23
Exhaust System................................................................................................24
Fuel Management System.............................................................................................25
Fuel Management Components...... ...... ... ... ... .... ... ...... ... ... ... .... ... ... ... ... ... .... ... ...... ..25
Injection Control Pressure (ICP) System Components and High-pressure Oil Flow..............26
Fuel Injectors...................................................................................................29
Fuel Supply System.....................................................................................................33
Fuel System Components and Fuel Flow.................................................................33
Fuel Flow Schematic..........................................................................................34
Engine Lubrication System ...........................................................................................37
Lubrication System Components and Oil Flow.. ........................................................37
Cooling System..........................................................................................................40
Cooling System Components and Coolant Flow.........................................................40
Electronic Control System.............................................................................................43
Electronic Control System Components..................................................................43
Injection Drive Module (IDM).................................................................................45
Engine and Vehicle Sensors.................................................................................47
Diamond Logic® Engine Brake System....... ... ... ... ... .... ... ... ... ... ....... ................ ... .... ... ... ... ...53
Engine Brake Components...................................................................................53
Engine Brake Control.........................................................................................54
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.

6ENGINE 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.

ENGINE SYSTEMS 7
Engine Identification
Engine Serial Number
Figure 1 Engine serial number (right side front)
Figure 2 Engine serial number (right side rear)
Engine Serial Number Locations
• The engine serial number is stamped on a
crankcase pad on the right side of the crankcase
(front for earlier model years and rear for later
model years).
• The engine serial number is also on the engine
emission label.
Engine Serial Number Examples
DT 466 engine: 466HM2UXXXXXXX
DT 570 engine: 570HM2UXXXXXXX
Engine Serial Number Codes
466 – Engine displacement
570 – Engine displacement
H–Diesel, turbocharged, Charge Air Cooler (CAC),
and electronically controlled
M2 – Motor truck
U–United States
7digitsuffix–Engine serial number sequence
beginning with 2,000,000
EGES-265-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.

8ENGINE SYSTEMS
Engine Emission Label
A common emission label is issued for the
International® DT 466 and DT 570 diesel engines.
Figure 3 Engine emission label (Example)
The Environmental Protection Agency (EPA) emission
label is on top of the valve cover. The engine label
includes the following:
• Model year
• Engine family, model, and displacement
• Advertised brake horsepower and torque rating
• Emission family and control systems
• U.S. Family Emission Limits (FEL), if applicable
• Valve lash specifications
• Engine serial number
• EPA, EURO, and reserved fields for specific
applications
Engine Accessories
The following engine accessories may have
manufacturer’s labels or identification plates:
• Air compressor (for brake or suspension system)
• Air conditioning compressor
• Alternator
• Cooling fan clutch
• EVRT® electronically controlled turbocharger –
International’s version of a Variable Geometry
Turbocharger (VGT)
• Power steering pump
•Startermotor
Labels or identification plates include information
and specifications helpful to vehicle operators and
technicians.
EGES-265-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.

ENGINE SYSTEMS 9
Engine Description
Table 1 International® DT 466 and DT 570 Features and Specifications
Engine 4 stroke, in-line six cylinder diesel
ConfigurationFour valves per cylinder
Displacement 7.6L(466in
3)
Displacement9.3L(570in
3)
Bore (sleeve diameter) 116.6 mm (4.59in)
Stroke
DT 466
DT 570
119 mm (4.68 in)
146 mm (5.75 in)
Compressionratio
DT 466
DT 570
16.5 : 1
17.5 : 1
Aspiration VGT turbocharged and Charge Air Cooled (CAC)
Rated power @ rpm
DT 466*
DT 570**
210 bhp @ 2600 rpm
285 bhp @ 2200 rpm
Peak torque@rpm
DT 466*
DT 570**
520 lbf•ft @ 1400 rpm
800 lbf•ft @ 1200 rpm
Engine rotation (facing flywheel) Counterclockwise
Combustion system Direct injection turbocharged
Fuel system International® electro-hydraulic generation 2 injection
Total engine weight (dry without
accessories)
DT 466
DT 570
671 kg (1,480 lbs)
708 kg (1,560 lbs)
Cooling system capacity (engine only) 12.8 L (13.5 qts US)
Lube system capacity (including filter) 28L(30qtsUS)
Lube system capacity (overhaul only, with
filter)
34 L (36 qts US)
Firing order 1-5-3-6-2-4
* 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.

10 ENGINE SYSTEMS
Engine Features
Table 2
Standard Features Optional Features
Four valves per cylinder Air compressor
Dual timing sensors Power steering pump
Replaceable piston and sleeve configuration Front cover PTO access
Gerotor lube oil pump Engine Fuel Pressure (EFP) sensor
International® common rail high-pressure injection
system Diamond Logic® engine brake
Variable Geometry Turbocharger (VGT) Diamond Logic® exhaust brake
Exhaust Gas Recirculation (EGR) Fuel heater
Water supply housing (Freon® compressor bracket)Oil pan heater
Alternator bracket Coolant heater assembly
Control modules
Water In Fuel (WIF) separation
Water In Fuel (WIF) sensor
Inlet Air Heater (IAH) – single or dual element
Standard Features
DT 466, DT 570, and HT 570 are in-line six cylinder
engines (medium range). Engine displacements are
7.6 liters (466 cubic inches) for the DT 466 and 9.3
liters (570 cubic inches) for the DT 570, and HT 570.
The firing order of the cylinders is 1–5–3–6–2–4.
The cylinder head has four valves per cylinder for
improved air flow. Each fuel Injector is centrally
located between the four valves and directs fuel
over the piston bowl for improved performance and
reduced emissions. The overhead valve train includes
mechanical roller lifters, push rods, rocker arms, and
dual valves that open using a valve bridge.
A one piece crankcase withstands high-pressure
loads during diesel operation.
The lower end of the DT 570 and HT 570 engines (for
ratings above 300 hp) includes a crankcase ladder
designed to absorb additional loads generated by
increased horsepower. Seven main bearings support
the crankshaft for DT 466, DT 570, and HT 570
engines. Fore and aft thrust are controlled at the rear
bearing. Four insert bushings support the camshaft
for each engine. The rear oil seal carrier is part of
the flywheel housing. The open crankcase breather
assembly uses a road draft tube to vent crankcase
pressure and an oil separator that returns oil to the
crankcase.
The crankshaft (CKP) and camshaft (CMP) sensors
are used by the ECM and IDM to calculate rpm, fuel
timing, fuel quantity, and duration of fuel injection.
Two different kinds of pistons are used in the in-line
engines:
• The DT 466 engine has one piece aluminum alloy
pistons.
• The DT 570 and HT 570 engines have two piece
articulated pistons with a steel crown.
All pistons are mated to fractured cap joint connecting
rods. Replaceable wet cylinder sleeves are used with
the pistons.
A gerotor lube oil pump, mounted to the front cover, is
driven directly by the crankshaft. All engines use an
oil cooler and spin-on oilfilter.
A low-pressure fuel supply pump draws fuel from the
fuel tank through a fuelfilter assembly that includes
astrainer,filter element, primer pump, drain valves,
EGES-265-2
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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.

ENGINE SYSTEMS 11
and Water In Fuel (WIF) sensor. After filtering, fuel is
pumped to the cylinder head fuel rail.
The International® common rail high-pressure
injection system includes a cast iron oil manifold,
fuel injectors, and a high-pressure oil pump.
The key feature of the VGT is actuated vanes
in the turbine housing. The vanes modify flow
characteristics of exhaust gases through the turbine
housing. The benefit is the ability to control boost
pressure for various engine speeds and load
conditions. An additional benefit is lower emissions.
An EGR control valve regulates cooled exhaust
gases entering the inlet air stream. Cool exhaust gas
increases engine tolerance for EGR, while reducing
smoke formed by gas dilution in the mixture. Three
EGR coolers are available depending on applications.
A water supply housing (Freon® compressor bracket)
is a coolant supply housing that includes an auxiliary
water connection.
Three control modules monitor and control the
electronic engine systems:
• Diamond Logic® engine controller – Electronic
Control Module (ECM)
• Injector Drive Module (IDM)
• Exhaust Gas Recirculation (EGR) drive module
Water In Fuel (WIF) separation occurs when the filter
element repels water molecules and water collects
at the bottom of the element cavity in the fuel filter
housing.
A Water In Fuel (WIF) sensor in the element cavity
of the fuel filter housing detects water. When enough
water accumulates in the element cavity, the WIF
sensor sends a signal to the Electronic Control
Module (ECM). A fuel drain valve handle on the
housing can be opened to drain water from the fuel
filter housing.
An Inlet Air Heater (IAH) – a single or dual element –
warms the intake air entering the cylinder head.
Optional Features
An air compressor is available for applications
requiring air brakes or air suspension.
A hydraulic power steering pump can be used with or
without an air compressor.
The front cover includes a mounting flange for Power
Take Off (PTO) accessories. The air compressor drive
gear train, used with a spline adapter, provides power
for front mounted PTO accessories.
An optional Engine Fuel Pressure (EFP) sensor
detects low pressure caused by high fuel filter
restriction and sends a signal to the ECM; the ECM
illuminates the amber FUEL FILTER lamp on the
instrument panel.
The Diamond Logic® engine brake is new for medium
range diesel engines. This compression braking
system uses a high-pressure rail assembly and the
VGT for additional braking. The operator controls the
engine brake for different operating conditions.
The Diamond Logic® exhaust brake system uses only
the VGT to restrict exhaust flow for additional braking.
The operator controls the exhaust brake for different
operating conditions.
Options for vehicles and applications used in cold
climates include the following:
•Oil pan heater
The oil pan heater warms engine oil in the pan and
ensures oil flow to the injectors.
•Coolant heater
The coolant heater raises the temperature of
coolant surrounding the cylinders for improved
performance and fuel economy during start-up.
•Fuel heater
The fuel heater (a 300 watt element) in the base of
the fuel filter assembly heats the fuel for improved
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.

12 ENGINE SYSTEMS
Engine Component Locations
Figure 4 Component location – top
1. Exhaust Back Pressure (EBP)
sensor
2. Valve cover
3. Exhaust emission label (location)
4. EGR cooler assembly
5. Breather assembly
6. Inlet and EGR mixer duct
7. EGR control valve
EGES-265-2
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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.

ENGINE SYSTEMS 13
Figure 5 Component location – front
1. Exhaust gas crossover (EGR
cooler to EGR valve)
2. Water outlet tube assembly
(thermostat outlet)
3. Front cover (front half)
4. Fan drive pulley
5. Engine mounting bracket (front)
6. Vibration damper
7. Water inlet elbow
8. Water pump pulley
9. Camshaft Position (CMP) sensor
10. Auto tensioner assembly (belt)
11. ECT sensor (location)
12. Flat idler pulley assembly
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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.

14 ENGINE SYSTEMS
Figure 6 Component location, electrical– left
1. Manifold Absolute Pressure
(MAP) sensor
2. EGR control valve
3. Manifold Air Temperature (MAT)
sensor
4. Inlet Air Heater (IAH) cable –
dual element
5. Valve cover gasket pass-through
connector
a. (Six) four wire connectors
for fuel injectors
b. (One) three wire connector
for ICP sensor
c. Engine brake application –
(one) three wire connector
for the BCP sensor and
(one) three wire connector
for the brake valve.
6. ECM and IDM module assembly
7. IAH relay
8. Crankshaft Position (CKP)
sensor
9. EGR drive module
10. Ground stud
11. Engine Oil Pressure (EOP)
sensor
12. Engine Oil Temperature (EOT)
sensor
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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.

ENGINE SYSTEMS 15
Figure 7 Component location, mechanical – left
1. Oil level gauge tube
2. High-pressure oil hose
3. Water drain valve (fuel)
4. Fuel filter header assembly
5. Breather assembly
6. Lifting eye
7. Vent and drain tube assembly
8. Intake manifold
9. Drain valve (fuel strainer)
10. Coolant line
11. Power steering pump
12. Oil pan assembly
13. Air compressor
14. Oil supply line
15. Fuel primer pump assembly
16. Low-pressure fuel supply pump
17. High-pressure oil pump
assembly
EGES-265-2
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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.

16 ENGINE SYSTEMS
Figure 8 Component location – right
1. EGR cooler return tube
assembly
2. Exhaust manifold assembly
3. EGR cooler assembly
4. Variable Geometry Turbocharger
(VGT)
5. Engine lifting eye
6. Water supply housing (Freon®
compressor bracket)
7. Alternator bracket
8. EGR cooler supply tube
assembly
9. Crankcase
10. Secondary filtration filter
(optional)
11. Turbocharger control module
12. Coolant drain plug (underneath
location)
13. Oil cooler
14. Oil filter
15. Turbo oil inlet tube (supply)
EGES-265-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.