SERVICE MANUAL

SERVICE MANUAL

INTERNATIONAL® DT 466, DT 570, HT 570

DIESEL ENGINE
SERVICE MANUAL

DIESEL ENGINE (S/N 2000001 AND ABOVE)

INTERNATIONAL® DT 466, DT 570, HT 570
FORM EGES-265-2

2004 MODEL YEAR AND ABOVE

FORM EGES-265-2

© 2009 Navistar. Inc.

Printed in the United States of America
 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
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Follow all warnings, cautions, and notes.
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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.

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 ENGINE SERVICE MANUAL 1

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. Procedures, specifications,
literature may be altered.
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
This Engine Service Manual provides a general
overhaul (removal, inspection, and installation). For
sequence of procedures for out-of-chassis engine
in-chassis service of parts and assemblies, the
overhaul (removal, inspection, and installation). For
sequence may vary.
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
NOTE: Photo illustrations identify specific parts or
areas in a photo illustration may not be exact.
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.
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)

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Follow all warnings, cautions, and notes.
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2 ENGINE SERVICE MANUAL

Service Diagnosis • Knowledge of the principles of operation for

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

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Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
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 ENGINE SERVICE MANUAL 3

Safety Information • Restrain long hair.

This manual provides general and specific Vehicle

maintenance procedures essential for reliable engine • Make sure the vehicle is in neutral, the parking
operation and your safety. Since many variations in brake is set, and the wheels are blocked before
procedures, tools, and service parts are involved, servicing engine.
advice for all possible safety conditions and hazards
cannot be stated. • Clear the area before starting the engine.

Read safety instructions before doing any service and Engine

test procedures for the engine or vehicle. See related • The engine should be operated or serviced only
application manuals for more information. by qualified individuals.
Disregard for Safety Instructions, Warnings, Cautions, • Provide necessary ventilation when operating
and Notes in this manual can lead to injury, death or engine in a closed area.
damage to the engine or vehicle.
• Keep combustible material away from engine
Safety Terminology exhaust system and exhaust manifolds.

Three terms are used to stress your safety and safe • Install all shields, guards, and access covers
operation of the engine: Warning, Caution, and Note before operating engine.

Warning: A warning describes actions necessary to • Do not run engine with unprotected air inlets or
prevent or eliminate conditions, hazards, and unsafe exhaust openings. If unavoidable for service
practices that can cause personal injury or death. reasons, put protective screens over all openings
before servicing engine.
Caution: A caution describes actions necessary
to prevent or eliminate conditions that can cause • Shut engine off and relieve all pressure in the
damage to the engine or vehicle. system before removing panels, housing covers,
and caps.
Note: A note describes actions necessary for correct,
efficient engine operation. • If an engine is not safe to operate, tag the engine
and ignition key.
Safety Instructions Fire Prevention
Work Area • Make sure charged fire extinguishers are in the
• Keep work area clean, dry, and organized. work area.

• Keep tools and parts off the floor. NOTE: Check the classification of each fire
extinguisher to ensure that the following fire types
• Make sure the work area is ventilated and well lit. can be extinguished.
• Make sure a First Aid Kit is available. 1. Type A — Wood, paper, textiles, and rubbish
Safety Equipment 2. Type B — Flammable liquids
• Use correct lifting devices. 3. Type C — Electrical equipment
• Use safety blocks and stands. Batteries
Protective Measures • Always disconnect the main negative battery
• Wear protective safety glasses and shoes. cable first.

• Wear correct hearing protection. • Always connect the main negative battery cable
last.
• Wear cotton work clothing.
• Avoid leaning over batteries.
• Wear sleeved heat protective gloves.
• 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.
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4 ENGINE SERVICE MANUAL

• Do not expose batteries to open flames or sparks. • Check for frayed power cords before using power
tools.
• Do not smoke in workplace.
Fluids Under Pressure
Compressed Air
• Use extreme caution when working on systems
• Use an OSHA approved blow gun rated at 207
under pressure.
kPa (30 psi).
• Follow approved procedures only.
• Limit shop air pressure to 207 kPa (30 psi).
Fuel
• Wear safety glasses or goggles.
• Do not over fill the fuel tank. Over fill creates a fire
• Wear hearing protection.
hazard.
• Use shielding to protect others in the work area.
• Do not smoke in the work area.
• Do not direct compressed air at body or clothing.
• Do not refuel the tank when the engine is running.
Tools
Removal of Tools, Parts, and Equipment
• Make sure all tools are in good condition.
• Reinstall all safety guards, shields, and covers
• Make sure all standard electrical tools are after servicing the engine.
grounded.
• 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.

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 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.
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6 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.
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 ENGINE SYSTEMS 7

Engine Identification Engine Serial Number Examples

Engine Serial Number 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
7 digit suffix – Engine serial number sequence
beginning with 2,000,000

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.

EGES-265-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
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8 ENGINE SYSTEMS

Engine Emission Label The Environmental Protection Agency (EPA) emission

label is on top of the valve cover. The engine label
A common emission label is issued for the
includes the following:
International® DT 466 and DT 570 diesel engines.
• 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
• Starter motor
Labels or identification plates include information
and specifications helpful to vehicle operators and
technicians.

Figure 3 Engine emission label (Example)

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 ENGINE SYSTEMS 9

Engine Description

Table 1 International® DT 466 and DT 570 Features and Specifications

Engine 4 stroke, in-line six cylinder diesel

Configuration Four valves per cylinder
Displacement 7.6 L (466 in3)
Displacement 9.3 L (570 in3)
Bore (sleeve diameter) 116.6 mm (4.59 in)
Stroke
DT 466 119 mm (4.68 in)
DT 570 146 mm (5.75 in)
Compression ratio
DT 466 16.5 : 1
DT 570 17.5 : 1
Aspiration VGT turbocharged and Charge Air Cooled (CAC)
Rated power @ rpm
DT 466* 210 bhp @ 2600 rpm
DT 570** 285 bhp @ 2200 rpm
Peak torque @ rpm
DT 466* 520 lbf•ft @ 1400 rpm
DT 570** 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)
671 kg (1,480 lbs)
DT 466
708 kg (1,560 lbs)
DT 570
Cooling system capacity (engine only) 12.8 L (13.5 qts US)
Lube system capacity (including filter) 28 L (30 qts US)
Lube system capacity (overhaul only, with 34 L (36 qts US)
filter)
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.

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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
Diamond Logic® engine brake
system
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 assembly uses a road draft tube to vent crankcase

pressure and an oil separator that returns oil to the
DT 466, DT 570, and HT 570 are in-line six cylinder
crankcase.
engines (medium range). Engine displacements are
7.6 liters (466 cubic inches) for the DT 466 and 9.3 The crankshaft (CKP) and camshaft (CMP) sensors
liters (570 cubic inches) for the DT 570, and HT 570. are used by the ECM and IDM to calculate rpm, fuel
The firing order of the cylinders is 1–5–3–6–2–4. timing, fuel quantity, and duration of fuel injection.
The cylinder head has four valves per cylinder for Two different kinds of pistons are used in the in-line
improved air flow. Each fuel Injector is centrally engines:
located between the four valves and directs fuel
• The DT 466 engine has one piece aluminum alloy
over the piston bowl for improved performance and
pistons.
reduced emissions. The overhead valve train includes
mechanical roller lifters, push rods, rocker arms, and • The DT 570 and HT 570 engines have two piece
dual valves that open using a valve bridge. articulated pistons with a steel crown.
A one piece crankcase withstands high-pressure All pistons are mated to fractured cap joint connecting
loads during diesel operation. rods. Replaceable wet cylinder sleeves are used with
the pistons.
The lower end of the DT 570 and HT 570 engines (for
ratings above 300 hp) includes a crankcase ladder A gerotor lube oil pump, mounted to the front cover, is
designed to absorb additional loads generated by driven directly by the crankshaft. All engines use an
increased horsepower. Seven main bearings support oil cooler and spin-on oil filter.
the crankshaft for DT 466, DT 570, and HT 570
A low-pressure fuel supply pump draws fuel from the
engines. Fore and aft thrust are controlled at the rear
fuel tank through a fuel filter assembly that includes
bearing. Four insert bushings support the camshaft
a strainer, filter element, primer pump, drain valves,
for each engine. The rear oil seal carrier is part of
the flywheel housing. The open crankcase breather

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 ENGINE SYSTEMS 11

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

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12 ENGINE SYSTEMS

Engine Component Locations

Figure 4 Component location – top

1. Exhaust Back Pressure (EBP) 3. Exhaust emission label (location) 6. Inlet and EGR mixer duct
sensor 4. EGR cooler assembly 7. EGR control valve
2. Valve cover 5. Breather assembly

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 ENGINE SYSTEMS 13

Figure 5 Component location – front

1. Exhaust gas crossover (EGR 4. Fan drive pulley 9. Camshaft Position (CMP) sensor
cooler to EGR valve) 5. Engine mounting bracket (front) 10. Auto tensioner assembly (belt)
2. Water outlet tube assembly 6. Vibration damper 11. ECT sensor (location)
(thermostat outlet) 7. Water inlet elbow 12. Flat idler pulley assembly
3. Front cover (front half) 8. Water pump pulley

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14 ENGINE SYSTEMS

Figure 6 Component location, electrical– left

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

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 ENGINE SYSTEMS 15

Figure 7 Component location, mechanical – left

1. Oil level gauge tube 7. Vent and drain tube assembly 13. Air compressor
2. High-pressure oil hose 8. Intake manifold 14. Oil supply line
3. Water drain valve (fuel) 9. Drain valve (fuel strainer) 15. Fuel primer pump assembly
4. Fuel filter header assembly 10. Coolant line 16. Low-pressure fuel supply pump
5. Breather assembly 11. Power steering pump 17. High-pressure oil pump
6. Lifting eye 12. Oil pan assembly assembly

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16 ENGINE SYSTEMS

Figure 8 Component location – right

1. EGR cooler return tube 7. Alternator bracket 13. Oil cooler
assembly 8. EGR cooler supply tube 14. Oil filter
2. Exhaust manifold assembly assembly 15. Turbo oil inlet tube (supply)
3. EGR cooler assembly 9. Crankcase
4. Variable Geometry Turbocharger 10. Secondary filtration filter
(VGT) (optional)
5. Engine lifting eye 11. Turbocharger control module
6. Water supply housing (Freon® 12. Coolant drain plug (underneath
compressor bracket) location)

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 ENGINE SYSTEMS 17

Figure 9 Component location – rear

1. Valve cover 4. Cylinder head assembly 9. Flywheel or flexplate assembly
2. Valve cover gasket with 5. Turbo oil inlet tube (supply)
pass-through connectors 6. Crankcase
3. EGR cooler return tube 7. Rear engine mount brackets (2)
assembly 8. Flywheel housing

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18 ENGINE SYSTEMS

Engine Systems
Engine System Diagram

Figure 10 Engine systems

The primary engine systems are Air Management and • The Lube Oil System provides lubrication and
Fuel Management which share some subsystems or heat transfer to engine components.
have a subsystem that contributes to their operation.
• The ICP system uses lube oil for hydraulic fluid to
• The Electronic Control system controls the Air actuate the fuel injectors.
Management System and Fuel Management
• The Fuel Supply System pressurizes fuel for
System.
transfer to the fuel injectors.
• The Coolant System provides heat transfer for
EGR gases and lubrication oil.

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 ENGINE SYSTEMS 19

Air Management System

Air Management Components and Air Flow

Figure 11 Air Management System (AMS)

1. Intake air 8. EGR valve 14. Exhaust gas crossover
2. Exhaust gas 9. Manifold Absolute Pressure 15. Variable Geometry Turbocharger
3. Air cleaner (MAP) sensor (VGT)
4. Charge Air Cooler (CAC) 10. Manifold Air Temperature (MAT) 16. Muffler
5. Inlet and EGR mixer duct sensor 17. Exhaust Back Pressure (EBP)
6. Inlet Air Heater (IAH) assembly 11. Cylinder head sensor
– single or dual element 12. Exhaust manifold
7. Intake manifold 13. EGR cooler

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20 ENGINE SYSTEMS

The Air Management system includes the • The VGT compressor wheel, on the same shaft
following: as the turbine wheel, compresses the mixture of
filtered air.
• Air filter assembly
The VGT responds directly to engine loads. During
• Chassis mounted Charged Air Cooler (CAC)
heavy load, an increased flow of exhaust gases turns
• Variable Geometry Turbocharger (VGT) the turbine wheel faster. This increased speed turns
the compressor impeller faster and supplies more air
• Inlet Air Heater (IAH) assembly – single or dual
or greater boost to the intake manifold. Conversely,
element
when engine load is light, the flow of exhaust gas
• Intake manifold decreases and less air is directed into the intake
manifold.
• Exhaust Gas Recirculation (EGR) system
• Exhaust system
Charge Air Cooler (CAC)
• Inlet and EGR mixer duct
• Diamond Logic® engine brake
• Catalytic converter– dependent on application
• Catalyzed Diesel Particulate Filter (CDPF) –
dependent on application

Air Flow
Air flows through the air filter assembly and enters
the Variable Geometry Turbocharger (VGT). The
compressor in the VGT increases the pressure,
temperature, and density of the intake air before
it enters the Charge Air Cooler (CAC). Cooled
compressed air flows from the CAC into the EGR
mixer duct.
• If the EGR control valve is open, exhaust gas will Figure 12 Charge Air Cooler (typical)
mix with filtered intake air and flow into the intake 1. Air outlet
manifold. 2. Charge Air Cooler (CAC)
• If the EGR control valve is closed, only filtered air 3. Air inlet
will flow into the intake manifold. 4. Radiator

After combustion, exhaust gas is forced through the

exhaust manifold to the EGR cooler and VGT. The CAC is mounted on top of the radiator. Air from
• Some exhaust gas is cooled in the EGR cooler the turbocharger passes through a network of heat
and flows through the EGR control valve to the exchanger tubes before entering the EGR mixer duct.
EGR mixer duct. When exhaust gas mixes with Outside air flowing over the tubes and fins cools the
filtered air, nitrogen oxide (NOx) emissions and charged air. Charged air is cooler and denser than
noise are reduced. the uncooled air; cooler and denser air improves
the fuel-to-air ratio during combustion, resulting in
• The rest of the exhaust gas flows to the VGT, spins improved emission control and power output.
and expands through the turbine wheel, varying
boost pressure.

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 ENGINE SYSTEMS 21

Variable Geometry Turbocharger (VGT)

Figure 13 Variable Geometry Turbocharger (VGT)

1. Turbine outlet 5. Turbine inlet 9. Electrical connector and wire
2. Oil supply port 6. Turbine housing 10. Turbocharger control module
3. Compressor outlet 7. Oil drain port 11. VGT linkage
4. Compressor housing 8. Compressor inlet

The Variable Geometry Turbocharger (VGT) has VGT Closed Loop System
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.

Figure 14 VGT closed loop system

The Variable Geometry Turbocharger (VGT) is a

closed loop system that uses the Exhaust Back
Pressure (EBP) sensor to provide feedback to the
ECM. The ECM uses the EBP sensor to continuously

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22 ENGINE SYSTEMS

monitor EBP and adjust the duty cycle to the VGT to The VGT actuator is a control module that contains
match engine requirements. a microchip and a DC motor. The VGT actuator
is located below the turbocharger. The microchip
VGT Control operates a DC motor which rotates a crank lever
controlling the vane position in the turbine housing.
The position of the vanes is based off the pulse-width
modulated signal sent from the ECM.
Actuated vanes are mounted around the inside
circumference of the turbine housing. A unison ring
links all the vanes. When the unison ring moves,
all vanes move to the same position. Unison ring
movement occurs when the crank lever in the control
module moves.
Exhaust gas flow can be regulated depending on
required exhaust back pressure for engine speed
and load. As demand for EBP increases, the ECM
increases the pulse-width modulation to the VGT
control module. When EBP demand decreases, the
ECM decreases the duty cycle to the control module.

Figure 15 VGT control

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 ENGINE SYSTEMS 23

Exhaust Gas Recirculation (EGR) System EGR Control Valve

The EGR system includes the following:

• EGR control valve
• EGR cooler
• Intake manifold
• Inlet and EGR mixer duct
• Exhaust manifold
• Exhaust gas crossover
The Exhaust Gas Recirculation (EGR) system
reduces Nitrogen Oxide (NOx) emissions.
NOX forms during a reaction between nitrogen and
oxygen at high temperature during combustion.
Combustion starts when fuel is injected into the
cylinder before or slightly after the piston reaches
top-dead-center.

EGR Flow
Some exhaust from the exhaust manifold flows into
the EGR cooler. Exhaust from the EGR cooler flows
through the exhaust gas crossover to the EGR valve.
When EGR is commanded, the EGR control valve
opens allowing cooled exhaust gases to enter the
EGR mixer duct to be mixed with filtered intake air.

Figure 16 EGR control valve

1. Connector
2. DC motor with position sensor
3. Valve assembly

The EGR valve uses a DC motor to control the position

of the valve assembly. The motor pushes directly
on the valve assembly. The valve assembly has two
valve heads on a common shaft.
The EGR actuator consists of three major
components, a valve, an actuator motor, and
Integrated Circuit (IC). The IC has three Hall effect
position sensors to monitor valve movement. The

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24 ENGINE SYSTEMS

EGR actuator is located at the front of the engine on

the intake manifold.

Figure 18 EGR control

Exhaust System

Figure 17 EGR closed loop operation with fault The exhaust system includes the following:
management • Exhaust valves
• Exhaust manifold
The EGR drive module controls the EGR actuator and • Diamond Logic® engine brake
is located on the left side of the engine on the ECM
and Injector Driver Module (IDM). • Variable Geometry Turbocharger (VGT)

The EGR drive module receives the desired EGR • Exhaust piping
actuator position from the ECM across the CAN • Muffler and catalytic converter – dependent on
2 datalink to activate the valve for exhaust gas application
recirculation. The EGR drive module provides
feedback to the ECM on the valve position. The • Catalyzed Diesel Particulate Filter (CDPF) –
EGR drive module interprets the ECM command dependent on application
and sends the command using three pulse-width The exhaust system removes exhaust gases from
modulated signals to the valve actuator. the engine. Exhaust gases exit from exhaust valves,
The system is closed loop control using the EGR through exhaust ports, and flow into the exhaust
position signals. manifold. Expanding exhaust gases are directed
through the exhaust manifold. The exhaust manifold
directs some exhaust gases into the Exhaust Gas
Recirculation (EGR) cooler. Exhaust gases flowing
into the turbocharger drive the turbine wheel. Exhaust
gases exit the turbocharger and flow into the exhaust
piping, through the muffler and catalytic converter
or CDPF, depending on application, and out the
discharge pipe to the atmosphere.

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 ENGINE SYSTEMS 25

Fuel Management System

Fuel Management Components

Figure 19 Fuel management system

The fuel management system includes the following: • Fuel injectors

• Injection Control Pressure (ICP) system • Lubrication system
• Fuel supply system • Electronic control system

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26 ENGINE SYSTEMS

Injection Control Pressure (ICP) System

Components and High-pressure Oil Flow

Figure 20 Injection Control Pressure (ICP) system

1. High-pressure oil manifold 3. High-pressure pump assembly 6. High-pressure oil inlet (injector)
assembly 4. High-pressure oil inlet (pump) 7. Oil exhaust port (2)
2. Fuel injector 5. High-pressure oil hose 8. Fuel inlet (4)

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 ENGINE SYSTEMS 27

High-pressure Oil Flow ICP System Control

The oil reservoir in the front cover provides a constant
supply of oil to a high-pressure oil pump mounted to
the backside of the front cover. Oil drawn from the oil
reservoir is constantly refilled by the engine lubrication
system.
The gear-driven, high-pressure oil pump delivers oil
through a high-pressure oil hose, through a cylinder
head passage into the high-pressure oil manifold
beneath the valve cover. The manifold distributes to
the top of each fuel injector.
When the OPEN coil for each injector is energized, the
injectors use high-pressure oil to inject and atomize
fuel in the combustion chambers. To end injection, the
CLOSE coils are energized. Exhaust oil exits through
two ports in the top of the fuel injectors, then drains
back to sump.

Injection Control Pressure (ICP) Closed Loop

System
Figure 22 ICP control

ICP Operation
The IPR solenoid receives a pulse width modulated
signal from the ECM that indicates the on and off time
the control valve is energized. The pulse is calibrated
to control ICP pressure in a range from 5 MPa (725
psi) up to 28 MPa (4,075 psi). Maximum pressure
relief occurs at about 32 MPa (4,600 psi).
The IPR valve is mounted in the body of the
high-pressure pump. The IPR valve maintains
the desired ICP by dumping excess oil back to the
crankcase sump.

Figure 21 ICP closed loop system As demand for ICP increases, the ECM increases the
pulse - width modulation to the IPR solenoid. When
ICP demand decreases, the ECM decreases the duty
The ICP is a closed loop system that uses the ICP cycle to the solenoid, allowing more oil to flow from the
sensor to provide feedback to the ECM. The ECM drain orifice.
uses the ICP sensor to continuously monitor injection The ECM sets Diagnostic Trouble Codes (DTCs), if
control pressure and adjust the duty cycle of the IPR the ICP electrical signal is out of range. DTCs are
valve to match engine requirements. also set if an ICP signal corresponds to an out of
range value for injection control pressure for a given
operating condition.
The ECM will ignore ICP signals that are out of range
and the IPR valve will operate from programmed
default values. This is called Open Loop operation.

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28 ENGINE SYSTEMS

The ICP sensor is installed under the valve cover,

forward of the No. 6 fuel injector in the high-pressure
oil rail.

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 ENGINE SYSTEMS 29

Fuel Injectors

Figure 23 Fuel injector assembly

1. Exhaust port (oil) 8. Needle 14. Fuel inlet check ball
2. Inlet port (oil) 9. Nozzle gasket 15. Fuel inlet (4)
3. Control valve body 10. Valve Opening Pressure (VOP) 16. Plunger
4. OPEN coil spring 17. Barrel
5. Intensifier piston spring 11. Lower O-ring 18. Intensifier piston
6. Upper O-ring 12. Reverse flow check 19. CLOSE coil
7. Nozzle assembly 13. Edge filter 20. Spool valve (control valve)

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30 ENGINE SYSTEMS

Fuel Injector Features Fill stage

Two 48 volt 20 amp coils control a spool valve
that directs oil flow in and out of the injector. The
injector coils are turned on for approximately 800
µs (microseconds or millionths of a second). Each
injector has a single four pin connector that couples
to the valve cover gasket assembly.

Injector Coils and spool valve

An OPEN coil and a CLOSE coil on the injector move
the spool valve from side to side using magnetic force.
The spool has two positions:
• When the spool valve is open, oil flows into the
injector from the high-pressure oil rail.
• When the spool valve is closed oil exhausts from
the top of the fuel injector and drains back to the
crankcase.

Intensifier piston and plunger

When the spool valve is open, high-pressure oil
enters the injector pushing down the intensifier piston
and plunger. Since the intensifier piston is 7.1 times
greater in surface area than the plunger, the injection
pressure is also 7.1 times greater than ICP pressure
on the plunger.

Plunger and barrel

Fuel pressure builds at the base of the plunger in the
barrel. When the intensifier piston pushes the plunger
down, the plunger increases fuel pressure in the barrel
7.1 times greater than ICP. The plunger has tungsten
carbide coating to resist scuffing.

Injector needle
The injector needle opens inward, off its seat when Figure 24 Fill stage
fuel pressure overcomes the Valve Opening Pressure
1. CLOSE coil (off)
(VOP) of 28 MPa (4,075 psi). Fuel is atomized at high
2. OPEN coil (off)
pressure through the nozzle tip.
3. Needle (seated)
4. Disk check (seated)
5. Fuel inlet (4)
Fuel Injector Operation
The injection operation has three stages:
During the fill stage both coils are de-energized and
• Fill stage
the spool valve is closed. High-pressure oil from the
• Main injection high-pressure oil rail is deadheaded at the spool valve.
• End of main injection Low-pressure fuel fills the four ports and enters
through the edge filter on its way to the chamber

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 ENGINE SYSTEMS 31

beneath the plunger. The needle control spring holds Main injection (Step 2)
the needle onto its seat to prevent fuel from entering
the combustion chamber.

Main injection (Step 1)

Figure 26 Main injection (Step 2)

1. CLOSE coil (off)
2. OPEN coil (off)
Figure 25 Main injection (Step 1) 3. Needle (unseated – VOP)
1. CLOSE coil (off) 4. Fuel inlet check ball (seated)
2. OPEN coil (on)
3. Needle (seated)
4. Fuel inlet check ball (seated) The pulse-width controlled current to the OPEN coil
is shut off, but the spool valve remains open. High
pressure oil from high pressure oil rail continues to
A pulse width current energizes the OPEN coil. flow past the spool valve. The intensifier piston and
Magnetic force moves the spool valve open. plunger continue to move and fuel pressure increases
High-pressure oil flows past the spool valve and in the barrel. When fuel pressure rises above the VOP
onto the top of the intensifier piston. Oil pressure - about 28 MPa (4,075 psi) - the needle lifts of its seat
overcomes the force of the intensifier piston spring and injection begins.
and the intensifier starts to move down. An increase
in fuel pressure under the plunger seats the fuel inlet
check ball, and fuel pressure starts to build on the
needle.

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32 ENGINE SYSTEMS

End of main injection (Step 1) End of main injection (Step 2)

Figure 27 End of main injection (Step 1) Figure 28 End of main injection (Step 2)
1. CLOSE coil (on)
1. CLOSE coil (off)
2. OPEN coil (off)
2. OPEN coil (off)
3. Needle (unseated / closing)
3. Needle (seated)
4. Check disk (seated)

The pulse width controlled current to close the coil

When the Injector Drive Module (IDM) determines is shut off, but the spool valve remains closed. The
that the correct injector on-time has been reached intensifier piston and plunger return to their initial
(the correct amount of fuel has been delivered), the positions. Oil above the intensifier piston flows past
IDM sends a pulse width controlled current to the the spool valve through the exhaust ports. Fuel
CLOSE coil of the injector. The current energizes pressure decreases until the needle control spring
the CLOSE coil and magnetic force closes the spool forces the needle back onto its seat.
valve. High-pressure oil is deadheaded against the
spool valve.

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 ENGINE SYSTEMS 33

Fuel Supply System

Fuel System Components and Fuel Flow

Figure 29 Fuel supply system

1. Cylinder head assembly 6. Primer pump assembly 11. Fuel filter assembly
2. Fuel injector 7. Water drain valve 12. Fuel line from tank
3. Low-pressure fuel rail 8. Drain valve (fuel) 13. Test fitting
4. Transfer pump outlet tube 9. Transfer pump inlet tube 14. Fuel inlet (4)
assembly assembly
5. Low-pressure fuel supply pump 10. Fuel filter access cap

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34 ENGINE SYSTEMS

Fuel Flow Schematic

Figure 30 Fuel flow

The fuel filter housing includes the following • Water separator

components:
• Water In Fuel (WIF) sensor
• 150 micron fuel strainer
• Water drain valve
• 300W fuel heating element (optional)
• Fuel pressure regulator
• Primer pump assembly
• Engine Fuel Pressure (EFP) sensor (optional)
• Fuel filtering element

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 ENGINE SYSTEMS 35

Fuel Flow

4
23
5

19 20 21 22 6

18
8
17
16 9

15 14 10

11

12

13

H11049

Figure 31 Fuel filter assembly

1. Housing cover assembly 8. Fuel filter housing 16. Self tapping screw (4)
2. M12 port fitting (factory fill) 9. M10 Plug assembly 17. Cartridge check valve
3. O-ring seal 10. Fuel strainer 18. Retainer ring
4. Fuel filter element 11. Bowl O-ring seal 19. Primer pump assembly
5. O-ring seal 12. Fuel bowl (with heater option) 20. Bolt, M8 x 20 (2)
6. Fuel pressure regulator 13. Drain valve 21. Primer pump seal
assembly 14. Fitting assembly, ⅜ tube 22. Water In Fuel (WIF) sensor
7. Plug or EFP sensor (optional) 15. Water drain valve assembly 23. Stand pipe

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36 ENGINE SYSTEMS

NOTE: Early fuel filter assemblies may have an M10 A built-in fuel regulator valve, calibrated to open at
Plug assembly (item 2) in the location of M12 port about 414 - 482 kPa (60 - 70 psi), regulates and
fitting (item 9). Item 2 is used by the assembly plants relieves excessive pressure. During idle and light
as a fuel fill. engine loads, when injector demand is low, most of
the fuel is cycled between the fuel filter housing and
• If item 2 is installed on housing cover assembly, it
low-pressure fuel pump. When engine demand
can be used to measure unfiltered fuel pressure.
increases, engine fuel consumption increases
• If item 2 is installed in item 9 location, it can be resulting in less fuel cycling. Under heavy loads
used to measure fuel inlet restriction. fuel flows through the filter with little or no cycling.
The low-pressure fuel supply pump draws fuel from Fuel is conditioned as it flows through a main filter and
the fuel tank through a 150 micron strainer in the fuel central post. The post prevents fuel from draining from
filter assembly. the fuel rail during servicing.
An optional electric heating element in the fuel filter An optional Engine Fuel Pressure (EFP) sensor
housing warms incoming fuel to prevent waxing. detects low pressure caused by high fuel filter
restriction and sends a signal to the ECM; the ECM
If water is in the fuel, the filter element repels water
illuminates the amber FUEL FILTER lamp on the
molecules, water collects at the bottom of the element
instrument panel.
cavity in the fuel filter housing, and a Water In Fuel
(WIF) sensor in the element cavity detects water Fuel flows from the fuel filter housing into the fuel rail,
in the fuel. When enough water accumulates in through the fuel rail into six drilled holes (one for each
the element cavity, the WIF sensor sends a signal injector) to each injector.
to the Electronic Control Module (ECM); the ECM
When the fuel injectors are activated, fuel flows (from
illuminates the amber WATER IN FUEL lamp on the
fuel rail) into four inlets in each injector.
instrument panel. A fuel drain valve handle on the
housing can be opened to drain contaminants (usually
water) from the fuel filter housing. Another drain valve
in the bottom of the housing drains strainer cavity.

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 ENGINE SYSTEMS 37

Engine Lubrication System

Lubrication System Components and Oil Flow

Figure 32 Lubrication system

1. Unfiltered oil 10. Variable Geometry Turbocharger 17. Crankshaft
2. Cooled unfiltered oil (VGT) 18. Piston cooling jet (6)
3. Filtered oil 11. Oil cooler 19. Main filtered oil gallery
4. Secondary filtration filter 12. Oil filter 20. Camshaft
(optional) 13. Oil cooler / filter header 21. Crankcase
5. Gerotor oil pump assembly 22. Vertical gallery
6. Front cover 14. Oil pressure regulator relief 23. Cylinder head
7. Reservoir for high-pressure oil valve 24. Valve cover
pump 15. Regulator relief valve drain to 25. Rocker arm assembly
8. Pick-up tube crankcase 26. Air compressor
9. Unfiltered oil gallery 16. Oil pan assembly

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38 ENGINE SYSTEMS

Oil Flow Diagram

Figure 33 Lubrication system

1. Sump 6. Regulator valve 10. Cam bearings
2. Oil pump 7. Variable Geometry Turbocharger 11. Main bearings
3. Secondary filtration filter (VGT) 12. Piston cooling tubes (6)
(optional) 8. Oil reservoir for high-pressure 13. Connecting rods
4. Oil cooler pump 14. Rocker arm shaft
5. Oil filter 9. To high-pressure oil system

The gerotor oil pump, driven by the engine crankshaft, outlet port in the front cover into the unfiltered oil
draws unfiltered oil from the oil pan through an oil gallery in the crankcase.
pick-up tube into the inlet port of the front cover.
The unfiltered oil gallery has one exit port to the
Unfiltered oil (under pressure) flows through the
header of the oil cooler. The oil is then internally

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 ENGINE SYSTEMS 39

diverted to the oil cooler plate stack or bypassed in Connecting rod bearings are fed through drilled
the oil cooler/filter module. passages in the crankshaft from main to rod journals,
receiving pressurized oil from the main bearings.
An oil temperature control valve, in the oil cooler/filter
header, senses inlet oil temperature. During engine Camshaft journals are fed through passages drilled
start-up, when the oil is cold the oil temperature vertically in the main bearing webs. Pressurized oil
control valve allows unfiltered oil to bypass the oil from the main gallery, through piston cooling jets,
cooler plate stack. When the unfiltered oil reaches lubricates and cools the pistons.
engine operating temperature, the oil temperature
Valve rocker arms are lubricated through an annulus
control valve routes unfiltered oil to the oil cooler. Oil
on the outside of the rear camshaft bushing. The oil
flows through both the oil cooler core and bypass
passes up and through the vertical gallery in the rear
gallery when the valve is partially open.
of the crankcase, through a passage in the cylinder
Unfiltered oil at full flow moves through plates in the head. Oil continues through rocker arm shaft pedestal
oil cooler. Engine coolant flows through the plates to and into the rocker arm shaft. Oil continues flowing
cool the surrounding oil. through drillings in the rocker arm shaft to the rocker
arms. The oil then drains to the oil pan through push
The cooled, unfiltered oil leaving the oil cooler stack
rod holes.
mixes with the uncooled, unfiltered oil (that bypassed
the oil cooler). The oil mixture flows through the oil Filtered oil from the main gallery flows up through a
filter (from element outside to element inside). The passage in the front of the crankcase and front cover
oil filter bypass valve in the header ensures full flow into the oil reservoir for the high-pressure oil pump.
of oil to the engine should the filter element become
The turbocharger receives filtered oil through an
plugged. Oil bypass occurs within the module when
external tube connected to the oil cooler header. Oil
differential filter pressure reaches 345 kPa (50 psi) .
drains back to the oil pan through a tube connected
Cooled, filtered oil flows to and past the oil pressure to the crankcase.
regulator valve, in the oil cooler module. The oil
The air compressor (if equipped) receives filtered oil
pressure regulator valve maintains correct operating
from the main oil gallery through an external tube
oil pressure.
connected to the left side of the crankcase. Oil drains
The pressure regulator valve opens at 379 kPa to the front cover and back to the oil pan.
(55 psi) and dumps excess oil into the crankcase.
The front gear train is splash lubricated with oil
The filtered oil continues to the main oil gallery for
draining from the high-pressure reservoir and the air
distribution throughout the engine.
compressor (if equipped).

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40 ENGINE SYSTEMS

Cooling System
Cooling System Components and Coolant Flow

Figure 34 Engine cooling system

1. Cylinder head assembly 8. EGR cooler 16. Water supply from front cover to
2. Water outlet tube assembly 9. Water outlet from crankcase to crankcase
(thermostat outlet) front cover 17. Water pump impeller assembly
3. Thermostat assembly 10. Crankcase 18. Front cover
4. Air compressor 11. Water inlet to crankcase 19. Water inlet elbow
5. Water return from cylinder head 12. EGR cooler supply tube
to crankcase 13. Oil system module assembly
6. Cylinder sleeve 14. Oil cooler tube
7. EGR coolant return tube 15. Water inlet to front cover and
assembly water pump

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 ENGINE SYSTEMS 41

Cooling System Flow rear of the cooler into the rear of the cylinder head. A
deaeration port is on top of the EGR cooler.
The cooling system keeps the engine within
a designated temperature range. The major
Thermostat Operation
components of the cooling system include the
following: The thermostat has two outlets. One directs coolant
to the radiator when the engine is at operating
• Radiator and fan combination (chassis
temperature. The other directs coolant to the water
components)
pump until the engine reaches operating temperature.
• Water pump assembly The thermostat begins to open at 88 °C (190 °F) and
is fully open at 96 °C (205 °F).
• Thermostat assembly
• Oil system module assembly
• EGR cooler assembly
A belt-driven, centrifugal water pump set into the front
cover has three passages. One passage channels
coolant from the water pump to the crankcase, the
second returns coolant to the water pump, and the
third (a bypass) channels coolant back to the water
pump when the thermostat is closed.
Incoming coolant flows from the bottom of the radiator
through a water inlet elbow to the front cover and water
pump. Coolant is pumped to the crankcase through a
passage in the front cover and crankcase.
Water jackets in the crankcase direct coolant from
front to rear, distributing coolant evenly to the lower
sections of the cylinder sleeves. Coolant flow is
directed tangent to each cylinder sleeve, causing a
swirling motion up to the cylinder head. The swirling
action improves heat absorption.
Coolant flows from the cylinder sleeve areas in three
ways:
• Coolant flows into the oil system module Figure 35 Thermostat closed
assembly through the right side of the crankcase,
passes through the oil system module, and 1. Coolant flow to heater port
returns through a tube to the front cover. 2. Coolant in from engine
3. Bypass to water pump
• Coolant is routed through hoses to and from the
air compressor on the left side of the crankcase.
• Coolant exits the crankcase at the upper end When engine coolant is below 88 °C (190 °F), the
of each cylinder sleeve bore, distributed evenly thermostat is closed, blocking flow to the radiator.
through metering holes in the cylinder head. Coolant is forced to flow through a bypass port back
Coolant then flows through the cylinder head to the water pump.
(back to front) to the thermostat.
The EGR cooler receives coolant from the front cover.
Coolant flows from the front of the cooler and exits the

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42 ENGINE SYSTEMS

When coolant temperature reaches the nominal

opening temperature at 88 °C (190 °F), the thermostat
opens allowing some coolant to flow to the radiator.
When coolant temperature exceeds 96 °C (205 °F),
the lower seat blocks the bypass port directing full
coolant flow to the radiator.

Figure 36 Thermostat open

1. Coolant out to radiator
2. Coolant flow to heater port
3. Coolant in from engine

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 ENGINE SYSTEMS 43

Electronic Control System

Electronic Control System Components

Figure 37 Electronic Control System

Operation and Function 1. Reference voltage (VREF)

The Electronic Control Module (ECM) monitors and The ECM supplies a 5 volt VREF signal to input sensors
controls engine performance to ensure maximum in the electronic control system. By comparing
performance and adherence to emissions standards. the 5 volt VREF signal sent to the sensors with their
The ECM has four primary functions: respective returned signals, the ECM determines
pressures, positions, and other variables important to
• Provides Reference Voltage (VREF)
engine and vehicle functions.
• Conditions input signals
The ECM supplies two independent circuits for VREF:
• Processes and stores control strategies
• VREF A supplies 5 volts to engine sensors
• Controls actuators
• VREF B supplies 5 volts to vehicle sensors

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44 ENGINE SYSTEMS

2. Signal conditioner RAM

The signal conditioner in the internal microprocessor RAM stores temporary information for current engine
converts analog signals to digital signals, squares up conditions. Temporary information in RAM is lost
sine wave signals, or amplifies low intensity signals to when the ignition key is turned to OFF or when ECM
a level that the ECM microprocessor can process. power is interrupted. RAM information includes the
following:
3. Microprocessor
• Engine temperature
The ECM microprocessor stores operating
• Engine rpm
instructions (control strategies) and value tables
(calibration parameters). The ECM compares stored • Accelerator pedal position
instructions and values with conditioned input values
to determine the correct operating strategy for all 4. Actuator control
engine operations.
The ECM controls the actuators by applying a low
Continuous calculations in the ECM occur at level signal (low side driver) or a high level signal (high
two different levels or speeds: Foreground and side driver). When switched on, both drivers complete
Background. a ground or power circuit to an actuator.
• Foreground calculations are much faster than Actuators are controlled in three ways, determined by
background calculations and are normally more the kind of actuator.
critical for engine operation. Engine speed control
• A duty cycle (percent time on/off)
is an example.
• A controlled pulse width
• Background calculations are normally variables
that change at a slower rates. Engine • Switched on or off
temperature is an example.
Diagnostic Trouble Codes (DTCs) are generated by
ECM Control of Engine Operation
the microprocessor, if inputs or conditions do not
comply with expected values. The ECM controls engine operation with the following:
Diagnostic strategies are also programmed into the • Variable Geometry Turbocharger (VGT) control
ECM. Some strategies monitor inputs continuously module
and command the necessary outputs to achieve the
• EGR control module and control valve
correct performance of the engine.
• Diamond Logic® engine brake
Microprocessor memory
• IPR valve
The ECM microprocessor includes Read Only
• Inlet Air Heater (IAH) assembly
Memory (ROM) and Random Access Memory (RAM).
Variable Geometry Turbocharger (VGT) control
ROM
module
ROM stores permanent information for calibration
The VGT control module controls vane position in
tables and operating strategies. Permanently stored
the turbine housing. Vane position is controlled by
information cannot be changed or lost by turning the
a switching voltage source in the ECM. The ground
ignition key OFF or when ECM power is interrupted.
circuit is supplied directly from the battery ground at
ROM includes the following:
all times.
• Vehicle configuration, modes of operation, and
The actuator control is set by a pulse width modulated
options
signal in response to engine speed, desired fuel
• Engine Family Rating Code (EFRC) quantity, boost or exhaust back pressure and altitude.
• Engine warning and protection modes

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 ENGINE SYSTEMS 45

Exhaust Gas Recirculation (EGR) Control Valve Injection Drive Module (IDM)
The EGR valve controls the flow of exhaust gases into
the inlet and EGR mixer duct.
The EGR drive module controls the EGR actuator.
The EGR drive module receives the desired EGR
actuator position from the ECM across the CAN
2 datalink to activate the valve for exhaust gas
recirculation. The EGR drive module provides
feedback to the ECM on the valve position.
The EGR drive module constantly monitors the EGR
actuator. When an EGR control error is detected, the
EGR drive module sends a message to the ECM and
a DTC is set.

Brake Shut-off Valve

The brake shut-off valve controls pressure in the oil
gallery of the high-pressure oil rail. When the engine
brake is activated, the ECM provides power to activate
the brake shut-off valve to allow oil from the injector
oil gallery to flow to the brake oil gallery. High oil
pressure activates the brake actuator pistons to open
the exhaust valves.

Injection Pressure Regulator (IPR) Figure 38 Injection Drive Module (IDM)

The IPR valve controls pressure in the Injection 1. Camshaft with peg
Control Pressure (ICP) system. The IPR valve is a 2. Camshaft Position (CMP) signal
variable position valve controlled by the ECM. This 3. Crankshaft position sensor timing disk
regulated pressure actuates the fuel injectors. The 4. Crankshaft Position (CKP) signal
valve position is controlled by switching the ground 5. Electronic Control Module (ECM)
circuit in the ECM. The voltage source is supplied by 6. Camshaft Position Output (CMPO) signal
the ignition switch. 7. Crankshaft Position Output (CKPO) signal
8. Controller Area Network (CAN 2) communication
Inlet Air Heater (IAH) 9. Injection Drive Module (IDM)
10. Fuel injectors
The IAH system warms the incoming air supply prior to
cranking to aid cold engine starting and reduce white
smoke during warm-up. The IDM has three functions:
The ECM is programmed to energize the IAH • Electronic distributor for injectors
elements through the IAH relays while monitoring
certain programmed conditions for engine coolant • Power source for injectors
temperature, engine oil temperature, and atmospheric • IDM and injector diagnostics
pressure.
Electronic Distributor for Injectors
The IDM distributes current to the injectors. The IDM
controls fueling to the engine by sending high voltage
pulses to the OPEN and CLOSE coils of the injector.
The IDM uses information from the ECM to determine
the timing and quantity of fuel for each injector.

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46 ENGINE SYSTEMS

The ECM uses CMP and CKP input signals to driver supplies a return circuit to the IDM for each
calculate engine speed and position. The ECM injector coil (open and close). The high side driver
conditions both input signals and supplies the IDM controls the power supply to the injector. During each
with CMP and CKP output signals. The IDM uses injection event, the low and high side drivers are
CMP and CKP output signals to determine the correct switched on and off for each coil.
sequence for injector firing.
IDM and injector diagnostics
The ECM sends information (fuel volume, EOT, and
ICP) through the CAN 2 link to the IDM; the IDM uses The IDM determines if an injector is drawing enough
this information to calculate the injection cycle. current. The IDM sends a fault to the ECM, indicating
potential problems in the wiring harness or injector,
Injector power source and the ECM will set a DTC. The IDM also does
self-diagnostic checks and sets a DTC to indicate
The IDM creates a constant 48 volt (DC) supply to
failure of the IDM.
all injectors by making and breaking a 12 volt source
across a coil in the IDM. The 48 volts created by the On demand tests can be done using the Electronic
collapsed field is stored in capacitors until used by the Service Tool (EST). The EST sends a request to the
injectors. ECM and the ECM sends a request to the IDM to do
a test. Some tests generate a DTC when a problem
The IDM controls when the injector is turned on and
exists. Other tests require the technician to evaluate
how long the injector is active. The IDM first energizes
parameters, if a problem exists.
the OPEN coil, then the CLOSE coil. The low side

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 ENGINE SYSTEMS 47

Engine and Vehicle Sensors

Figure 39 Engine and vehicle sensors

1. Electronic Control Module 9. Vehicle Speed Sensor (VSS) 15. Manifold Absolute Pressure
(ECM) 10. Barometric Absolute Pressure (MAP)
2. Engine Oil Temperature (EOT) (BAP) 16. Brake Control Pressure (BCP)
3. Engine Coolant Temperature 11. Accelerator Position Sensor 17. Engine Oil Pressure (EOP)
(ECT) (APS) 18. Engine Fuel Pressure (EFP)
4. Manifold Air Temperature (MAT) 12. Exhaust Gas Recirculation valve sensor
5. Intake Air Temperature (IAT) Position (EGRP) 19. Injection Control Pressure (ICP)
6. Water In Fuel (WIF) sensor 13. Engine Coolant Level (ECL) 20. Exhaust Back Pressure (EBP)
7. Crankshaft Position (CKP) 14. Driveline Disengagement Switch
8. Camshaft Position (CMP) (DDS)

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48 ENGINE SYSTEMS

supply housing (Freon® compressor bracket), left of

the flat idler pulley assembly.

Engine Oil Temperature (EOT)

The ECM monitors the EOT signal to control fuel
quantity and timing when operating the engine. The
EOT signal allows the ECM and IDM to compensate
for differences in oil viscosity for temperature
changes. This ensures that power and torque are
available for all operating conditions. The EOT sensor
is installed in the rear of the front cover, outboard of
the high-pressure oil pump assembly.

Intake Air Temperature (IAT)

Figure 40 Thermistor
The ECM monitors the IAT signal to control timing and
1. Temperature sensor fuel rate during cold starts. The IAT sensor is chassis
2. Electronic Control Module (ECM) mounted on the air filter housing.
3. Microprocessor
4. Voltage Reference (Vref) Manifold Air Temperature (MAT)
5. Ground
The ECM monitors the MAT signal for EGR operation.
The MAT sensor is installed right of the MAP sensor
Thermistors in the intake manifold.

• ECT
• EOT
• IAT
• MAT
A thermistor sensor changes its electrical resistance
with changes in temperature. Resistance in the
thermistor decreases as temperature increases, and
increases as temperature decreases. Thermistors
work with a resistor that limits current in the ECM to
form a voltage signal matched with a temperature
value.
The top half of the voltage divider is the current limiting
resistor inside the ECM. A thermistor sensor has two Figure 41 Variable capacitance sensor
electrical connectors, signal return and ground. The 1. Pressure sensor
output of a thermistor sensor is a nonlinear analog 2. Electronic Control Module (ECM)
signal. 3. Ground
4. Microprocessor
Engine Coolant Temperature (ECT) 5. Voltage reference (VREF)
The ECM monitors the ECT signal and uses this
information for the instrument panel temperature Variable Capacitance Sensors
gauge, coolant compensation, Engine Warning
Protection System (EWPS), and intake heater • BAP
operation. The ECT is a backup, if the EOT is • EBP
out of range. The ECT sensor is installed in the water
• EFP

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 ENGINE SYSTEMS 49

• EOP and EWPS. The EOP sensor is installed in the left

side of the crankcase below and left of the fuel filter
• MAP
housing.
Variable capacitance sensors measure pressure. The
pressure measured is applied to a ceramic material. Manifold Absolute Pressure (MAP)
The pressure forces the ceramic material closer to a
The ECM monitors the MAP signal to determine intake
thin metal disk. This action changes the capacitance
manifold pressure (boost). This information is used
of the sensor.
to control fuel rate and injection timing. The MAP
The sensor is connected to the ECM by three wires: sensor is installed left of the MAT sensor in the intake
manifold.
• VREF
• Signal return
• Signal ground
The sensor receives the VREF and returns an analog
signal voltage to the ECM. The ECM compares the
voltage with pre-programmed values to determine
pressure.
The operational range of a variable capacitance
sensor is linked to the thickness of the ceramic disk.
The thicker the ceramic disk the more pressure the
sensor can measure.

Barometric Absolute Pressure (BAP)

The ECM monitors the BAP signal to determine Figure 42 Micro Strain Gauge sensor
altitude, adjust timing, fuel quantity, and inlet air 1. Pressure sensor
heater operation. The BAP sensor is located in the 2. Electronic Control Module (ECM)
cab. 3. Ground
4. Microprocessor
Exhaust Back Pressure (EBP) 5. Voltage reference (VREF)
The EBP sensor measures exhaust back pressure
so that the ECM can control the VGT and EGR
Micro Strain Gauge (MSG) Sensors
systems. The sensor provides feedback to the ECM
for closed loop control of the Variable Geometry • BCP
Turbocharger (VGT). The EBP sensor is installed
• ICP
in a bracket mounted on the water supply housing
(Freon® compressor bracket). A Micro Strain Gauge (MSG) sensor measures
pressure. Pressure to be measured exerts force on
Engine Fuel Pressure (EFP) a pressure vessel that stretches and compresses
to change resistance of strain gauges bonded to
The ECM uses the EFP sensor signal to monitor
the surface of the pressure vessel. Internal sensor
engine fuel pressure and give an indication when
electronics convert the changes in resistance to a
the fuel filter needs to be changed. The EFP sensor
ratiometric voltage output.
is installed in the rear of the fuel filter assembly
(crankcase side). The sensor is connected to the ECM by three wires:
• VREF
Engine Oil Pressure (EOP)
• Signal return
The ECM monitors the EOP signal, and uses this
information for the instrument panel pressure gauge • Signal ground

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50 ENGINE SYSTEMS

The sensor receives the VREF and returns an analog

signal voltage to the ECM. The ECM compares the
voltage with pre-programmed values to determine
pressure.

Brake Control Pressure (BCP)

The ECM monitors the BCP signal to determine the oil
pressure in the brake gallery of the high-pressure oil
rail. The BCP sensor is under the valve cover, forward
of the No. 2 fuel injector in the high-pressure oil rail.

Injection Control Pressure (ICP)

The ECM monitors the ICP signal to determine the
injection control pressure for engine operation. The
ICP signal is used to control the IPR valve. The ICP
sensor provides feedback to the ECM for Closed Loop
ICP control. The ICP sensor is under the valve cover,
forward of the No. 6 fuel injector in the high-pressure
oil rail.

Figure 43 Magnetic pickups

1. Crankshaft Position (CKP) signal
2. Crankshaft position sensor timing disk
3. Crankshaft Position (CKP) sensor
4. Camshaft position (CMP) signal
5. Camshaft with peg
6. Camshaft position (CMP) sensor
7. Vehicle speed signal
8. Electronic Control Module (ECM)
9. Vehicle Speed Sensor (VSS)

Magnetic pickup sensors

• CKP
• CMP
• VSS
A magnetic pickup sensor generates an alternating
frequency that indicates speed. Magnetic pickups
have a two wire connection for signal and ground.
This sensor has a permanent magnetic core
surrounded by a wire coil. The signal frequency
is generated by the rotation of gear teeth that disturb
the magnetic field.

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 ENGINE SYSTEMS 51

Crankshaft Position (CKP) sensor

The CKP sensor provides the ECM with a signal
that indicates crankshaft speed and position. As the
crankshaft turns the CKP sensor detects a 60 tooth
timing disk on the crankshaft. Teeth 59 and 60 are
missing. By comparing the CKP signal with the CMP
signal, the ECM calculates engine rpm and timing
requirements. The CKP is installed in the top left side
of the flywheel housing.
NOTE: This long CKP sensor, used with
International® DT 466, DT 570, and HT 570
diesel engines, is the Camshaft Position (CMP)
sensor used with other International® diesel engines.

Camshaft Position (CMP)

The CMP sensor provides the ECM with a signal that
indicates camshaft position. As the cam rotates, the
sensor identifies the position of the cam by locating
a peg on the cam. The CMP is installed in the front
Figure 44 Potentiometer
cover, above and to the right of the water pump pulley.
1. Ground
NOTE: This short CMP sensor, used with
2. Electronic Control Module (ECM)
International® DT 466, DT 570, and HT 570 diesel
3. Microprocessor
engines, is the Crankshaft Position (CKP) sensor
4. Voltage reference (VREF)
used with other International® diesel engines.
5. Accelerator Position Sensor (APS)

Vehicle Speed Sensor (VSS)

The VSS provides the ECM with transmission tail shaft Potentiometers
speed by sensing the rotation of a 16 tooth gear on
• APS
the rear of the transmission. The detected sine wave
signal (AC), received by the ECM, is used with tire size A potentiometer is a variable voltage divider that
and axle ratio to calculate vehicle speed. The VSS is senses the position of a mechanical component.
on left side of the transmission. A reference voltage is applied to one end of the
potentiometer. Mechanical rotary or linear motion
moves the wiper along the resistance material,
changing voltage at each point along the resistive
material. Voltage is proportional to the amount of
mechanical movement.

Accelerator Position Sensor (APS)

The APS provides the ECM with a feedback signal
(linear analog voltage) that indicates the operator’s
demand for power. The APS is mounted in the
accelerator pedal. A remote accelerator or throttle
device can be used in addition to the accelerator
pedal.

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52 ENGINE SYSTEMS

switch grounds the circuit when closed, causing a

zero voltage signal. Grounding switches are usually
installed in series with a current limiting resistor.

Driveline Disengagement Switch (DDS)

The DDS determines if a vehicle is in gear. For
manual transmissions, the clutch switch serves as
the DDS. For automatic transmissions, the neutral
indicator switch functions as the DDS.

Engine Coolant Level (ECL)

ECL is part of the Engine Warning Protection System
(EWPS). The ECL switch is used in plastic deaeration
Figure 45 Switch tank. When a magnetic switch is open, the tank is full.
1. Accelerator pedal If engine coolant is low, the red ENGINE lamp on the
2. Idle Validation Switch (IVS) instrument panel is illuminated.
3. Voltage source with current limiting resistor
4. Microprocessor Idle Validation Switch (IVS)
5. ECM
The IVS is a redundant switch that provides the ECM
6. Ground
with a signal that verifies when the APS is in the idle
position.
Switches
Water In Fuel (WIF)
• DDS
A Water In Fuel (WIF) sensor detects water in the
• ECL fuel. When enough water accumulates at the bottom
of the housing, the WIF sensor sends a signal to
• IVS
the Electronic Control Module (ECM); the ECM sets
• WIF a Diagnostic Trouble Code (DTC) and illuminates
the amber WATER IN FUEL lamp on the instrument
Switch sensors indicate position. They operate open
panel. The WIF is installed in the base of the fuel filter
or closed, allowing or preventing the flow of current.
housing.
A switch sensor can be a voltage input switch or a
grounding switch. A voltage input switch supplies the
ECM with a voltage when it is closed. A grounding

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 ENGINE SYSTEMS 53

Diamond Logic® Engine Brake

System
The Diamond Logic® engine brake system is available
for all engine displacements.

Engine Brake Components

Figure 46 Diamond Logic® engine brake – system

1. ECM 5. Brake shutoff valve assembly 8. Variable Geometry Turbocharger
2. Brake pressure relief valve 6. Injection Control Pressure (ICP) (VGT)
3. High-pressure oil rail sensor 9. Turbocharger control module
4. Brake Control Pressure (BCP) 7. Front of engine
sensor

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54 ENGINE SYSTEMS

The Diamond Logic® engine brake, a compression • At the top of the compression stroke energy
release brake system, provides the following: dissipates, pressure to force the piston down is
eliminated, and energy is absorbed by the vehicle
• Significant noise reduction
drive pulling the piston down.
• Improved engine braking
• High durability Engine Brake Control
• Compatibility with cruise control system
• Lower operating cost and longer service life for
brake shoes
The Diamond Logic® engine brake is available for
all engine displacements. The operator can select
one of three brake settings, depending on terrain and
driving conditions. See vehicle Operator’s Manual for
complete operating instructions.

Engine Brake Concept

The engine brake system retards vehicle speed
during deceleration or braking. During deceleration
and braking, the vehicle wheels drive the engine; the
engine acts as an energy absorber.

Engine Brake Operation Figure 47 High-pressure oil rail

To absorb energy, the Diamond Logic® engine brake 1. High-pressure oil rail
combines bleeding off compressed intake air, VGT 2. ICP sensor
controlling exhaust back pressure, and vehicle driven 3. Brake shutoff valve assembly
piston movement. 4. BCP sensor
5. Brake pressure relief valve
• Energy is absorbed during the compression
6. Front of engine
stroke, when intake air is compressed and forced
through a slightly open exhaust valve, providing
compressed air flow to the VGT.
The high-pressure oil rail uses high-pressure oil from
• VGT turbine vanes create the desired energy the injection control pressure system to open exhaust
absorbing, back pressure and intake boost. valves.

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 ENGINE SYSTEMS 55

Figure 48 Brake shutoff valve and brake actuator– OFF

1. High-pressure oil rail 4. Brake shutoff valve assembly 7. Valve lash (actuator retracted)
2. Injector oil gallery 5. Brake actuator piston assembly 8. Oil inlet
3. Brake oil gallery 6. Exhaust valve bridge

During normal engine operation, oil in the rail, is closed to prevent oil from entering the brake
high-pressure rail goes to the fuel injectors only. A gallery.
brake shutoff valve, mounted in the high-pressure oil

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56 ENGINE SYSTEMS

Operation of Diamond Logic® Engine Brake in

Braking Mode

Figure 49 Brake shutoff valve and brake actuator– ON

1. High-pressure oil rail 4. Brake shutoff valve assembly 8. Normal oil seepage
2. High-pressure oil flow to brake 5. Brake actuator piston assembly 9. Oil inlet
oil gallery 6. Exhaust valve bridge
3. Brake oil gallery 7. Valve lash (actuator deployed)

The ECM monitors the following criteria to make sure If On is selected, and the above criteria is met, the
certain conditions are met. engine brake will activate.
• ABS (inactive) When the engine brake is activated, the ECM provides
the power to activate the brake shutoff valve to allow
• RPM (greater than 1200)
oil from the injector oil gallery to flow to the brake oil
• APS (less than 5%) gallery. High oil pressure activates the brake actuator
pistons to open the exhaust valves.
• Idle validation
During an ABS event, the engine brake is deactivated.
• EOT (greater than or equal to 60 °C [140 °C])
The engine brake is activated once the ABS event is
• Operator input switches (On/Off) (power selection over.
– Low, Med, High)

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 ENGINE SYSTEMS 57

The ECM removes the ground source from the

brake shutoff valve to deactivate the engine brake.
Residual brake gallery pressure initially bleeds from
the actuator bore. When brake gallery pressure
reaches 1000 psi, the brake pressure relief valve
opens, and oil drains back to sump.

Figure 50 Brake pressure relief valve in

high-pressure oil rail
1. Front of engine
2. Brake pressure relief valve

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58 ENGINE SYSTEMS

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 MOUNTING ENGINE ON ENGINE STAND 59

Table of Contents

Engine Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Cleaning the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Draining Engine Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Component Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Turbocharger Oil Inlet Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Oil System Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Mounting Adapter Plate and Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Adapter Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

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60 MOUNTING ENGINE ON ENGINE STAND

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 MOUNTING ENGINE ON ENGINE STAND 61

Engine Preparation 1. Cap all openings to prevent water and degreased

agents from entering any engine components
Cleaning the Engine
internally.
2. Cover any exposed electrical pin connectors and
ECM, IDM, and EGR modules using plastic and
GOVERNMENT REGULATION: Engine duct tape.
fluids (oil, fuel, and coolant) may be a hazard
3. Use an appropriate detergent mixed in the correct
to human health and the environment.
ratio of water and apply to engine using a
Handle all fluids and other contaminated
hot water pressure washer or similar cleaning
materials (e.g. filters, rags) in accordance
equipment.
with applicable regulations. Recycle
or dispose of engine fluids, filters, and
other contaminated materials according to
Draining Engine Fluids
applicable regulations.

WARNING: To prevent personal injury or

death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or

death, shift transmission to park or neutral, set
parking brake, and block wheels before doing
diagnostic or service procedures.

WARNING: To prevent personal injury or

death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).
Figure 51 Coolant drain plug location
WARNING: To prevent personal injury or
death, disconnect ground (-) cable from battery
before doing service or diagnostic procedures. 1. Place a coolant drain pan beneath the coolant
drain plug. Remove coolant drain plug (M18) and
WARNING: To prevent personal injury or O-ring from the bottom of the oil system module.
death, allow engine to cool before working with Discard O-ring. Open radiator cap to allow system
components. to drain quicker.
2. After draining coolant, install new O-ring on plug
WARNING: To prevent personal injury or and install in module. Torque plug to the standard
death, do not let engine fluids stay on your skin. torque value (General Torque Guidelines, page
Clean skin and nails using hand cleaner and wash 445). Dispose of used coolant according to
with soap and water. Wash or discard clothing applicable laws
and rags contaminated with engine fluids.

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62 MOUNTING ENGINE ON ENGINE STAND

Turbocharger

WARNING: To prevent personal injury or

death, inspect turbocharger with engine off,
and turbocharger not spinning. Turbocharger
components may be extremely hot. Turbocharger
wheels are very sharp and spin at high speeds.

WARNING: To prevent personal injury or

death, support turbocharger assembly during
removal and installation.

Figure 52 Draining the oil

3. Place a oil drain pan beneath the oil drain plug to

collect the oil.
4. Remove oil pan drain plug (M25) and O-ring.
Drain engine oil and dispose of used engine oil
according to applicable laws.
5. Discard O-ring, inspect drain plug and replace if
necessary. Place a new O-ring onto drain plug
and install to oil pan. See special torque value
(Table 3).
Figure 53 Turbocharger mounting nuts
1. Nut, M10 (4)

Component Removal
NOTE: To aid in the disassembly of the turbocharger,
Turbocharger Oil Inlet Tube
loosen four nuts (M10) between 1/8 and 1/4 of a
1. Loosen turbocharger oil inlet tube assembly nut turn then tap each nut using a socket or flat punch
from fitting on top of oil filter header. and hammer. This will knock the “peaks” of the stud
threads off the “ramps” of the special Spiralock® nuts,
2. Remove two mounting bolts (M8 x 20) securing
thus allowing the nuts to unthread with considerable
the turbocharger and oil inlet tube assembly to the
ease.
top of the turbocharger central housing. Remove
turbocharger oil inlet tube assembly. Discard NOTE: Remove turbocharger and oil drain tube as an
flange O-ring. assembly. The oil drain tube is trapped between the
turbocharger and crankcase.
3. Remove turbocharger oil drain tube bracket and
bolt (M8 x 16) at crankcase. 1. Remove four nuts (M10 flange head) securing
turbocharger assembly to exhaust manifold
flange.

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 MOUNTING ENGINE ON ENGINE STAND 63

2. Remove turbocharger assembly, oil drain tube, Mounting Adapter Plate and Engine
and turbo mounting O-ring from engine. Discard
Adapter Plate
oil drain tube O-rings.
3. Cap all openings on turbocharger assembly.
WARNING: To prevent personal injury or
NOTE: If plastic caps are not available, use duct tape death, use a chain hoist rated for the weight of
to cover openings. the engine, follow manufacturer’s installation and
safety instructions, and attach safety latch lifting
Oil Filter
hooks to lifting eyes on the engine.

WARNING: To prevent serious personal

injury, possible death or damage to the engine or
vehicle, use only metric grade 10.9 or SAE grade
8 bolts when mounting adapter plate to engine
as well as the engine stand. See instructional
literature included with adapter plate for specific
directions of its safe use.
1. Match Engine Mounting Plate (Table 4) with bolt
holes on right side of engine to determine adapter
plate orientation to the Engine Stand (Table 4).

Figure 54 Removing the oil filter

1. Oil filter header
2. Oil cooler
3. Oil filter (spin-on)
4. Oil filter gasket

Remove oil filter from oil cooler filter header. Discard

oil filter.
Figure 55 Installing the adapter plate to engine
stand
Oil System Module
1. Remove one bolt (M8 x 16) securing oil cooling 2. Install recommended Engine Mounting Plate
drain tube assembly to crankcase. (Table 4) to engine stand and secure by using
2. Remove eight bolts (M8 x 30) securing oil system eight (grade 8) bolts and nuts. Tighten bolts
module to crankcase. to the standard torque value (General Torque
Guidelines, page445).
3. Remove oil system module and oil cooler drain
tube as an assembly from crankcase and discard
O-rings. The oil cooler drain tube is trapped
between the oil system module and the front
cover.

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64 MOUNTING ENGINE ON ENGINE STAND

Engine
1. Remove oil system module and oil cooler drain
tube as an assembly from crankcase and discard
O-rings. The oil cooler drain tube is trapped
between the oil system module and the front
cover.
2. Raise or lower engine to approximate height of
Engine Stand (Table 4).
3. Align engine stand and Engine Mounting Plate
(Table 4) to engine, rotating stand and / or raising
engine to match adapter plate. Secure one bolt
and rotate stand if necessary to thread remaining
bolts.
4. Use metric grade 10.9 bolts to secure engine to
Engine Mounting Plate (Table 4). Tighten bolts
to the standard torque value (General Torque
Figure 56 Torquing engine mounting bolts
Guidelines, page445).

5. Slowly release tension from engine hoist.

6. remove hoist safety chain hooks from engine
lifting eyes.

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 MOUNTING ENGINE ON ENGINE STAND 65

Special Torque

Table 3 Engine Mounting Special Torques

Oil pan drain plug (M25) 68 N·m (50 lbf·ft)

Special Service Tools

Table 4 Special Tools

Engine Mounting Plate ZTSE4649
Engine Stand OTC1750A

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66 MOUNTING ENGINE ON ENGINE STAND

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 EVRT® ELECTRONICALLY CONTROLLED TURBOCHARGER 67

Table of Contents

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Variable Geometry Turbocharger (VGT) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Turbocharger and Related Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Checking Turbine and Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Checking Rotation of Actuator Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Variable Geometry Turbocharger (VGT) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

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68 EVRT® ELECTRONICALLY CONTROLLED TURBOCHARGER

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 EVRT® ELECTRONICALLY CONTROLLED TURBOCHARGER 69

Description • Installation of Turbocharger Actuator Linkage

(1171908R1 Turbocharger VGT Linkage Kit,
For the procedures in this manual, the term Variable page 499). This service kit provides instructions
Geometry Turbocharger (VGT) will be used. See for replacement of the turbocharger actuator
(Variable Geometry Turbocharger (VGT), page 21) linkage without removal of the turbocharger from
for complete description of the EVRT® electronically the engine.
controlled turbocharger.
• Installation of Turbocharger Actuator Flange and
This “EVRT® Electronically Controlled Turbocharger” Pivot Shaft (1171915R2 Turbocharger Actuator
section is for basic removal, exterior inspection Flange and Pivot Shaft Kit, page 508). This
and cleaning, and installation of the complete VGT service kit provides instructions for replacement
assembly. See additional specific procedures in of internal turbocharger actuator flange and pivot
Appendix E for the following VGT components: shaft. These procedures require removal of the
turbocharger actuator, turbocharger actuator linkage, turbocharger from the engine.
turbocharger actuator flange and pivot shaft, and
turbine vane assembly • Cleaning Turbine Vane Assembly (1171913R1
Turbine Vane Assembly Cleaning Kit, page
Instruction Sheets in Appendix E 503). This service kit provides instructions for
• Installation of Turbocharger Actuator (1171855R1 cleaning the turbine vane area inside the housing
Turbo Actuator Service Kit (SRA), page497). This when vanes become stuck due to excessive oil
service kit provides instructions for replacement of deposits. These procedures require removal of
the turbocharger actuator without removal of the the turbocharger from the engine.
turbocharger from the engine.

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70 EVRT® ELECTRONICALLY CONTROLLED TURBOCHARGER

Figure 57 Variable Geometry Turbocharger (VGT) components

1. Turbine outlet 5. Turbine inlet 9. Electrical connector and wire
2. Oil supply port 6. Turbine housing 10. Turbocharger control module
3. Compressor outlet 7. Oil drain port 11. VGT linkage
4. Compressor housing 8. Compressor inlet

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 EVRT® ELECTRONICALLY CONTROLLED TURBOCHARGER 71

Removal
Variable Geometry Turbocharger (VGT) Assembly

GOVERNMENT REGULATION: Engine

fluids (oil, fuel, and coolant) may be a hazard
to human health and the environment.
Handle all fluids and other contaminated
materials (e.g. filters, rags) in accordance
with applicable regulations. Recycle
or dispose of engine fluids, filters, and
other contaminated materials according to
applicable regulations.
Figure 58 Oil inlet tube assembly
1. Nut
WARNING: To prevent personal injury or 2. Bolt, M8 x 20 (2)
death, read all safety instructions in the “Safety
Information” section of this manual.
1. Remove turbo oil inlet tube assembly nut from
fitting on top of oil filter header.
WARNING: To prevent personal injury or
death, shift transmission to park or neutral, set 2. Remove two M8 x 20 bolts from turbo oil inlet tube
parking brake, and block wheels before doing assembly. Remove tube assembly, and discard
diagnostic or service procedures. O-ring.

WARNING: To prevent personal injury or

death, allow engine to cool before working with
components.

WARNING: To prevent personal injury or

death, disconnect ground (-) cable from battery
before doing service or diagnostic procedures.

WARNING: To prevent personal injury or

death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).

WARNING: To prevent personal injury or

death, support turbocharger assembly during
removal and installation. Figure 59 Oil drain tube bracket and bolt

WARNING: To prevent personal injury or

death, do not let engine fluids stay on your skin. 3. Remove the M8 x 16 bolt from the turbo oil drain
Clean skin and nails using hand cleaner and wash tube bracket.
with soap and water. Wash or discard clothing 4. Disconnect electrical harness from VGT actuator.
and rags contaminated with engine fluids.

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72 EVRT® ELECTRONICALLY CONTROLLED TURBOCHARGER

6. Support the VGT assembly, remove the fourth

M10 nut, and remove the VGT assembly and
turbocharger oil drain tube as a combined unit.
7. Remove the oil drain tube from VGT assembly
and discard the oil drain tube O-rings.
8. Remove and discard the turbocharger mounting
gasket.
9. Discard used M10 Spiralock® nuts.

Cleaning
Turbocharger and Related Parts
Figure 60 VGT mounting
1. M10 Spiralock® nut (4) WARNING: To prevent personal injury or
death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).
NOTE: To aid removal of the turbocharger, loosen four
M10 nuts 1/4 turn then tap each nut using a socket or 1. Use soap and water to clean piping between
flat punch and a hammer. This will knock the “peaks” VGT and air cleaner assembly. Use filtered
of the threads down, allowing the nuts to unthread compressed air to dry piping.
easily. 2. Use filtered compressed air to clean the air inlet
piping and connecting hoses.
WARNING: To prevent personal injury or
3. Use a suitable solvent and a nylon brush to clean
death, support turbocharger assembly during
the oil inlet tube and oil drain tube. Use filtered
removal and installation.
compressed air to dry the tubes. Replace any
5. Remove three of four M10 Spiralock® nuts damaged tubes.
holding the VGT assembly to the exhaust
4. Clean remaining gasket material from mounting
manifold.
surface of the turbine housing and exhaust
manifold.

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 EVRT® ELECTRONICALLY CONTROLLED TURBOCHARGER 73

Inspection Installation
Checking Turbine and Compressor Variable Geometry Turbocharger (VGT) Assembly

WARNING: To prevent personal injury or 1. Position VGT on a workbench so the oil supply
death, inspect turbocharger with engine off, port faces up.
and turbocharger not spinning. Turbocharger
2. Prelube the VGT assembly by adding oil to the
components may be extremely hot. Turbocharger
oil supply port while rotating the turbine shaft.
wheels are very sharp and spin at high speeds.
Continue to add oil until oil comes out the oil drain
1. Position VGT on a workbench so that the shaft is port.
horizontal.
3. Place a new turbocharger mounting gasket onto
turbocharger flange studs.
4. Place a new O-ring onto each end of the
turbocharger oil drain tube and lubricate with
clean engine oil.
CAUTION: To prevent serious personal injury,
possible death, or damage to the engine or vehicle,
exercise special care not to cut or damage oil drain
tube O-rings.
5. Install oil drain tube into turbocharger side and
then move turbocharger and oil drain tube into
cylinder block as a unit.

Figure 61 Checking shaft rotation

2. Turn shaft by hand and check for wheel rub within

each housing.
The wheels must rotate freely. If there is
any rubbing or interference, replace the VGT
assembly.
NOTE: Do not straighten bent blades.
3. Check the compressor impeller and turbine
wheel. If there are deposits on the blades or any
blades are bent, broken or eroded, replace the
VGT assembly. Figure 62 VGT mounting
1. M10 Spiralock® nut (4)
Checking Rotation of Actuator Shaft
1. Place VGT assembly onto a clean workbench.
2. Position VGT assembly so that actuator linkage WARNING: To prevent personal injury or
can be easily accessed and viewed. death, support turbocharger assembly during
removal and installation.
3. Move the actuator shaft through its entire travel.
The actuator shaft should rotate 90° and return 6. Lift VGT assembly onto engine and insert VGT
under spring tension (Table 5). mounting studs into the exhaust manifold flange.

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74 EVRT® ELECTRONICALLY CONTROLLED TURBOCHARGER

Install two new M10 Spiralock® nuts on the VGT

mounting studs.
7. Install two new M10 Spiralock® nuts on the
exhaust manifold studs.
8. Verify the oil drain tube is seated in the crankcase
oil drain port.
9. Tighten four M10 Spiralock® nuts to the special
torque (Table 6).

Figure 64 Oil inlet tube assembly

1. Nut
2. Bolt, M8 x 20 (2)

12. Thread two bolts (M8 x 20) through turbo oil inlet
tube assembly at the top of the VGT. Do not
tighten these bolts yet.
13. Thread oil inlet tube assembly nut onto fitting
located on top of oil filter header.
Figure 63 Oil drain tube bracket and bolt
14. Tighten two bolts (M8 x 20) at the top of the oil
inlet tube assembly to the standard torque value
(General Torque Guidelines, page445).
10. Align oil drain tube bracket with bolt (M8 x 16) and
hole and tighten bolt to the standard torque value 15. Tighten oil inlet tube assembly nut to the standard
(General Torque Guidelines, page445). torque value (General Torque Guidelines, page
445).
11. Place a new turbo oil inlet O-ring over oil inlet
flange located on top of the VGT central housing. 16. Connect electrical harness to VGT actuator.

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 EVRT® ELECTRONICALLY CONTROLLED TURBOCHARGER 75

Specifications

Table 5 VGT Specifications

VGT axial linkage shaft Must strike open and closed
stops in actuator, 90° rotation

Special Torque

Table 6 VGT Special Torques

VGT Spiralock® nuts (M10) 71 N·m (52 lbf·ft)

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76 EVRT® ELECTRONICALLY CONTROLLED TURBOCHARGER

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 INTAKE, INLET, AND EXHAUST MANIFOLDS 77

Table of Contents

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Inlet and EGR Mixer Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Aluminum Air Inlet Adapter and Inlet Air Heater Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Intake Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Intake Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Intake Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Inlet and EGR Mixer Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

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78 INTAKE, INLET, AND EXHAUST MANIFOLDS

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 INTAKE, INLET, AND EXHAUST MANIFOLDS 79

8 9

5
4 7
3 10
2 11
1

12
13
14

16 15

H14002

Figure 65 Intake manifold, inlet and EGR mixer, and exhaust manifold assemblies
1. Exhaust manifold flange head 6. Manifold, exhaust rear (short or 12. Intake manifold bolt, M10 x 35
bolt, M12 x 35 (11) long EGR cooler version) (13)
2. Manifold, exhaust front 7. Exhaust manifold gasket 13. Intake manifold
3. Stud, M10 (2) 8. Inlet and EGR mixer duct 14. Fuel (Schrader) valve
4. Manifold, exhaust center (low or 9. EGR mixer flange bolt, M8 x 60 15. Intake manifold plug (2)
high mount turbo versions) (4) 16. Intake manifold gasket
5. Exhaust manifold and EGR 10. EGR mixer support bolt, M10 x
bracket flange head bolt, M12 x 90
120 (1) 11. Intake manifold to mixer gasket

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80 INTAKE, INLET, AND EXHAUST MANIFOLDS

Removal
WARNING: To prevent personal injury or
death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash
GOVERNMENT REGULATION: Engine with soap and water. Wash or discard clothing
fluids (oil, fuel, and coolant) may be a hazard and rags contaminated with engine fluids.
to human health and the environment.
NOTE: For information regarding the removal or
Handle all fluids and other contaminated
installation of adjacent components, refer to the
materials (e.g. filters, rags) in accordance
following service procedures located in other sections
with applicable regulations. Recycle
of this manual:
or dispose of engine fluids, filters, and
other contaminated materials according to • VGT turbo
applicable regulations.
• EGR valve
• Fuel filter assembly
WARNING: To prevent personal injury or • Crankcase breather
death, read all safety instructions in the “Safety
Information” section of this manual. • Oil fill tube assembly
Exhaust Manifold
WARNING: To prevent personal injury or
death, shift transmission to park or neutral, set
parking brake, and block wheels before doing
diagnostic or service procedures.

WARNING: To prevent personal injury or

death, allow engine to cool before working with
components.

WARNING: To prevent personal injury or

death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).

WARNING: To prevent personal injury or Figure 66 EBP tubing nut

death, do not smoke and keep fuel away from
flames and sparks. 1. EBP tubing nut

1. Disconnect the EBP tubing nut at exhaust

manifold.

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 INTAKE, INLET, AND EXHAUST MANIFOLDS 81

Figure 69 Removing exhaust manifold

Figure 67 Removing EBP tubing bracket
1. EBP tubing bracket bolt (2) 5. Remove exhaust manifold from the engine and
discard the one piece gasket.

2. Remove EBP tubing bracket bolts at water

housing (Freon® compressor bracket). Inlet and EGR Mixer Duct
3. Lift the EBP tubing and bracket assembly from the
engine.

Figure 70 Inlet and EGR mixer duct related

components
1. EGR valve mounting bolt (4)
2. Inlet and EGR mixer duct
3. Inlet Air Heater (IAH) connections
Figure 68 Exhaust manifold mounting bolts
1. Exhaust manifold mounting bolt, M12 x 35 (11)
2. Exhaust manifold mounting bolt, M12 x 120
1. Remove four EGR valve mounting bolts at the
EGR valve to mixer duct connection.
2. Remove EGR valve and discard gasket.
4. Remove 11 mounting bolts (M12 x 35) and
one mounting bolt (M12 x 120) securing the
three-piece exhaust manifold to the cylinder
head.

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82 INTAKE, INLET, AND EXHAUST MANIFOLDS

4. Remove the inlet and EGR mixer duct bolts.

Figure 73 Inlet and EGR mixer duct gasket

Figure 71 Intake air heater – dual element

1. Inlet and EGR mixer 5. Lift inlet and EGR mixer duct away from the intake
2. Intake air heater cable locations manifold. Remove gasket and discard.
3. Intake air heater element

Aluminum Air Inlet Adapter and Inlet Air Heater

See (TSI-05-12-35 New 1500 Watt Single Grid Intake Option
Air Heater Production Option, page466). See (1171846R1 Aluminum Air Inlet Adapter, page
3. Disconnect Inlet Air Heater (IAH) cable(s). 492).

Intake Manifold
1. Disconnect wire from MAP and MAT sensor
connectors.
2. Disconnect injector harness anchor points.
3. Pull out wiring harness and connectors.
4. Disconnect the high-pressure oil hose at pump.

Figure 72 Inlet and EGR mixer duct bolts

1. Inlet adapter
2. Inlet and EGR mixer support bolt, M10 x 90
3. Inlet mixer bolt, M8 x 60 (4)

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 INTAKE, INLET, AND EXHAUST MANIFOLDS 83

Figure 75 Checking exhaust manifold for cracks

and warpage

Figure 74 Intake manifold mounting bolts

b. Use a 0.25 mm (0.010 in) feeler gauge
to measure the gap between the mating
5. Remove 13 intake manifold mounting bolts (M10 surfaces of the manifold and engine. If the
x 35). feeler gauge passes through the gap, the
6. Remove intake manifold and gasket from the manifold must be resurfaced.
engine. Discard gasket. NOTE: A maximum of 0.64 mm (0.025 in) of
material can be ground off to correct warpage.
c. Remove 12 bolts (M12 x 35) and manifold.
Cleaning and Inspection d. If the warpage cannot be corrected by
grinding manifold mating surface, replace
Exhaust Manifold
manifold.
1. Clean exhaust manifold thoroughly with a suitable
non-caustic solvent. Scrape off excess scale and
rust from manifold surfaces. Intake Manifold
CAUTION: To prevent engine damage, do not attempt
WARNING: To prevent personal injury or to grind or machine the intake manifold to compensate
death, wear safety glasses with side shields. for a warped condition.
Limit compressed air pressure to 207 kPa (30 psi).
1. Clean intake manifold thoroughly with a suitable
2. After cleaning, blow dry exhaust manifold using non-caustic solvent.
filtered compressed air.
3. Inspect manifold for cracks or damage. Replace WARNING: To prevent personal injury or
manifold as necessary. death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).
4. Check for warpage as follows:
2. After cleaning, blow dry using filtered compressed
a. Install exhaust manifold without the gasket
air.
to a cleaned cylinder head mating surface.
Torque 12 mounting bolts (M12 x 35) to the 3. Check manifold for cracks and damage. Replace
special torque value (Table 8). intake manifold as necessary.

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84 INTAKE, INLET, AND EXHAUST MANIFOLDS

Installation This will ensure a proper alignment of the exhaust

manifold and gasket.
Exhaust Manifold
CAUTION: To prevent engine damage, make sure
exhaust manifold gasket and exhaust manifold are
aligned before tightening bolts to the specified torque
value.

Figure 77 Exhaust manifold mounting bolts

Figure 76 Installing exhaust manifold 1. Exhaust manifold mounting bolt, M12 x 35 (11)
2. Exhaust manifold mounting bolt, M12 x 120
1. Bolts installed holding gasket

3. Install assembled exhaust manifold with a new

1. Apply anti-seize compound to all 11 bolt (M12 x
gasket to cylinder head.
35) threads and one bolt (M12 x 120) used with
the EGR cooler bracket. NOTE: Refer to the EGR Cooler and Tubing Section
for instructions assembling the EGR cooler.
2. Insert an exhaust manifold bolt (M12 x 35) at each
end of the assembled exhaust manifold. Place 4. Torque the exhaust manifold bolts in the following
the exhaust manifold gasket over these two bolts. three step sequence.

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 INTAKE, INLET, AND EXHAUST MANIFOLDS 85

Exhaust Manifold Torque Sequence

M12 x 120 (1)

9 5 1 4 8 12

10 6 2 3 7 M12 x 35 (11)
11
H14024

Figure 78 Exhaust manifold torque sequence

a. Torque all bolts in sequence 1 through 12 to CAUTION: To prevent engine damage, make
27 N·m (20 lbf·ft). sure that the EGR cooler bracket bolt (M12 x
120) has a final torque value of 116 N·m (85
b. Torque all bolts in sequence 1 through 12 to
lbf·ft). This applies only to this bolt (number 4
54 N·m (40 lbf·ft).
in the sequence).
c. Torque all bolts in sequence 1 through 12 to
109 N·m (80 lbf·ft).

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86 INTAKE, INLET, AND EXHAUST MANIFOLDS

6. Torque tubing nut to the standard torque value

(General Torque Guidelines, page445).
7. Torque EBP tubing bracket bolts to the standard
torque value (General Torque Guidelines, page
445).
8. Install the EBP sensor connector.

Intake Manifold

Figure 79 Installing EBP tubing bracket

1. EBP tubing bracket bolts, M8 x 20 (2)

5. Install EBP tubing bracket assembly and

bolts onto the water supply housing (Freon®
compressor bracket) and finger tighten.

Figure 81 Aligning intake gasket to manifold

1. Insert an intake manifold bolt (M10 x 35) into each

end of the intake manifold (both top holes). Place
intake manifold gasket over these two bolts to
ensure proper alignment between the manifold
and gasket.
2. Install the intake manifold and gasket to the
cylinder head by starting the two top end bolts by
hand.
Figure 80 Installing EBP tubing nut
1. EBP tubing nut

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 INTAKE, INLET, AND EXHAUST MANIFOLDS 87

1 2

3 H14026

Figure 82 Intake manifold and inlet duct bolt configuration

1. Inlet and EGR mixer support 2. Bolt, M10 x 35 (12)
bolt, M10 x 90 3. Bolt / Stud, M10 x 35 / 20

3. Place bolt / stud, (M10 x 35 / 20) into the rear most 1. Install inlet and EGR mixer with new gasket.
bolt hole along the bottom finger tight.
4. Install the remaining short intake manifold
mounting bolts (M10 x 35) finger tight, in their
correct positions. One bolt hole should remain
open for later installation of the inlet and EGR
mixer support and bolt.
5. Connect injectors and anchor harness.
6. Connect harness to MAP and MAT sensors.

Inlet and EGR Mixer Duct

Figure 84 Mounting the inlet and EGR mixer

1. Inlet and EGR mixer support bolt, M10 x 90
2. Inlet mixer bolts, M8 x 60 (4)

2. Install four bolts (M8 x 60) that hold the inlet and
EGR mixer to the intake manifold, but do not
tighten.
3. Thread the inlet and EGR mixer duct support bolt
(M10 x 90) finger tight.

Figure 83 Inlet and EGR mixer gasket

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88 INTAKE, INLET, AND EXHAUST MANIFOLDS

13 9 5 1 4 8 12

14 10 6 2 3 7 11
H14025

Figure 85 Intake manifold torque sequence

4. Torque intake manifold bolts including the inlet

and EGR mixer support bolt (M10 x 90) to
the standard torque value (General Torque
Guidelines, page 445) and in the recommended
sequence.

Figure 87 Intake air heater – dual element

1. Inlet and EGR mixer
Figure 86 Torque the inlet and EGR mixer bolts 2. Intake air heater cable locations
3. Intake air heater element

5. Torque four inlet mixer bolts (M8 x 60) to

the standard torque value (General Torque See (TSI-05-12-35 New 1500 Watt Single Grid Intake
Guidelines, page445). Air Heater Production Option, page466).
6. Install fuel assembly valve if removed, and tighten 8. Connect Inlet Air Heater (IAH) cable(s).
to the special torque value (Table 8).
7. Install intake plug assemblies, if removed (M12)
and tighten to the special torque value (Table 8).

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 INTAKE, INLET, AND EXHAUST MANIFOLDS 89

Specifications

Table 7 Exhaust Manifold Specifications

Allowable warpage (max.) 0.10 mm (0.004 in) overall
Flange thickness (min.) 21.59 mm (0.850 in)

Special Torque

Table 8 Intake Manifold, Inlet and EGR Mixer, and Exhaust Manifold Special Torques
Exhaust manifold mounting torque and sequence. See “Exhaust manifold torque
sequence” (page 85).
Fuel assembly valve 15 N·m (132 lbf·in)
Intake manifold mounting bolts 40 N·m (30 lbf·ft)
Intake plug assembly 25 N·m (18 lbf·ft)

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 EGR COOLER AND TUBING 91

Table of Contents

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
EGR Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

EGR System Components (Beginning Model Year 2004). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Removal of EGR System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Cleaning EGR System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Inspection of EGR Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Installation EGR System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Modification 1 – Deeper O-ring Location into EGR Coolant Return Tube plus Retaining Clip. . . . . . . . . . .103 .
Removal of EGR Coolant Return Tube and Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
.
Installation of EGR Coolant Return Tube and Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
.

Modification 2 – EGR Coolant Return Tube Adapter and EGR Coolant Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
.
Removal of EGR Coolant Return Tube Adapter and EGR Coolant Hose. . . . . . . . . . . . . . . . . . . . . . . . . . .108 .
Installation of EGR Coolant Return Tube Adapter and EGR Coolant Hose. . . . . . . . . . . . . . . . . . . . . . . . .108 .

Modification 3 – Round EGR Cooler and EGR Return Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 .

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
.
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
.

EGR Coolant Return Kits (Conversion from EGR Cooler Return Tube to Hose). . . . . . . . . . . . . . . . . . . . . . . . . . . .112 .
Removal of EGR Coolant Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
.
Installation of EGR Coolant Return Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 .

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

.

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

.

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 EGR COOLER AND TUBING 93

Description • EGR coolant return tube adapter and EGR

coolant hose
EGR COOLANT SYSTEM • Round EGR coolers and EGR coolant hose

The original production version of the complete • Service kits to convert from original or first
EGR coolant system and first EGR cooler return modification of EGR coolant return tube design
configuration, beginning model year 2004, starts at changes to a more robust EGR coolant return
the front of this section. hose design.

Over the production life of the International® DT 466, See specific EGR coolant return system
DT 570 and HT 570 Diesel Engines, the EGR coolant modifications, listed in the Table of Contents in
return system was modified according to the following this section for service procedures.
EGR cooler return configurations:
• Deeper O-ring location in EGR coolant return tube
plus retaining clip

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94 EGR COOLER AND TUBING

EGR System Components

(Beginning Model Year 2004)
Removal of EGR System Components

Figure 88 EGR system

1. EGR tube assembly 8. EGR cooler return elbow 14. Gasket, cool side
2. Bolt, M8 x 25 (7) 9. Bolt, M8 x 30 (2) 15. Bolt, M12 x 120
3. Bolt, M8 x 35 (4) 10. O-ring (2) 16. EGR cooler bracket clamp
4. Gasket 11. EGR cooler supply tube 17. EGR cooler assembly
5. Bolt, M10 x 90 12. EGR cooler supply tube retaining 18. EGR cooler assembly gasket
6. EGR cooler return tube bolt, M8 x 16 19. EGR valve assembly
7. O-ring (3) 13. Gasket, hot side

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 EGR COOLER AND TUBING 95

Table 9 EGR Cooler – Applications

WARNING: To prevent personal injury or
EGR Cooler Engine Rated Brake death, wear safety glasses with side shields.
Length (inches) Model Horsepower Limit compressed air pressure to 207 kPa (30 psi).
(bhp)
11.5 DT 466 225 and below
DT 466 245 and above
17.0 DT and HT 295 and below
570
21.0 DT and HT 300 and above
570

GOVERNMENT REGULATION: Engine

fluids (oil, fuel, and coolant) may be a hazard
to human health and the environment.
Handle all fluids and other contaminated Figure 89 EGR tube assembly at EGR cooler
materials (e.g. filters, rags) in accordance
with applicable regulations. Recycle
or dispose of engine fluids, filters, and 1. Remove three bolts (M8 x 25) from the EGR tube
other contaminated materials according to assembly at the EGR cooler assembly.
applicable regulations.

WARNING: To prevent personal injury or

death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or

death, shift transmission to park or neutral, set
parking brake, and block wheels before doing
diagnostic or service procedures.

WARNING: To prevent personal injury or

death, make sure that the engine has cooled
before removing components.
Figure 90 Removing the gasket

WARNING: To prevent personal injury or

death, do not let engine fluids stay on your skin. 2. Pull tube assembly away and discard gasket.
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing
and rags contaminated with engine fluids.

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96 EGR COOLER AND TUBING

Figure 91 EGR tube assembly at EGR valve Figure 93 EGR valve retaining bolts
1. Bolt, M8 x 25 (3) 1. Bolt, M8 x 35 (4)

3. Remove three bolts (M8 x 25) securing the EGR 6. Remove four bolts (M8 x 35) securing the EGR
tube assembly at the EGR valve assembly. valve assembly to the EGR mixer duct.

Figure 92 Removing the EGR tube assembly Figure 94 Removing the EGR valve to EGR
gasket mixer gasket

4. Remove EGR tube assembly and discard gasket. 7. Remove and discard gasket between EGR valve
assembly and EGR mixer.
5. Disconnect wiring harness connector at EGR
valve assembly. NOTE: Do not attempt to remove the EGR cooler
supply tube from the engine until the EGR cooler
assembly has been removed. The EGR cooler supply
tube is trapped between the EGR cooler and the rear
half of the front cover.

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 EGR COOLER AND TUBING 97

Figure 95 EGR cooler supply tube assembly Figure 97 EGR cooler return tube and elbow
retaining bolt O-rings

8. Remove the EGR cooler supply tube assembly 10. Remove the EGR cooler return tube assembly
retaining bolt (M8 x 16). and elbow from engine and discard all O-rings.

Figure 96 EGR cooler return tube assembly Figure 98 EGR cooler retaining bolts at exhaust
retaining bolt manifold
1. Bolt, M8 x 30 (2)

9. Remove the EGR cooler return tube assembly

retaining bolt (M8 x 25).
11. Remove two bolts (M8 x 30) retaining the EGR
cooler to the exhaust manifold.

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98 EGR COOLER AND TUBING

15. Discard gasket between EGR cooler assembly

and exhaust manifold.

Figure 99 EGR cooler mounting bracket

hardware Figure 101 EGR cooler supply tube

1. EGR cooler bracket clamp

2. EGR cooler mounting bracket 16. Remove EGR cooler supply tubing from rear half
3. Bolt, M12 x 120 of front cover. Discard O-ring from end of tube.

12. Remove M12 x 120 bolt from EGR cooler Cleaning EGR System Components
mounting bracket and exhaust manifold.
1. Clean off any gasket material and carbon deposits
13. Remove the EGR cooler bracket clamp. between the EGR cooler and exhaust manifold
mating surfaces.
2. Clean mating surfaces between EGR cooler and
exhaust gas crossover.
3. Clean mating surfaces between exhaust gas
crossover and EGR valve.
4. Clean mating surfaces between EGR valve and
intake mixer duct.

Inspection of EGR Cooler

1. Bolt EGR cooler pressure test plates (Table 11) to
each end of the EGR cooler assembly.

WARNING: To prevent personal injury or

death, wear safety glasses with side shields.
Figure 100 Removing the EGR cooler assembly Limit compressed air pressure to 207 kPa (30 psi).
1. O-ring gasket 2. Connect air pressure to EGR cooler pressure test
plate and regulate pressure to not more than 207
kPa (30 psi).
14. Remove the EGR cooler assembly by pulling out
from EGR cooler supply tube and discard O-ring
gasket.

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 EGR COOLER AND TUBING 99

3. Install a new gasket between the EGR cooler

assembly and exhaust manifold.

Figure 102 EGR cooler pressure test

1. EGR cooler pressure test plates (2)
2. Air pressure regulator

Figure 104 Installing the EGR cooler assembly

3. Submerge assembly into a tank of water. Watch
for air bubbles coming out of the coolant ports. 1. O-ring gasket
Discard EGR cooler if any air bubbles are
produced from any ports.
4. Install EGR cooler assembly by pushing in
towards the EGR cooler supply tube. Make sure
Installation EGR System Components EGR cooler supply tube fully engages the EGR
NOTE: Assemble the following parts in order, but do cooler assembly. The cooler tube should be
not torque any bolts until all components have been trapped between the EGR cooler and the rear
installed and bolts threaded finger tight. half of the front cover.

1. Install new O-rings onto each end of the EGR

cooler supply tube.

Figure 105 EGR cooler support bracket

Figure 103 EGR cooler supply tube retaining bolt
1. EGR cooler bracket clamp
2. Install the EGR cooler supply tube into the open 2. EGR cooler mounting bracket
port in rear half of front cover. 3. Bolt, M12 x 120

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100 EGR COOLER AND TUBING

5. Install M12 x 120 bolt through the EGR cooler 9. Install new O-rings onto each end of the EGR
support bracket and exhaust manifold to support cooler return tube. Lubricate O-rings with P-80 or
and secure the EGR cooler assembly. Hand equivalent.
tighten bolt.
6. Install the EGR cooler into the mounting bracket
and close EGR cooler bracket clamp.

Figure 108 EGR cooler return tube assembly

retaining bolt

Figure 106 EGR cooler retaining bolts at

10. Position the EGR cooler return tube assembly into
exhaust manifold
place and install retaining bolt (M8 x 25) finger
1. Bolt, M8 x 30 (2) tight.

7. Place EGR gasket between EGR cooler and

exhaust manifold.
8. Install two EGR cooler retaining bolts (M8 x 30).
Thread bolts finger tight at the exhaust manifold.

Figure 109 EGR cooler supply tube assembly

retaining bolt

11. Install the EGR cooler supply tube assembly

retaining bolt (M8 x 16) finger tight.
Figure 107 EGR cooler return tube O-rings

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 EGR COOLER AND TUBING 101

Figure 112 EGR gasket at EGR valve

Figure 110 EGR valve gasket at EGR mixer duct 14. Position a new gasket between the EGR tube
assembly and EGR valve assembly.

12. Place a new gasket between the EGR mixer duct

and EGR valve assembly.

Figure 113 EGR tube assembly at EGR valve

1. Bolt, M8 x 25 (3)
Figure 111 EGR valve mounting bolts
1. Bolt, M8 x 35 (4) 15. Install three EGR tube assembly bolts (M8 x 25)
finger tight.

13. Secure EGR valve assembly with four bolts (M8 x

35) finger tight.

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102 EGR COOLER AND TUBING

17. Install three bolts (M8 x 25) finger tight to join the
EGR tube assembly at the EGR cooler assembly.
18. Tighten all EGR system component bolts to the
standard torque (General Torque Guidelines,
page445) in the following order:
a. EGR cooler at exhaust manifold
b. EGR tube assembly at EGR cooler
c. EGR valve mounting bolts
d. EGR tube assembly at EGR valve
e. EGR cooler return tube assembly retaining
bolt
f. EGR cooler supply tube assembly retaining
Figure 114 Installing a new gasket bolt
g. EGR cooler support bracket retaining bolt
16. Position a new gasket between the EGR tube
assembly and EGR cooler.

Figure 115 EGR tube assembly at EGR cooler

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 EGR COOLER AND TUBING 103

Modification 1 – Deeper O-ring 3. If applicable, remove two set screws or retaining

Location into EGR Coolant Return clip retaining the EGR cooler elbow.

Tube plus Retaining Clip 4. Remove EGR return tube and elbow as an
assembly by lifting it out of the EGR cooler.
Removal of EGR Coolant Return Tube and Elbow
CAUTION: To prevent engine damage, do not mix the
new longer leg EGR coolant return tube elbow with the Installation of EGR Coolant Return Tube and
original short adapter end EGR cooler return tube. Elbow

The EGR coolant return tube and mating elbow were 1. Install two O-rings onto EGR cooler elbow and
redesigned as a production running change to locate one O-ring onto pilot of EGR coolant return tube
the elbow O-ring one inch deeper into the EGR assembly.
coolant return tube. Both the EGR coolant return tube CAUTION: To prevent engine damage, do not use
and EGR coolant return elbow were redesigned to engine oil or any other petroleum based products on
accomplish this. The EGR coolant return tube has EGR coolant return tube or elbow O-rings. These
a one inch longer arm to locate the O-ring one inch O-rings are not compatible with petroleum based
deeper into the EGR coolant return tube adapter end. lubricants.
1. Drain coolant to a level below the cylinder head.
2. Remove bolt from EGR return tube located at
back of cylinder head. Retain bolt for reuse with
new EGR cooler return tube assembly.

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104 EGR COOLER AND TUBING

Figure 116 Brushing lubricant and sealant onto pilot end (left) and adapter end of EGR coolant
return tube (right)

2. Using P-80 or equivalent, lubricate the pilot O-ring

on one end and the adapter on the other end.

Figure 117 Lubricating both ends of the EGR cooler elbow

3. Using P-80 or equivalent, lubricate both O-rings

on the EGR cooler elbow.

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 EGR COOLER AND TUBING 105

Figure 118 EGR cooler return elbow Figure 120 Installing the EGR cooler return tube

4. Install EGR cooler return elbow into the EGR 6. While holding the elbow and tube with one hand,
cooler assembly without wire retaining clip. The swivel the EGR cooler return tube into position as
shorter arm of the elbow goes into EGR cooler. needed, aligning the O-ring pilot into the cylinder
head.
7. With palm of left hand, forcefully push the flange
face forward into the cylinder head, fully engaging
both ends while also maintaining alignment of
elbow and return tube with right hand.

Figure 119 EGR cooler return tube

5. Assemble EGR cooler return tube at the elbow

end, pushing in until O-ring is well into tube
adapter. Figure 121 Installing the EGR return tube
mounting bolt

8. Install EGR return tube mounting bolt (M8 x 25)

into cylinder head (finger tight).

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106 EGR COOLER AND TUBING

10. Tap top of EGR cooler elbow with rubber mallet to

ensure retaining clip is fully engaged in elbow.

Figure 122 Installing the retaining clip (outboard

hole first)

Figure 124 Torquing the EGR cooler return tube

9. Ensure that EGR cooler elbow and return tube mounting bolt
are straight. Hand seat elbow downward as far
as possible and install wire retaining clip into
outboard hole of EGR cooler and slide retaining 11. Torque EGR cooler return tube mounting bolt
clip around into remaining hole. to the standard torque value (General Torque
Guidelines, page445).

Figure 123 Seating the EGR cooler elbow and

retaining clip

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 EGR COOLER AND TUBING 107

12. If equipped, slide elbow retaining bracket between

cylinder head and EGR cooler assembly. Install
flat washer and M10 x 25 bolt. Tighten bolt to
the standard torque (General Torque Guidelines,
page445).

Figure 125 Installing the EGR elbow bracket and

mounting hardware
1. Bracket
2. M10 x 25 Bolt and 3/8 flat washer

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108 EGR COOLER AND TUBING

Modification 2 – EGR Coolant Installation of EGR Coolant Return Tube Adapter

Return Tube Adapter and EGR and EGR Coolant Hose

Coolant Hose
Removal of EGR Coolant Return Tube Adapter
and EGR Coolant Hose

Figure 126 EGR coolant return tube adapter and

EGR coolant hose
1. EGR coolant hose
2. Constant tension EGR hose clamp (2)
3. EGR cooler
4. EGR coolant return tube adapter
5. Bolt, M8 x 25 (in flange)
6. O-ring seal
Figure 127 EGR cooler return tube adapter

1. Drain coolant.
1. Install a new O-ring onto new EGR cooler return
2. Loosen two constant tension EGR hose clamps tube adapter.
and remove EGR coolant hose from EGR coolant
return tube adapter and EGR cooler. CAUTION: To prevent engine damage, do not use
engine oil or any other petroleum based products
3. Remove M8 x 25 EGR coolant return tube adapter on EGR cooler return tube adapter O-ring. This
bolt and pull EGR coolant return tube adapter O-ring is not compatible with petroleum based
straight out of the cylinder head. Discard O-ring. lubricants.
2. Using P-80 or equivalent, lubricate O-ring on
adapter.

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 EGR COOLER AND TUBING 109

Figure 128 Installing the EGR return tube

adapter mounting bolt

3. Position adapter into cylinder head coolant port

and install EGR coolant return tube adapter bolt
(M8 x 25). Tighten bolt to the standard torque
(General Torque Guidelines, page445).

Figure 130 EGR lower hose clamp details

4. Position EGR coolant hose and two constant

tension EGR hose clamps between EGR cooler
and EGR cooler return tube adapter.
5. Tighten constant tension EGR hose clamps to the
special torque (Table 10).
6. Fill engine with coolant and check for leaks.
7. Start engine and let engine warm up to operating
temperature.
8. Shut down engine and let engine cool to ambient
air temperature.
9. Retighten constant tension EGR hose clamps to
the special torque (Table 10).

Figure 129 EGR upper hose clamp details

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110 EGR COOLER AND TUBING

Modification 3 – Round EGR Cooler

and EGR Return Hose
Removal

Figure 131 Round EGR cooler

1. EGR return hose 8. EGR tube assembly 13. EGR hot side gasket
2. Constant tension EGR hose 9. EGR cooler supply tube 14. Exhaust manifold
clamp (2) assembly 15. EGR coolant return adapter tube
3. EGR cooler 10. EGR cooler supply tube retaining retaining bolt (M8 x 25)
4. EGR cooler mounting bracket bolt (M8 x 16) 16. EGR coolant return adapter tube
5. Deaeration hose fitting 11. EGR cooler mounting bracket
6. EGR tube to EGR valve gasket lower bolt (M12 x 120)
7. EGR tube assembly bolt (M8 x 12. EGR rear mounting bolt (M8 x
25) (3) 30) (2)

1. Drain engine cooling system. 7. Loosen and remove EGR cooler mounting bracket
lower bolt.
2. Loosen and remove EGR cooler supply tube
retaining bolt. 8. Pull EGR cooler and mounting bracket away from
exhaust manifold, EGR cooler supply tube, and
3. Loosen and remove three bolts holding EGR tube
EGR tube assembly.
assembly to EGR cooler.
9. Remove EGR cooler supply tube assembly from
4. Loosen EGR return hose clamp and pull EGR
rear half of front cover. Remove and discard
return hose off of EGR cooler.
O-rings from ends of cooler supply tube and
5. Loosen clamp holding deaeration hose to the clean tube ends.
deaeration hose fitting and pull hose off of EGR
10. Remove old gaskets and clean gasket surfaces of
cooler.
EGR tube assembly and exhaust manifold.
6. Remove EGR rear mounting bolts.

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 EGR COOLER AND TUBING 111

Installation 9. Tighten EGR cooler mounting bracket lower bolt

(M12 x 120) to the special torque (Table 10).
1. Clean port in rear half of front cover which EGR
cooler supply tube fits into. 10. Tighten EGR cooler mounting bracket to the
special torque (Table 10).
CAUTION: To prevent engine damage, do not
use engine oil or any other petroleum based 11. Tighten three bolts (M8 x 25) holding EGR tube
products on EGR cooler supply tube O-rings. assembly to EGR cooler to the standard torque
These O-rings are not compatible with petroleum (General Torque Guidelines, page445).
based lubricants.
12. Tighten EGR cooler supply tube retaining bolt (M8
2. Install new O-ring seals on EGR cooler supply x 16) to the special torque (Table 10).
tube assembly ends and reinstall tube into port in
13. Push EGR return hose onto EGR cooler and
rear half of front cover.
tighten constant tension EGR hose clamps to the
3. Install new EGR hot side gasket on new EGR special torque value (Table 10).
cooler.
14. Push deaeration hose onto EGR cooler
4. Position EGR cooler on the engine and install deaeration fitting and tighten clamp.
two new EGR rear mounting bolts. Finger tighten
15. Refill engine cooling system.
bolts.
16. Start engine and let engine warm up to operating
5. Reinstall EGR cooler mounting bracket lower bolt
temperature.
and finger tighten.
17. Shut down engine and let engine cool to ambient
6. Push EGR cooler supply tube assembly into EGR
air temperature.
cooler and finger tighten retaining bolt.
18. Retighten constant tension EGR hose clamps to
7. Install new EGR tube to EGR valve gasket and
the special torque value (Table 10).
finger tighten three bolts holding EGR tube to
EGR cooler.
8. Tighten EGR rear mounting bolts (M8 x 30) to
the standard torque (General Torque Guidelines,
page445).

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112 EGR COOLER AND TUBING

EGR Coolant Return Kits 3. Lubricate both O-rings with P-80 or equivalent.
(Conversion from EGR Cooler
Return Tube to Hose)
Removal of EGR Coolant Return
NOTE: See Technical Service Information (TSI)
bulletin (TSI-07-12-12 EGR Coolant Return Kit, page
477) for Exhaust Gas Recirculation (EGR) kits.
1. Drain coolant to a level below the cylinder head.
2. Remove and save bolt from EGR cooler return
tube flange.
3. Remove spring clip or set screws from EGR return
tube elbow.
4. Remove old EGR return tube and elbow.

Figure 133 EGR coolant return

Installation of EGR Coolant Return Kit
1. EGR coolant return hose
CAUTION: To prevent engine damage, do not use 2. Constant tension EGR hose clamp
engine oil or other petroleum products on EGR coolant 3. M8 x 25 bolt
return hose or O-rings. 4. EGR cooler return adapter tube
5. EGR elbow retaining clip
6. EGR coolant return elbow

4. Install EGR coolant return elbow.

5. Slide new EGR coolant return hose onto coolant
return elbow and position hose clamp.
6. Put hose clamp on EGR coolant return hose,
insert EGR cooler return adapter tube into hose,
and position clamp.
7. Install M8 x 25 bolt (finger tight) to secure EGR
cooler return adapter tube to cylinder head.
8. Install EGR elbow retaining clip (outboard hole
Figure 132 EGR coolant return elbow first). Tap top of elbow with rubber mallet to
1. EGR coolant return elbow
ensure retaining clip is fully engaged.
2. O-ring seal 9. Tighten M8 x 25 bolt to the standard torque
(General Torque Guidelines, page445).

1. Put O-ring seal on new EGR coolant return elbow. 10. Tighten constant tension EGR hose clamps to the
special torque (Table 10).
2. Put O-ring seal on new EGR coolant return
adapter tube.

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 EGR COOLER AND TUBING 113

11. Position EGR cooler return bracket between

cylinder head and EGR cooler.
12. Install 3/8 in flat washer and M10 Bolt.
13. Tighten M10 bolt to the standard torque (General
Torque Guidelines, page445).
14. Refill engine cooling system.
15. Start engine and let engine warm up to operating
temperature.
16. Shut down engine and let engine cool to ambient
air temperature.
17. Retighten constant tension EGR hose clamps to
special torque (Table 10).

Figure 134 EGR cooler return bracket

1. EGR tube bracket
2. Flat washer, 3/8 in
3. Bolt, M10 x 1.5 x 25 mm

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114 EGR COOLER AND TUBING

Special Torque

Table 10 EGR Cooler Special Torques

Constant tension EGR hose clamps (if equipped) 3.4 N·m (30 lbf·in)
EGR cooler mounting bracket lower bolt, M12 x 120 116 N·m (85 lbf·ft)
EGR cooler mounting bracket 116 N·m (85 lbf·ft)
EGR cooler supply tube retaining bolt 15-22 N·m (11.3-16.2
lbf·ft)

Special Service Tools

Table 11 EGR System Special Service Tools

EGR cooler pressure test plates ZTSE4636

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 CYLINDER HEAD AND VALVE TRAIN 115

Table of Contents

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
.

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
.
Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 .
Removing Rocker Arm Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 .
Measuring Camshaft Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 .
Removing Rocker Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123 .
Removing Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123 .
Roller Tappets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 .

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
.
Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 .

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
.
Valve Train Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 .
Push Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 .
Rocker Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 .
Rocker Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126 .
Cylinder Head Warpage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 .
Cylinder Head Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 .
Valve Seat Leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 .
Cylinder Head Cracking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 .
Pressure Check Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 .

Reconditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
.
Removing Valves from Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 .
Inspecting Valve Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 .
Replacing Valve Guides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 .
Inspecting Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 .
Refacing Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 .
Valve Face. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 .
Valve Stem Tip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133 .
Checking Valve Face-to-Valve Seat Contact. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134 .
Resurfacing Valve Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 .
Replacing Valve Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136 .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138 .
Inspecting Valve Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139 .
Inspecting Valve Rotators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 .
Inspecting Valve Spring Retainer Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141 .
Replacing Fuel Injector Sleeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141 .
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141 .
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141 .
Installing Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142 .
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142 .
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142 .

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116 CYLINDER HEAD AND VALVE TRAIN

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
.
Roller Tappets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144 .
Installing the Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144 .
Torque-to-Yield Procedure for Cylinder Head Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146 .
Valve Train Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148 .
Installing Rocker Arms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Installing the Rocker Arm Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149 .
Valve Lash for Intake and Exhaust Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150 .
Adjusting Valve Lash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150 .
High-pressure Oil Rail Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152 .
Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152 .

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
.

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

.

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156

.

EGES-265-2
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Follow all warnings, cautions, and notes.
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 CYLINDER HEAD AND VALVE TRAIN 117

Description The bridge can be installed on the intake or exhaust

in either direction, and still allow compression brake
The DT 466 and DT 570 cylinder heads are cast iron operation through the pad on top.
and feature four valves per cylinder.
A single roller tappet transfers lifting forces through
The design of the cylinder head valve train focuses a push rod, rocker arm, and then onto a valve
on component commonality between the intake bridge where both valves are opened and closed
and exhaust sides of the head. Shared parts simultaneously. This allows for a greater quantity of
include: valve bridges, guides, springs, retainer air to flow through the engine than comparably sized
keys, rotators, and valve stem seals. These parts engines using only two valves per cylinder.
are also compatible between the 466 and 570 engine
families. Phosphate coating has been carried over from past
production to rocker arms for initial break-in and to
The valve rotators create positive valve rotation for extend life.
increased valve face life.
Pressurized oil is fed from the crankcase through the
The valve stem seals are one piece design, easy to head at cylinder number 6 exhaust lower support. Oil
install, and have a hardened washer for valve spring then enters shaft and is distributed to all rocker arms.
seating.
The valve guides and valve seats are replaceable.

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118 CYLINDER HEAD AND VALVE TRAIN

Figure 135 Cylinder head and valve train components

1. Valve spring retainer keys 6. Fuel injector sleeve 11. Cylinder head gasket
2. Valve rotators 7. Front lifting eye 12. Valve seat insert
3. Valve springs 8. Cylinder head bolt, (26) 13. Exhaust valve
4. Valve stem seals 9. Bolt, M12 x 25 (4) 14. Intake valve
5. Valve guide inserts 10. Rear lifting eye 15. Valve assemblies

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 CYLINDER HEAD AND VALVE TRAIN 119

Figure 136 Valve train components

1. Intake rocker arm (6) 5. Rocker pivots (12) 11. Roller tappet guide (6)
2. Valve lash adjustment nuts, M10 6. Valve bridge (12) 12. Push rods (12)
(12) 7. Rocker arm shaft 13. Valve lash adjuster screw, M10
3. Exhaust rocker arm (6) 8. Rocker shaft support (6) (12)
4. Rocker shaft clamp assembly 9. Lower support washer (6) 14. Rocker shaft plug (2)
(12) 10. Roller tappets (12)

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120 CYLINDER HEAD AND VALVE TRAIN

Removal
WARNING: To prevent personal injury or
death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash
GOVERNMENT REGULATION: Engine with soap and water. Wash or discard clothing
fluids (oil, fuel, and coolant) may be a hazard and rags contaminated with engine fluids.
to human health and the environment.
CAUTION: To prevent engine damage, do not reuse
Handle all fluids and other contaminated
cylinder head bolts; install new bolts.
materials (e.g. filters, rags) in accordance
with applicable regulations. Recycle NOTE: For information regarding the removal or
or dispose of engine fluids, filters, and installation of adjacent components, refer to the
other contaminated materials according to following service procedures located in other sections
applicable regulations. of this manual:
• VGT turbocharger

WARNING: To prevent personal injury or • Intake and exhaust manifolds

death, read all safety instructions in the “Safety • EGR system components
Information” section of this manual.
• High-pressure oil manifold or Diamond Logic®
Engine Brake (if equipped)
WARNING: To prevent personal injury or
death, shift transmission to park or neutral, set • Fuel filter assembly
parking brake, and block wheels before doing • Fuel injector assembly
diagnostic or service procedures.
• Crankcase breather assembly
WARNING: To prevent personal injury or • Coolant outlet tube assembly
death, allow engine to cool before working with
• Water supply housing
components.
Valve Cover
WARNING: To prevent personal injury or 1. If cylinder head is to be removed in chassis, drain
death, disconnect ground (-) cable from battery coolant to a level below the head gasket joint.
before doing service or diagnostic procedures.
2. Disconnect crankcase ventilation and drain tubing
from breather assembly. The breather assembly
WARNING: To prevent personal injury or can remain attached to the valve cover during
death, wear safety glasses with side shields. the valve cover removal (Crankcase Ventilation
Limit compressed air pressure to 207 kPa (30 psi). System, page253).

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 CYLINDER HEAD AND VALVE TRAIN 121

1 1

1 1 2 H08100

Figure 137 Valve cover assembly detail

1. Bolt / stud, M8 x 80 / 19 (4) 3. Valve cover harness mounting 4. Bolt, M8 x 80 (6)
2. Extension bracket bracket

3. Remove four valve cover bolt / studs (M8 x 80 /

19).
4. Remove six valve cover bolts (M8 x 80).
5. Lift valve cover off of cylinder head.

WARNING: To prevent personal injury or

death, disconnect the main battery negative
terminal before disconnecting or connecting
electrical components.
6. Disconnect all electrical and injector connectors at Figure 138 Removing rocker arm assembly
valve cover gasket.
7. Remove valve cover gasket.
2. Loosen all rocker arm adjusting screws and nuts.
This will avoid possible valve train damage during
installation.
Removing Rocker Arm Assembly
3. Loosen but do not remove 12 rocker shaft clamp
1. Remove high-pressure oil rail. See (Figure 640) .
bolts.
4. Lift the rocker arm shaft assembly up and away
from the cylinder head and set aside.
NOTE: There are six nylon washers, one for
each rocker shaft support, that are for assembly
purposes. Make sure that you have these
washers for installing the rocker arm shaft.

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122 CYLINDER HEAD AND VALVE TRAIN

NOTE: If a complete engine overhaul is scheduled,

camshaft lobe wear can be determined by measuring
lobes (Checking Camshaft Lobes and Journals, page
263) with a micrometer after the camshaft is removed.

At this stage of disassembly, determine the

appropriate stage of camshaft inspection. If this
is not a complete engine overhaul, measure camshaft
lobe lift now using the following procedure.

Figure 139 Removing the valve bridge

5. If removing valve bridges, mark all valve bridges

for installation (original orientation) later on.

Measuring Camshaft Lift

Figure 141 Mounting magnetic base dial

indicator

1. Mount a magnetic base dial indicator onto the

cylinder head.
2. Place dial indicator tip on top of push rod and
rotate engine until push rod is at its lowest point
of travel (base circle), then “zero” indicator.

Figure 140 Measuring cam lobes with

micrometer

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 CYLINDER HEAD AND VALVE TRAIN 123

Figure 142 Recording camshaft lobe reading

3. Rotate the crankshaft and bring push rod to its

highest point of travel. Record indicator reading.
4. Repeat this procedure for all lobes.
5. For specifications on camshaft lobe (Table 13).
Figure 143 Rocker arm configuration
1. Clamp bolt assembly
Removing Rocker Arms 2. Exhaust rocker arm
3. Rocker arm shaft support
NOTE: Mark rocker arms and rocker shaft supports
4. Lower support washer
for location to ensure correct placement for later
5. Machined recessed
reassembly.
6. Intake rocker arm
1. Place the rocker arm assembly on a clean flat
surface. Mark each rocker arm before removal to
aid in assembly of the rocker arm shaft later on. 3. Slide rocker arm assembly components off shaft.
2. Remove the 12 rocker shaft clamps. 4. Tag all pushrods with cylinder number and valve
association (intake or exhaust).
5. Remove all pushrods.

Removing Cylinder Head

CAUTION: To prevent engine damage, remove
injectors before cylinder head removal (High-pressure
Oil Rail Assembly, page346).
1. Remove and discard 26 cylinder head mounting
bolts (M15 x 180).

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124 CYLINDER HEAD AND VALVE TRAIN

4. Remove the cylinder head gasket from the

WARNING: To prevent serious personal crankcase. Discard the gasket.
injury, possible death, or damage to the engine
or vehicle, chain must be equipped with safety
hooks. See safety section in front of manual.

Figure 144 Removing cylinder head from

crankcase Figure 146 Removing alignment dowels

2. Attach appropriate hoist and lifting hooks to lifting 5. Remove the alignment dowels from the top of the
eyes. Carefully lift the cylinder head from the crankcase, only if damaged.
crankcase.
3. After cylinder head been placed on a workbench
surface, remove both lifting eyes and four bolts Roller Tappets
(M12 x 25) from cylinder head.

Figure 147 Roller tappets and guide

Figure 145 Removing cylinder head gasket Remove each roller tappet and guide from tappet bore
and mark with cylinder number, valve association
(intake or exhaust), and roller orientation.
NOTE: Place the cylinder head on wood blocks to
protect the valves and bottom deck surface.

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 CYLINDER HEAD AND VALVE TRAIN 125

Cleaning 2. Inspect each push rod for wear at both ends. If

push rod is worn, install new push rod.
Cylinder Head
CAUTION: To prevent engine damage, leave the
valves installed within the cylinder head. This protects
the valve seats during the cleaning process.
1. Use a rotary wire brush or a sanding block with
mineral spirits to remove any deposits and gasket
material from the gasket surface of the cylinder
head.
2. Use an appropriately sized brush to clean all
mounting bolt holes in the cylinder head.
3. Wash rocker arm assemblies, hydraulic lifters,
and push rods in a suitable solvent and dry them
thoroughly. Replace any bolts that have damaged
threads.
CAUTION: To prevent engine damage, do not use
chlorinated solvents on bolts or crankcase tapped
holes. Parts should be clean, dry, and free of any
chemical residuals other than engine oil. Figure 148 Check push rods for straightness

3. Check all push rods for straightness by rolling

Inspection push rods on a flat surface with the cap end over
the edge of the flat surface.
Valve Train Components
4. Measure push rod runout with a feeler gauge
Engine valve train load carrying requirements have (page156) between the flat surface and push rod.
resulted in the release of several different push rod
and tappet configurations. The main differences are 5. If specifications (page 154) are exceeded, install
improved geometry designs and materials. new push rod.

For information on push rod and tappet compatibility

for different engine model year configurations, see Rocker Shaft
(TSI-06-12-14 Update Valve Train Components –
Push Rod and Tappet Compatibility, page469) . CAUTION: To prevent engine damage, if it is
necessary to replace the rocker shaft, all of the
rocker arms must be replaced. Reusing rocker arms
Push Rods on a new shaft will not allow for an adequate break-in
period, causing premature failure of the rocker arm
assembly.
WARNING: To prevent personal injury or
death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).
1. Thoroughly clean each push rod using a suitable
solvent and dry rods using filtered compressed air
.

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126 CYLINDER HEAD AND VALVE TRAIN

lower half of the rocker arm. The most significant

wear will occur at this location. Rocker arms
may be reused in their original locations if the
phosphate coating is worn off and the shaft was
not replaced.

Figure 149 Measuring rocker arm shaft

1. Check the rocker shaft for scoring, pitting and

wear. Replace rocker shaft and all of the rocker
arms as required.
NOTE: It is normal to see a slight polishing at the
rocker arm area. Figure 150 Measuring the rocker arm bore

2. Use an outside micrometer to measure a

non-contact area of the rocker shaft. This NOTE: The purpose of the black phosphate
dimension will be used as a baseline for the coating on the rocker arm is to provide a break-in
shaft diameter. lubricant between the rocker shaft and rocker
3. Use an outside micrometer to measure each of arm bore. It is normal to see the black phosphate
the 12 lever contact areas of the rocker shaft. If coatings worn off of the bottom of the lever arm
the difference between the baseline and any of the in the shaft and bore contact area. Rocker arms
measurements is greater than 0.03 mm (0.001 in), must be labeled and installed in their original
replace the rocker shaft and all of the rocker arms. locations to maintain the proper wear pattern.

4. To ensure that oil supply holes are open, insert a 2. Use a telescoping gauge and outside micrometer
small wire or another suitable tool. to measure the rocker arm bore diameter at two
locations. Measure the diameter at A-B and C-D.
5. Check the cup plugs at each end of the rocker If the difference between the diameters is greater
shaft. Do not disturb the cup plugs unless they than or equal to 0.03 mm (0.001 in), replace the
are damaged. If replacement is required, pry out rocker arm.
the plugs and press in new plugs.
3. Inspect the valve bridge contact pivot on the
rocker arm for scoring, pitting, or signs of
Rocker Arms excessive wear.
1. Inspect arms for scoring, pitting, or signs of 4. Inspect the valve lash adjuster for signs of wear.
excessive wear. If the bore has visible damage, Replace the adjuster screw if excessive wear is
replace the rocker arm. Be sure to inspect the found.

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 CYLINDER HEAD AND VALVE TRAIN 127

Cylinder Head Warpage Cylinder Head Thickness

Figure 151 Checking for warpage

Figure 153 Checking cylinder head thickness

Use a 6-7 inch outside micrometer to measure

the thickness of the cylinder head at six locations
(four corners and two center points). Cylinder
Figure 152 Checking pattern head thickness must equal or exceed the minimum
specification after resurfacing. If the minimum
specification after resurfacing cannot be met, replace
Use a straightedge and feeler gauge to check the cylinder head.
gasket surface of the cylinder head for warpage.
Use the checking pattern that is shown. If warpage is
present as indicated by a feeler gauge measurements Valve Seat Leakage
exceeding cylinder head gasket surface flatness NOTE: This test does not check for the condition of
specifications, check thickness of cylinder head. the valve guides or the valve stem-to-valve guide
clearance.
1. Position the cylinder head on wood blocks with the
gasket surface facing down.
2. Squirt mineral spirits into the intake and exhaust
valve ports and wait 5 minutes.
3. Use an inspection mirror to check valve seat area
for leakage of the mineral spirits past the valve
seats.
NOTE: If leakage occurs, the valves must be
reconditioned.

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128 CYLINDER HEAD AND VALVE TRAIN

Cylinder Head Cracking

Figure 156 Wiping dye penetrant off cylinder

Figure 154 Spraying brake cleaner on cylinder
head
head

3. Wipe off dye penetrant. The dye will remain in any

NOTE: The cylinder head cracking inspection can be
cracks in the cylinder head.
performed with or without valves installed.
1. Spray brake cleaner on the gasket surface of the
cylinder head and wipe it dry.

Figure 157 Spraying developer on cylinder head

Figure 155 Spraying dye penetrant on cylinder 4. Spray developer on the gasket surface of the
head cylinder head. Allow the developer to dry for 5-15
minutes.

2. Spray dye penetrant on the gasket surface of the

cylinder head. Leave the dye penetrant on for
1-10 minutes.

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 CYLINDER HEAD AND VALVE TRAIN 129

Figure 159 Cylinder head pressure test tools

1. Cylinder head test plate (bolts not shown)
2. Water supply housing pressure adapter
Figure 158 Crack in cylinder head 3. Thermostat opening pressure adapter- cylinder head

NOTE: Any cracks will show up as purple lines against 4. Fasten the pressure plate to the cylinder head
the white developer. If any cracks are present, replace gasket surface using the 24 mounting bolts and
the cylinder head. nuts supplied with the kit.
Pressure Check Cylinder Head
WARNING: To prevent personal injury or
Pressure testing the cylinder head will reveal cracks
death, wear safety glasses with side shields.
in ports or sleeve leakage which cannot be observed
Limit compressed air pressure to 207 kPa (30 psi).
using dye penetrant. Pressure-test the cylinder head
as follows: 5. Remove thermostat and install air regulator.
Secure to cylinder head with two mounting bolts.
1. Install fuel injectors into cylinder head injector
bores and secure. Refer to Fuel Injectors (Fuel 6. Remove the pipe plug next to the thermostat
Injectors, page352) for installation procedure. opening. Fill cylinder head with hot water and
reinstall pipe plug
2. Remove the valves, using a valve spring
compressor. See “Reconditioning” in this section 7. Install a hose fitting to the cylinder head at the
for valve removal instructions. removed plug. Apply 124–138 kPa (18–20 psi)
air pressure and inspect for leaks at the:
3. Pressure test the cylinder head using the cylinder
head pressure test tools (Table 17). • Fuel injector nozzle sleeve area
• Ports
• Upper deck
• Lower deck
If leakage is observed at any port or the upper and
lower deck, replace the cylinder head.

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130 CYLINDER HEAD AND VALVE TRAIN

Reconditioning
Removing Valves from Cylinder Head

WARNING: To prevent serious personal

injury, possible death, or damage to the engine
or vehicle, wear safety glasses when removing
valves or valve spring retainer keys.
1. Install a valve spring compressor tool over the
valve, see Cylinder head and valve special
service tools (Table 17). Compress the valve
spring.

Figure 161 Removing valve rotator, spring, and

valve stem seal
1. Valve stem seal
2. Valve stem
3. Valve spring
4. Valve rotator

3. Remove valve spring compression tool, valve

rotator, and spring.
4. Remove and discard valve stem seal.
5. Remove valve from the cylinder head.
6. Repeat steps 1-5 for all 24 valve locations.

Inspecting Valve Guides

Figure 160 Removing valve spring retainer keys

1. Valve spring compressor tool
2. Valve spring retainer key
3. Magnet

2. Use a magnet to remove the valve spring retainer

keys.

Figure 162 Cleaning valve guides

1. After removing valves, use soap, water, and a

nylon brush to clean valve guides.

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 CYLINDER HEAD AND VALVE TRAIN 131

2. Position an inspection light at the bottom of the 3. Use a ball gauge and an outside micrometer to
valve guide bores. Inspect bores for signs of measure the inside diameter of each valve guide.
burning or cracking. Replace any valve guides
If inside diameter of valve guide exceeds
that are damaged.
specifications, replace valve guide.
4. Measure the valve guides within 0.64 mm
(0.025 in) of each end and 90 degrees from
the crankshaft center line. Record the readings
in order to determine the valve-to-guide running
clearance later.

Replacing Valve Guides

Figure 163 Measuring valve guide with ball

gauge

Figure 165 Pressing out valve guide insert

1. Arbor press ram
2. Valve guide removal tool

1. Secure the cylinder head on a press table. Align

the valve guide to be replaced with the center of
the press ram.
2. Insert the valve guide removal tool into the valve
guide from the top side of the cylinder head. Press
out the valve guide insert.
CAUTION: To prevent engine damage, do not use a
hammer or any other tool to remove or install the valve
Figure 164 Measuring ball gauge with an guide inserts into the cylinder head.
outside micrometer
NOTE: Chilling the valve guide inserts first may
facilitate installation.

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132 CYLINDER HEAD AND VALVE TRAIN

Figure 167 Measuring valve stem diameter

1. Two measurements 90 degrees apart
Figure 166 Pressing in the valve guide insert 2. Valve stem diameter measurement locations
1. Arbor press ram
2. Valve guide installation tool
3. Valve guide insert 3. To check for wear, use a micrometer to measure
the diameter of each valve stem.
4. Measure the valve stem diameter at two locations
3. Lubricate a new valve guide insert with clean that are approximately equidistant. At each
engine oil. Use the valve guide installation sleeve location, take two measurements that are 90
to install the valve guide insert until the installation degrees apart. Average the two measurements
sleeve bottoms out against the cylinder head. at each location and record the readings.
NOTE: Do not ream the inside diameter of the valve If the average of measurements at any of the
guide after installation. Service valve guides are two locations exceed the valve stem diameter
provided in a finish reamed condition. specification, replace the valve.
4. After installing the valve guide insert, debur the 5. Inspect the valve stem tip for scoring, pitting, or
valve guide by using the valve guide deburring signs of excessive wear.
tool.
6. Using the valve stem diameter and valve guide
inside diameter measurements, recorded earlier
Inspecting Valves (see “Inspecting Valve Guides”) determine
valve stem-to-guide running clearance. See
1. Remove all carbon deposits from the valve stems “Specifications”. Replace the valve or valve
and valve heads. guides as required.
2. Inspect each valve for burn marks, warpage, NOTE: Subtract the average valve stem diameter
scuffing and bending. Replace any damaged from the average valve guide inner diameter
valves. (determined earlier).

Valve Guide – Valve Stem = Running Clearance.

Refacing Valves
Valve Face
NOTE: If the valves are in serviceable condition, they
may be refaced to the specified angles, as required.

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 CYLINDER HEAD AND VALVE TRAIN 133

CAUTION: To prevent engine damage, maintain the NOTE: Intake valves and exhaust valves have
minimum valve face margin across the entire valve different valve face margins.
face. An insufficient valve face margin will not provide
2. Install valve in the grinder and set the grinder to
proper heat dissipation, ultimately causing the valve
the specified angle.
to warp or break.
3. Turn on coolant and grinder.
NOTE: Make sure that there is sufficient coolant in the
valve grinding machine reservoir. Turn coolant pump NOTE: Removal of too much material may reduce the
on before grinding. margin below minimum specifications.
1. Use the dressing stud attachment on the grinder 4. Grind the valve face. Only remove the minimum
to dress the cutting stone. amount of material necessary.

Figure 170 Measuring valve face margin

5. Use a caliper to measure the valve face margin

at four locations. If any of the measurements are
less than the minimum specification (Table 13),
Figure 168 Grinding valve face
replace valve.

Valve Stem Tip

CAUTION: To prevent engine damage, leave a
sufficient amount of material so that the valve bridge
does not contact the valve retainer keys or valve
rotator during operation. Refacing the tip of the valve
stem provides a new wear surface for the valve
bridge.
1. Use the dressing stud attachment on the grinder
to dress the cutting stone.

Figure 169 Valve face angles

1. Intake margin
2. Intake valve angle
3. Exhaust margin
4. Exhaust valve angle

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134 CYLINDER HEAD AND VALVE TRAIN

1. After refacing a valve, spread a thin film of

Prussian Blue® on the valve face and insert the
valve in the valve guide.

Figure 171 Grinding valve stem

Figure 173 Turning valve on valve seat

2. Install the valve in the grinder so that the tip of the
valve stem is close to the grinding stone.
2. Apply pressure on the center of the valve head
3. Briefly touch the tip of the valve stem to the
while turning the valve 90 degrees on the valve
grinding stone. Only remove the minimum
seat.
amount of material that is necessary.
3. Remove the valve from the cylinder head. Check
the impression that was made on the valve seat
Checking Valve Face-to-Valve Seat Contact and valve face. Prussian Blue should appear
around the entire contact surface of the valve
seat and valve face.
4. Perform this check several times to rule out any
errors. If the Prussian Blue® contact impression
is good, proceed to valve installation. If the
Prussian Blue® contact impression is not good,
continue with resurfacing valve seats.

Figure 172 Applying Prussian Blue® to valve

face

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 CYLINDER HEAD AND VALVE TRAIN 135

Resurfacing Valve Seats

Figure 175 Grinding the valve seat

1. Motor and drive
2. Holder
3. Grindstone

4. Turn on the power and gently apply the weight of

the grinding motor to the grindstone. Raise the
grinding stone frequently to prevent overheating.
Grind the valve seat to a smooth even finish,
paying attention to achieving an acceptable
Figure 174 Installing valve guide pilot
uniform width (Table 15).

1. Lightly lubricate the correct size of grinding pilot.

Install the pilot into the valve guide.
2. Choose the correct angle grinding stone and
dress the stone. See “Specifications” for the
correct valve seat angle.
3. Install the grinding stone over the pilot.

Figure 176 Checking valve seat width

5. Use a caliper to check the valve seat width. If

the valve seat width exceeds specifications, the
valve seat may be corrected by grinding with a 15
degree or smaller angle stone.

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136 CYLINDER HEAD AND VALVE TRAIN

Replacing Valve Seats

Removal

Figure 177 Checking valve recession

6. Install valve in guide. Use a depth micrometer

to check valve recession. If valve recession
is excessive, install a new valve or replace Figure 178 Grinding group tool
valve seat as necessary. If the valve protrudes 1. Air motor
above the surface of the cylinder head, regrind 2. Grinding base
the valve seat. After grinding the valve seat, 3. Grinding wheel
check valve seat width again. Also check the
valve face-to-valve seat contact (Checking Valve
Face-to-Valve Seat Contact, page134). 1. Use grinding group tool (Table 17) to cut a groove
7. Use an appropriate dial indicator to check in the valve seat insert.
the valve seat runout. If runout exceeds
specifications, replace valve seat.

Figure 179 Grinding groove in valve seat

2. Position the appropriate size extractor in the valve

seat.

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 CYLINDER HEAD AND VALVE TRAIN 137

Figure 180 Removing the valve seat insert

1. Lifting bridge
2. Valve seat remover (collet) Figure 181 Valve seat insert removed
1. Collet
2. Valve seat insert
3. Expand collet by threading the shaft into the valve
seat remover until it is tight inside the valve seat.
Turn T-handle on shaft to pull the valve seat insert 4. Unlock the collet by loosening the threaded shaft.
from cylinder head. Discard valve seat insert.

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138 CYLINDER HEAD AND VALVE TRAIN

Installation
1. Use a micrometer to measure the diameter of the
valve seat insert counterbore at two locations,
90° apart. Average the two measurements to
determine the appropriate size valve seat insert
to install.

Table 12 Valve Seat Insert Selection Chart

Available inserts (int. and Ave. dia. of intake counterbore Ave. dia. of exhaust counterbore
exh.)
Standard 40.119 - 40.170 mm (1.5795 - 1.5815 37.478 - 37.529 mm (1.4755 - 1.4775
in) in)
Oversize - 0.05 mm (0.002 in) 40.170 - 40.221 mm (1.5815 - 1.5835 37.529 - 37.579 mm (1.4775 - 1.4795
in) in)

2. Chill the valve seat insert in a freezer for 30

minutes. This will prevent the outer layer of metal
from being shaved off during installation.

Figure 183 Driving valve seat into place

4. Using a hammer and valve seat installation tool

Figure 182 Placing chilled valve seat into head drive the valve seat into place until it is fully
seated. See Cylinder head and valve special
service tools (Table 17).
3. Align insert over counterbore to avoid 5. Grind new valve seats to the specified angles and
misalignment. widths, see Cylinder Head Specifications (Table
15) in this section.

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 CYLINDER HEAD AND VALVE TRAIN 139

Inspecting Valve Springs NOTE: These wear notches can also be detected
by compressing the spring and listening for a
1. Clean all of the valve springs in a suitable solvent.
clicking sound.
CAUTION: To prevent engine damage, do not wire
brush or grind valve springs. Disruption of surface
may result in fatigue cracks and spring failure.
2. Check the valve springs for rust, cracks, and
pitting. Replace any damaged valve springs.

Figure 185 Checking perpendicularity and

flatness of valve spring

NOTE: Valve springs that are not perpendicular to a

flat surface place an unequal lateral load on the valve
stem during operation, causing premature valve guide
Figure 184 Valve spring inspection wear.
4. Use a square to check flatness and
perpendicularity of spring ends. If the end
3. Check both ends of each valve spring at the of any valve spring is not flat and square, replace
contact point between the cutoff end of the last spring.
coil and the adjacent coil. If the cutoff end has
worn a notch in the adjacent coil, replace the
spring.

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140 CYLINDER HEAD AND VALVE TRAIN

Figure 186 Measuring valve spring tension

Figure 187 Checking valve rotator
1. Ram
5. Use a Valve Spring Compressor (Table 17) to 2. Steel ball bearing
measure the valve spring tension. Measure the 3. Paint reference line
maximum and minimum lengths of the spring at 4. Spring
the appropriate test loads (valve closed and valve 5. Valve rotator
open). Replace any valve spring that does not
meet valve spring specifications (Table 14).
2. Lubricate the valve rotator with clean engine oil.
Place the valve spring and rotator in spring tester.
Inspecting Valve Rotators
3. Place a ball bearing between the valve rotator and
1. Clean all valve rotators in a suitable solvent. the ram of the spring tester. The ball bearing must
be large enough to prevent the ram from touching
any part of the rotator.
4. Paint a reference line on the valve rotator and
spring.
5. Compress the valve spring rapidly with even
pressure and observe the valve rotator as it turns.
Replace any valve rotator that does not turn.

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 CYLINDER HEAD AND VALVE TRAIN 141

Inspecting Valve Spring Retainer Keys 5. Use a stiff wire brush to clean deposits and
hardened sealant from the fuel injector bore.
1. Clean all valve spring retainer keys with a suitable
solvent. 6. Insert a small stiff nylon brush tool into oil gallery
for cleaning.
2. Check the inside and outside of the valve spring
retainer keys for wear. Replace any worn retainer
keys. WARNING: To prevent personal injury or
death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).
Replacing Fuel Injector Sleeves
7. Use compressed air to clean out all fuel and oil
Removal galleries of debris.
NOTE: If the fuel injector sleeve is being removed
while the engine is in-chassis, place a cup plug in the
Installation
bore before removal to prevent debris from entering
the cylinder bore. 1. Inspect installation tool for a bent pilot shaft or any
nicks where sleeve will seat
1. Insert the fuel injector sleeve removal tool into the
fuel injector bore.
2. Turn the removal tool to cut threads into the fuel
injector sleeve. Remove the tool from the bore.
3. Install the fuel injector sleeve puller tool into the
bore and tighten. Make sure that the puller tool is
threaded all the way into the fuel injector sleeve.
4. Install a slide hammer onto the puller tool.
Remove the fuel injector sleeve from the bore.

Figure 189 Applying Loctite® 620 sealant to fuel

injector sleeve

2. Place a new fuel injector sleeve on the end of

the installation tool. See cylinder head and valve
special service tools (Table 17).

Figure 188 Cleaning fuel injector bore

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142 CYLINDER HEAD AND VALVE TRAIN

installation tool is not causing such damage. Use

a different installation tool, if necessary.

Installing Valves
Cleaning

WARNING: To prevent personal injury or

death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).
1. Clean the valve faces and seats with a suitable
cleaning solvent. Dry all components using
filtered compressed air.
Figure 190 Installing fuel injector sleeve into
bore 2. To clean valve guides, coat a brush with soap and
water. Insert the brush into each valve guide bore
and rotate in one direction with an up and down
3. Apply Loctite® 620 around the outside diameter at motion. Dry the valve guide bores using filtered
the bottom of the sleeve and around the beginning compressed air.
of the taper at the middle of the sleeve. 3. Insert a large nylon brush in the rear of the fuel rail
gallery to loosen any dirt and deposits. Blow out
any debris using filtered compressed air.

Assembly

Figure 191 Installing fuel injector sleeve

4. Install the sleeve and installation tool into the fuel

injector bore. Figure 192 Installing valve stem seal, spring,
and valve rotator
5. Use a hammer to drive the fuel injector sleeve into
the bore. Remove the installation tool when the 1. Valve stem seal
sleeve is seated. 2. Valve stem
3. Valve spring
6. Use a soft nylon brush to clean the fuel injector
4. Valve rotator
sleeve after installation.
7. Inspect the inside surfaces of the installed fuel
injector sleeve. If nicks and scratches are evident, 1. Lubricate the valve stems with clean engine oil
replace the sleeve again. Make sure that the and insert into the valve guides.

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 CYLINDER HEAD AND VALVE TRAIN 143

2. Lubricate the inside diameter of the new valve

stem seals with clean engine oil. Install the seals
over the valve stems and valve guides. Make sure
that the seals are completely seated against the
cylinder head spring pockets.
3. Install the valve springs over the valve stem seals.
4. Then install the valve rotators on top of the valve
springs.

WARNING: To prevent serious personal

injury or possible death, wear safety glasses
before using the valve spring compressor.

Figure 193 Installing valve spring retainer keys

1. Valve spring compressor tool
2. Valve spring retainer key

5. Install a valve spring compressor tool over the

valve. See cylinder head and valve special
service tools (Table 17). Compress the valve
spring.
6. Install the valve spring retainer keys.

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144 CYLINDER HEAD AND VALVE TRAIN

Installation
Roller Tappets

Figure 195 Installing alignment dowels

Figure 194 Roller tappets and guide 3. Install or verify that alignment dowels are in the
top of the crankcase.
1. Lubricate roller tappets with clean engine oil.
2. Install each roller tappet and guide into tappet
bore. Install used roller tappets in their original
locations, revolving in the same direction as
before removal.

Installing the Cylinder Head

NOTE: Before cylinder head installation, check
cylinder sleeve protrusion (Checking Cylinder Sleeve
Protrusion, page229).
1. Install two lifting eyes with four bolts (M12 x 25)
onto cylinder head. Tighten bolts to the standard
torque value (General Torque Guidelines, page
445). Figure 196 Installing cylinder head gasket
2. Clean and dry the cylinder head gasket surface. 1. Alignment dowels
Also use the correct size tap to clean head bolt
holes in the crankcase.
4. Install a new cylinder head gasket over the
alignment dowels.

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 CYLINDER HEAD AND VALVE TRAIN 145

5. Attach an appropriate hoist and lifting hooks to the

lifting eyes. Carefully lower the cylinder head onto
the crankcase.

Figure 197 Lowering cylinder head onto

crankcase

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146 CYLINDER HEAD AND VALVE TRAIN

Torque-to-Yield Procedure for Cylinder Head

Bolts
CAUTION: To prevent engine damage, do not reuse
cylinder head bolts; install new bolts.
NOTE: Do not use chlorinated solvents on cylinder
head bolts. Parts should be clean, dry, and free of
chemicals other than engine oil.
1. Lightly lubricate threads and bolt flange of new 26
cylinder head bolts with clean engine oil.
2. Install all new cylinder head bolts finger tight.

20 12 4 5 13 21

24 16 8 1 9 17 25

23 15 7 2 10 18 26

19 11 3 6 14 22

H08040

Figure 198 Torque sequence A for cylinder head bolts

3. Tighten each cylinder head bolt to 204 N·m (150

lbf·ft) in cylinder head torque sequence A.

21 22 23 24 25 26

14 15 16 17 18 19 20

7 8 9 10 11 12 13

1 2 3 4 5 6

H08105

Figure 199 Torque sequence B for cylinder head bolts

4. Tighten each cylinder head bolt to 204 N·m (150 NOTE: It is necessary to tighten cylinder head bolts
lbf·ft) in cylinder head torque sequence B. in both sequence A and B to obtain uniform head bolt
torque.

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 CYLINDER HEAD AND VALVE TRAIN 147

CAUTION: To prevent engine damage, use 8. Install head bolt socket on head bolt to be torqued
permanent marker to identify internal engine (Cylinder head bolt torque sequence B) and align
components and their orientation. Do not use paint mark on socket with the mark on the head bolt.
or temporary markers.

Figure 201 Head bolt rotated 90° CW

9. Rotate cylinder head bolt 90 degrees CW (1/4

turn). The marks on the head bolt socket, head
Figure 200 Cylinder head and head bolt torque
bolt, and cylinder head surface should align.
markings
10. Repeat steps 8 and 9 for each cylinder head bolt
1. Mark on cylinder head bolt
in cylinder head bolt torque sequence B.
2. Mark on cylinder head surface next to head bolt mark
3. Mark on cylinder head surface 90° CW from head
bolt mark
4. Mark on cylinder head surface 120° CW from head
bolt mark

5. Using permanent marker, place a mark on each

head bolt and put another mark on the head
bolt socket directly in line with the mark on each
head bolt. Put another mark on the cylinder head
surface next to the head bolt mark. (Figure 200)
Items 1 and 2 Figure 202 Head bolt rotated 120° CW
6. Place a mark on the cylinder head surface 90
degrees clockwise (CW) from each head bolt
11. Rotate each cylinder head bolt an additional
mark. (Figure 200) Item 3
30 degrees CW in cylinder head bolt torque
7. Place a mark on the cylinder head surface 120 sequence B for a total of 120 degrees (two hex
degrees (two hex flats) CW from each head bolt flats). The marks on the head bolt socket, head
mark. (Figure 200) Item 4 bolt, and cylinder head surface should align.

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148 CYLINDER HEAD AND VALVE TRAIN

Valve Train Components Installing Rocker Arms

Engine valve train load carrying requirements
have resulted in different push rod and tappet
configurations. The main differences are noted
by improved geometry designs and materials.
For information on push rod and tappet compatibility
for different engine model year configurations, see
(TSI-06-12-14 Update Valve Train Components –
Push Rod and Tappet Compatibility, page469).
A small geometry adjuster kit provides a replacement
large geometry rocker shaft assembly with small
geometry adjuster screws that can be used with
existing small geometry push rods and tappets. See
(TSI-06-12-21 Update Valve Train Components –
Adjuster Screws, page474).

Figure 203 Rocker arm configuration

1. Clamp bolt assembly
2. Exhaust rocker arm
3. Rocker arm shaft support
4. Lower support washer
5. Machined recessed
6. Intake rocker arm

1. Install push rods.

2. Slide each of the 12 rocker arms onto the rocker
shaft in the order they were removed (rocker arms
should have been marked for this occasion).
NOTE: Ensure that the rocker arm shaft has the big T
stamped facing up (Figure 204).
3. Place a bolt and clamp assembly through each
rocker arm shaft support and align shaft with bolt
hole in cylinder head (Figure 203).
4. Install plastic washer (assembly aid) onto each
intake rocker arm retaining bolt.

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 CYLINDER HEAD AND VALVE TRAIN 149

Installing the Rocker Arm Assembly

1. Place valve bridges across each set of valves.
These should be marked if removed. The
recessed holes set over the valve stems.

FRONT

1 2 3 4 5 6 7 8 9 10 11 12

H08025

Figure 204 Rocker arm orientation

2. Align rocker arm assembly with bolts over

mounting holes and thread hand tight.

12 9 8 5 4 1 2 3 6 7 10 11

H08039

Figure 205 Rocker arm torque sequence

3. Torque bolts in two passes in the sequence b. Torque rocker arm clamp assembly bolts to 37
illustrated above and to the specified value. N·m (27 lbf·ft) for the final pass.
a. Torque rocker arm clamp assembly bolts to 27
N·m (20 lbf·ft) for the first pass.

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150 CYLINDER HEAD AND VALVE TRAIN

Valve Lash for Intake and Exhaust Valves Adjusting Valve Lash
During the procedure to adjust valve lash, the 1. Remove valve cover (Valve Cover, page120).
crankshaft is rotated two times:
2. Turn the crankshaft in the direction of engine
• Six adjustments are made when piston 1 is at Top rotation to remove gear lash. Position piston 1 at
Dead Center (TDC) compression. TDC compression by observing cylinder 6 rocker
arms in overlap as the vibration damper timing
• Six adjustments are made when piston 6 is at Top
mark approaches the TDC mark on the front
Dead Center (TDC) compression.
cover. Cylinder 6 exhaust valve will be closing
If the engine is equipped with the Diamond Logic® (coming up) and the intake valve will be starting
engine brake, corresponding brake actuator lash to open (going down).
(Adjusting Valve Lash, page 150) can be adjusted
3. If piston 1 is at TDC compression, see Chart 1
before and after rotating the crankshaft the second
(page151) and do steps 4 and 5 for cylinders 1, 3,
time.
and 5.

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 CYLINDER HEAD AND VALVE TRAIN 151

Chart 1
Valve and brake lash adjustments (inches) with piston 1 at TDC compression (Chart 1)
Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6
intake exhaust intake exhaust intake exhaust intake exhaust intake exhaust intake exhaust
1 2 3 4 5 6 7 8 9 10 11 12

0.019 0.019 0.019 0.019 0.019 0.019

Brake 0.019 Brake 0.019 Brake 0.019

Valve and brake lash adjustments with piston 1 at TDC compression

Chart 2
Valve and brake lash adjustments (inches) with piston 6 at TDC compression (Chart 2)
Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6
intake exhaust intake exhaust intake exhaust intake exhaust intake exhaust intake exhaust
1 2 3 4 5 6 7 8 9 10 11 12

0.019 0.019 0.019 0.019 0.019 0.019

Brake 0.019 Brake 0.019 Brake 0.019

Valve and brake lash adjustments with piston 6 at TDC compression

Figure 206 Valve lash adjustment

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152 CYLINDER HEAD AND VALVE TRAIN

remove feeler gauge. Recheck valve lash. A light

drag should be felt on the feeler gauge. If drag is
too tight or loose, repeat steps 4 and 5.
If engine is equipped with a Diamond Logic®
engine brake, corresponding brake actuator lash
can be adjusted before rotating crankshaft.
6. Turn crankshaft 360° in the direction of engine
rotation to remove gear lash. Position piston 6 at
TDC compression by observing cylinder 1 rocker
arms in overlap as the vibration damper timing
mark approaches the TDC mark on the front
cover.
7. If piston 6 is at TDC compression, see Chart 2
(page151) and do steps 4 and 5 for cylinders 2, 4,
and 6.

Figure 207 Feeler gauge between the pivot foot High-pressure Oil Rail Assembly
and valve bridge
1. Install high-pressure oil rail assembly. See
(High-pressure Oil Rail Assembly, page353).
4. Measure valve lash when engine is cold. Put
0.048 mm (0.019 in) feeler gauge (Table 56)
between the pivot foot and valve bridge. A light Valve Cover
drag on the feeler gauge should be felt. on the 1. Install valve cover gasket.
feeler gauge. If adjustment is required, loosen
locknut and turn valve adjustment screw until a 2. Connect all electrical and injector connectors to
light drag if felt. the valve cover gasket, if disconnected.

5. Once valve lash is set, tighten valve adjustment 3. Install valve cover onto cylinder head.
screw locknut to Special Torque (Table 55) and

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 CYLINDER HEAD AND VALVE TRAIN 153

1 1

1 1 2 H08100

Figure 208 Valve cover assembly detail

1. Bolt / stud, M8 x 80 / 19 (4) 3. Valve cover harness mounting 4. Bolt, M8 x 80 (6)
2. Extension bracket bracket

4. Install four valve cover bolt / studs (M8 x 80 / 19) 8. Connect crankcase ventilation piping (Crankcase
finger tight. Ventilation System, page274).
5. Install six valve cover bolts (M8 x 80) finger tight. 9. Add coolant (if cylinder head was removed in
chassis).
6. Tighten all bolts and studs to the standard torque
value (General Torque Guidelines, page445).
7. Add any necessary brackets to the appropriate
studs.

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154 CYLINDER HEAD AND VALVE TRAIN

Specifications

Table 13 Valve Specifications

Camshaft lobe lift Intake: 6.68 mm (0.263 in)
Exhaust: 6.91 mm (0.272 in)
Valve face angle Intake: 59.75 - 60.00°
Exhaust: 44.75 - 45.00°
Valve face margin (min.) Intake: 1.32 mm (0.052 in)
Exhaust: 1.16 mm (0.046 in)
Valve face-to-valve stem runout (max.) 0.038 mm (0.0015 in)
Valve lash (cold), intake and exhaust 0.48 mm (0.019 in)
Valve stem diameter (new condition) Intake: 7.928 ± 0.0089 mm (0.3121 ± 0.00035
in)
Exhaust: 7.908 ± 0.0089 mm (0.3113 ± 0.00035
in)
Valve stem-to-valve guide clearance (max.) Intake: 0.10 mm (0.004 in)
Exhaust: 0.11 mm (0.005 in)

Table 14 Valve Spring Specifications

Intake and Exhaust Valve Springs
Free length 52.35 mm (2.061 in)
Solid height (max.) 27.43 mm (1.080 in)
Valve closed test length @ 410.1 ± 24.5 N (92.2 ± 5.5 40 mm (1.575 in)
lbf) test load

Valve closed test length @ 764.2 ± 48.9 N (171.8 ± 29.3 mm (1.155 in)
11.0 lbf) test load

Table 15 Cylinder Head Specifications

Cylinder head gasket surface flatness 0.10 mm (0.004 in.) per 229 mm (9.0 in)
Cylinder head thickness New: 160.48 mm (6.318 in)
Minimum: 159.97 mm (6.298 in)
Exhaust valve seat insert counterbore diameter Standard: 37.503 ± 0.003 mm (1.477 ± 0.001 in)
Oversize: 0.05 mm (0.002 in) 37.55 ± 0.03 mm
(1.478 ± 0.001 in)
Exhaust valve seat outside diameter Standard: 37.56 mm (1.479 in)
Oversize: 0.05 mm (0.002 in) 37.61 mm (1.481 in)
Intake valve seat insert counterbore diameter Standard: 33.50 ± 0.03 mm (1.319 ± 0.001 in)

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 CYLINDER HEAD AND VALVE TRAIN 155

Table 15 Cylinder Head Specifications (cont.)

Oversize: 0.05 mm (0.002 in) 35.55± 0.03 mm
(1.321 ± 0.001 in)
Intake valve seat outside diameter Standard: 40.20 mm (1.583 in)
Oversize: 0.05 mm (0.002 in) 40.25 mm (1.585 in)
Push rod runout (maximum) 0.508 mm (0.020 in)
Valve guide bore diameter 14.308 ± 0.017 mm (0.5633 ± 0.0007 in)
Valve guide bore out-of-round (max.) 0.005 mm (0.0002 in)
Valve guide bore taper (max.) 0.013 mm (0.0005 in)
Valve guide height from cylinder head spring pocket
16.53 ± 0.13 mm (0.651 ± 0.005 in)
(intake)
Valve guide insert inside diameter (installed) 7.98 - 8.00 mm (0.314 - 0.315 in)
Valve guide insert interference fit dimension 0.043 mm (0.0017 in)
Valve guide insert outside diameter 14.351 ± 0.010 mm (0.5650 ± 0.0004 in)
Valve guide length (overall) 65.71 mm (2.587 in)
Valve recession Intake: 1.02 mm (0.040 in)
Exhaust: 1.40 mm (0.055 in)
Valve seat angles Intake: 59.75 - 60°
Exhaust: 44.75 - 45°
Valve seat runout (max.) 0.05 mm (0.002 in)
Valve seat width 1.91 - 2.16 mm (0.075 - 0.085 in)

Special Torque

Table 16 Cylinder Head and Valve Train Special Torques

BCP sensor 20 - 30 N·m (15 - 22 lbf·ft)
Cylinder head mounting bolts torque and sequence
Fuel injector mounting bolt 41 N·m (30 lbf·ft)
High-pressure oil hose fitting 46 N·m (34 lbf·ft)
ICP sensor 20 - 30 N·m (15 - 22 lbf·ft)
Rocker arm bolts torque and sequence (Installing Rocker Arms, page148)
Valve adjustment locknut 27 N·m (20 lbf·ft)

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156 CYLINDER HEAD AND VALVE TRAIN

Special Service Tools

Table 17 Cylinder Head Special Service Tools

Cylinder head test plate ZTSE4289A
Dye penetrant kit Obtain locally
Feeler gauge Obtain locally
Injector sleeve brush set (set of 2) ZTSE4304
Injector sleeve installer ZTSE4642
Injector sleeve remover ZTSE4643
Pressure regulator Obtain locally
Slide hammer puller set ZTSE1879
Small hole gauge set Obtain locally
Straightedge Obtain locally
Thermostat opening pressure adapter ZTSE4647
Valve guide deburring tool ZTSE4393
Valve guide installer ZTSE1943
Valve guide remover ZTSE4377
Valve seat extractor kit (universal) ZTSE1951C
Valve seat grinder ZTSE1631A
Valve seat grinding stones 45° (exhaust) Obtain locally
Valve seat grinding stones 60° (intake) Obtain locally
Valve seat installer ZTSE4641
Valve seat remover (collet) ZTSE4640
Valve spring compressor ZTSE1846
Valve spring compressor jaws ZTSE4652
Water supply housing pressure adapter ZTSE4648

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 FRONT COVER AND RELATED COMPONENTS 157

Table of Contents

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
.
Front Cover assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159 .
Gerotor oil pump assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159 .

Checking Gear Train Timing without Removing Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162 .

DT 466 Engines Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
.
Method One – Using a Feeler Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162 .
Method Two – Using a Dial Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162 .
DT 570 and HT 570 Engines Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163 .
Method One – Using a Feeler Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163 .
Method Two – Using a Dial Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163 .

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
.
Alternator Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164 .
Flat Idler Pulley and Automatic Belt Tensioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165 .
Water Supply Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165 .
Water Inlet Elbow, Water Outlet Tube, and Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165 .
Fan Drive Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166 .
Water Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167 .
Vibration Damper, Damper Hub, and Wear Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168 .
Gerotor Assembly Oil Pump and Front Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169 .
Front Engine Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171 .
Front Cover (Front Half). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172 .
Generation 1 (Mounting Bolts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172 .
Generation 2 (Mounting Bolts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173 .
Idler Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174 .
Front Cover (Rear Half). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176 .

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
.
Checking Lower Idler Gear Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177 .
Checking Upper Idler Gear Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177 .
Checking Camshaft Gear Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178 .
Gerotor Oil Pump Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178 .
Measuring Oil Pump Side Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178 .
Measuring Oil Pump End Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179 .

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
.
Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180 .
Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180 .
Mounting Bolts (Rear Half). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181 .
Idler Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182 .
Front Cover (Front Half). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184 .
Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184 .
Generation 1 (Mounting Bolts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185 .
Generation 2 (Mounting Bolts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186 .
Front Engine Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187 .

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158 FRONT COVER AND RELATED COMPONENTS

Gerotor Oil Pump Assembly and Front Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187 .

POSE Dust Seal and Wear Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190 .
Vibration Damper Hub and Damper Retaining Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191 .
Vibration Damper assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192 .
Fan Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
.
Horton DriveMaster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195 .
Water Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196 .
Water Supply Housing . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197 .
Alternator Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197 .
Flat Idler Pulley and Automatic Belt Tensioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198 .
Water Inlet Elbow, Water Outlet Tube, and Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198 .

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
.

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

.

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202

.

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 FRONT COVER AND RELATED COMPONENTS 159

Description NOTE: If the (rear half) of a Generation 1 front

cover assembly needs to be replaced, install a new
Generation 2 front cover assembly (front and rear
FRONT COVER ASSEMBLIES half). The (rear half) of the Generation 1 front cover
assembly is not available for service.
The front cover assembly was modified as a
production running change from Generation 1 to See removal and installation procedures for
Generation 2 for International® DT 466, DT 570 and Generation 1 (Mounting Bolts) and Generation 2
HT 570 Diesel Engines. (Mounting Bolts), listed in the Table of Contents in
this section.
• Generation 1 front cover assemblies include a
water pump wear plate; Generation 2 front cover
assemblies do not have a water pump wear plate. GEROTOR OIL PUMP ASSEMBLY
• Generation 2 front cover assemblies have
Up to late Model Year 2006, all International® DT 466,
additional bolts to secure the front cover (front
DT 570 and HT 570 Diesel Engines were equipped
half) to the front cover (rear half).
with an 8 lobe gerotor oil pump.
• Generation 1 and Generation 2 front cover
Later in Model Year 2006, International® DT 466 (210
assemblies are not interchangeable.
to 245 horsepower) Diesel Engines were equipped
• Some Generation 2 front covers are equipped with a 10 lobe gerotor oil pump.
with a sound shield. When replacing a front cover
NOTE: Removal, inspection, and installation
equipped with a sound shield, replace it only with
procedures for the Gerotor oil pump assembly, show
a cover equipped with a sound shield, to ensure
the 8 lobe gerotor oil pump. Removal, inspection,
that noise reduction requirements are maintained.
and installation procedures for the 10 lobe gerotor oil
pump are the same as for the 8 lobe gerotor oil pump.

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160 FRONT COVER AND RELATED COMPONENTS

1 2 3 4 5 6

56 57 58

9 10 11
59
51
50
49
48
47
55

54
53
45 46
52
13
44
12
14
15
30
31 60
32
33
34 16
18
43 35 17 19
20
21
22
23
42 24
25
41 36 26
27
37 28
38 29 H06086
40 39

Figure 209 Front cover related components (less gear train)

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 FRONT COVER AND RELATED COMPONENTS 161

1. Flat idler pulley assembly 24. Front oil seal 44. Auto tensioner
2. Bolt, M10 x 25 (4) 25. Wear sleeve 45. Fan drive assembly
3. Water supply housing 26. Damper hub 46. Coolant gasket
4. Coolant port seal 27. Damper retaining plate 47. Flat head socket screw, M5 (3)
5. Bolt, M8 x 25 (2) 28. Vibration damper 48. Water pump wear plate
6. Water outlet tube assembly 29. Bolt, M10 x 16 (6) (Generation 1 front covers
7. Thermostat assembly 30. Dowel only)
8. Alternator bracket 31. Water inlet gasket 49. Cup plug
9. Nut, M8 32. Water inlet elbow 50. Cover, rear half
10. Coolant gasket 33. Bolt, M8 x 30 (3) 51. Dowel
11. Oil gasket 34. Front cover gasket (oil) 52. Bolt, M8 x 20 (6)
12. Oil pump drive 35. O-ring seal 53. Fan drive pulley
13. Vibration damper key 36. Bolt, M8 x 30 see bolt locations 54. Bolt, (4) see bolt sizes (Table 18)
14. Dowels (2) (Figure 252) 55. Bolt, M6 x 12 (4)
15. Washer, seal 37. O-ring seal (#235), PTO 56. Bolt, (5) see water pump (Figure
16. Pin, 6 mm x 16 mm equipped only 272)
17. Bolt, M12 x 40 (3) 38. End cover adapter, PTO 57. Water pump assembly
18. Oil pump (housing plate) seal equipped only 58. Water pump seal
19. Oil pump housing plate 39. Bolt, M10 x 40 (2), PTO 59. Water pump pulley
20. Gerotor oil pump assembly equipped only 60. Bolt, M8 x 60 (2) see bolt
21. Oil pump (housing) seal 40. Bolt, M18 x 100 (2) locations (Figure 228)
22. Oil pump housing 41. Bolt, M18 x 70 (2)
23. Bolt, M8 x 25 (4) See bolt 42. Front engine mount
locations (Figure 228) 43. Cover, front half (PTO equipped)

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162 FRONT COVER AND RELATED COMPONENTS

Checking Gear Train Timing the timing notch as viewed from the front of the
without Removing Front Cover engine.

Valve train failures from broken or bent push rods, 3. Place a 0.28 mm (0.011 in) feeler gauge between
valves, rocker arms and worn valve keepers and/or the rocker arm and the valve bridge of the No. 1
rotators in many instances could be caused by intake valve. Slowly rotate the engine forward
improper timing of the gear train. Depending on valve (clockwise) until the intake valve starts to lift and
lash setting, if the camshaft gear is improperly timed the feeler gauge becomes tight. The mark should
by one tooth early, the engine pistons will strike the line up with the TDC arrow on the front cover or be
intake valve heads or if the timing is set one tooth within 3.5 crankshaft degrees of it. 3.5 degrees is
late, the exhaust valves may contact pistons. equivalent to a radial (or straight) line distance of
6.8 mm (0.27 in) at the damper pulley.
NOTE: Before attempting to check gear train timing,
it will be necessary to remove the valve cover, valve NOTE: One tooth “out of time” on the gear train equals
cover gasket, and high-pressure oil manifold or approximately 11 degrees of movement or 21.4 mm
Diamond Logic® engine brake. See the appropriate (27/32 in) of radial distance of damper pulley.
sections of this manual regarding removal and 4. If the timing on the No. 1 valve is within
installation procedures. specifications, the other valves, barring extreme
DT 466 Engines Only camshaft lobe wear or poor adjustment, will also
be in time. If timing is found to be incorrect,
Method One – Using a Feeler Gauge removal of the front cover is required to inspect
1. Rotate the engine to approximately TDC (Top the punch marks on the gear train.
Dead Center) compression on No. 1 cylinder (no
valves open). Set the lash on the No. 1 intake
valve to the nominal lash setting of 0.48 mm Method Two – Using a Dial Indicator
(0.019 in). 1. Adjust the No. 1 intake valve with the No. 1 piston
set at TDC (Top Dead Center) compression stroke
to 0.48 mm (0.019 in). Install a 0.28 mm (0.011
in) feeler gauge between the rocker arm and the
valve bridge of the No. 1 intake valve.
2. Position the magnetic base dial indicator on the
valve cover fence of the cylinder head rail with the
indicator tip on the No. 1 intake rocker arm tip.
3. Zero the dial indicator.
4. Rotate the engine approximately one full
revolution in either direction to a position 360
degrees from starting point.
Figure 210 Checking Engine Gear Train Timing 5. The dial indicator should read within the range of
0.13-0.25 mm (0.005-0.010 in) from the starting
1. Straight line dimension
position for proper gear train timing.
2. Radial distance dimension
3. Scribe mark 6. If dial indicator readings are found to be outside of
4. Damper timing notch this range, removal of the front cover is required
to inspect the punch marks on the gear train.

2. Scribe a mark on the damper pulley at a radial

distance of 82.5 mm (3.25 in) or a straight line
distance of 81 mm (3.188 in) clockwise from

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 FRONT COVER AND RELATED COMPONENTS 163

DT 570 and HT 570 Engines Only line up with the TDC arrow on the front cover or
be within 3.5 crankshaft degrees of it. 3.5 crank
Method One – Using a Feeler Gauge
degrees is equivalent to a radial (or straight) line
1. Rotate the engine to approximately TDC (Top distance of 8.1 mm (0.32 in) at the damper pulley.
Dead Center) compression on No. 1 cylinder (no
NOTE: One tooth “out of time” on the gear train equals
valves open). Set the lash on the No. 1 intake
approximately 11 degrees of movement or 21.4 mm
valve to the nominal lash setting of 0.48 mm
(27/32 in) of radial distance of damper pulley.
(0.019 in).
4. If the timing on the No. 1 valve is within
specifications, the other valves, barring extreme
camshaft lobe wear or poor adjustment, will also
be in time. If timing is found to be incorrect,
removal of the front cover is required to inspect
the punch marks on the gear train.

Method Two – Using a Dial Indicator

1. Adjust the No. 1 intake valve with the No. 1 piston
set at TDC (Top Dead Center) compression stroke
to 0.48 mm (0.019 in). Install a 0.28 mm (0.011
in) feeler gauge between the rocker arm and the
Figure 211 Checking Engine Gear Train Timing valve bridge of the No. 1 intake valve.

1. Straight line dimension 2. Position the magnetic base dial indicator on the
2. Radial distance dimension valve cover fence of the cylinder head rail with the
3. Scribe mark indicator tip on the No. 1 intake rocker arm tip.
4. Damper timing notch 3. Zero the dial indicator.
4. Rotate the engine approximately one full
2. Scribe a mark on the damper pulley at a radial revolution in either direction to a position 360
distance of 100.0 mm (3.94 in) or a straight line degrees from starting point.
distance of 97.8 mm (3.85 in) clockwise from 5. The dial indicator should read within the range of
the timing notch as viewed from the front of the 0.13-0.25 mm (0.005-0.010 in) from the starting
engine. position for proper gear train timing.
3. Place a 0.28 mm (0.011 in) feeler gauge between 6. If dial indicator readings are found to be outside of
the rocker arm and the valve bridge of the No. 1 this range, removal of the front cover is required
intake valve. Slowly rotate the engine forward to inspect the punch marks on the gear train.
(clockwise) until the intake valve starts to lift and
the feeler gauge becomes tight. The mark should

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164 FRONT COVER AND RELATED COMPONENTS

Removal
WARNING: To prevent personal injury or
death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash
GOVERNMENT REGULATION: Engine with soap and water. Wash or discard clothing
fluids (oil, fuel, and coolant) may be a hazard and rags contaminated with engine fluids.
to human health and the environment.
Alternator Bracket
Handle all fluids and other contaminated
materials (e.g. filters, rags) in accordance
with applicable regulations. Recycle
or dispose of engine fluids, filters, and
other contaminated materials according to
applicable regulations.

WARNING: To prevent personal injury or

death, read all safety instructions in the "Safety
Information" section of this manual.

WARNING: To prevent personal injury or

death, shift transmission to park or neutral, set
parking brake, and block wheels before doing
diagnostic or service procedures.
Figure 212 Alternator bracket bolts
WARNING: To prevent personal injury or 1. Bolt, M10 x 120 (2)
death, make sure engine has cooled before 2. Alternator bracket
removing components. 3. Bolt, M8 x 100 (2)

WARNING: To prevent personal injury or 1. Remove M8 bolt and harness routing guide.
death, do not open pressurized Freon® lines.
2. Remove two hex flange bolts and nuts (M10 x
120).
WARNING: To prevent personal injury or
3. Remove two hex flange bolts and nuts (M8 x 100).
death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi). 4. Remove alternator bracket.

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 FRONT COVER AND RELATED COMPONENTS 165

Flat Idler Pulley and Automatic Belt Tensioner 1. Support water supply housing and remove four
water supply housing bolts (M10 x 25).

Figure 213 Flat idler pulley and automatic belt

tensioner Figure 215 Water supply housing and coolant
port seal
1. Flat idler pulley assembly mounting bolt, M10 x 80
2. Automatic belt tensioner assembly mounting bolt,
M10 x 80
2. Tap water supply housing with a hammer to
break coolant seal. Remove housing and discard
coolant port seal.
1. Remove flat idler pulley mounting bolt (M10 x 80)
and assembly from the water supply housing.
2. Remove automatic belt tensioner mounting bolt Water Inlet Elbow, Water Outlet Tube, and
(M10 x 80) and assembly from the front cover Thermostat
assembly.
1. Remove three hex flange bolts (M8 x 30) securing
water inlet elbow to front cover.
Water Supply Housing

Figure 216 Water inlet elbow

Figure 214 Water supply housing bolts
1. Bolt, M10 x 25 (4)

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166 FRONT COVER AND RELATED COMPONENTS

2. Tap water inlet elbow with a hammer to break NOTE: The thermostat seal cannot be purchased
coolant seal. Remove water inlet elbow and separately. It is only available with the thermostat
discard gasket seal. assembly.
Fan Drive Hub

Figure 217 Water outlet tube assembly

1. Bolt, M8 x 25 (2)
2. Hex flange nut, M8 (2)

3. Remove two water outlet tube assembly bolts (M8 Figure 219 Removing the fan drive pulley
x 25) at the cylinder head.
4. Remove two hex flange nuts (M8) retaining the 1. Remove six hex flange bolts (M8 x 20) and the fan
water outlet tube assembly to front cover and drive pulley.
remove tube assembly.

Figure 218 Thermostat assembly

Figure 220 Fan hub assembly (typical)
5. Lift thermostat out of cylinder head. 1. Bolt, M8 x 65 (4)

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 FRONT COVER AND RELATED COMPONENTS 167

2. Remove four hex flange bolts. See fan drive

applications (Table 18).
3. Remove fan hub assembly.

Water Pump Assembly

Figure 222 Water pump assembly

7. Remove water pump assembly. Remove and

discard seal.

Figure 221 Water pump assembly

1. Bolt, M8 x 55 , nut, M8 (1)
2. Bolt, M8 x 100, nut, M8 (1)
3. Bolt, M8 x 16 (1)
4. Bolt, M6 x 12 (4)
5. Bolt, M8 x 40 (2)

1. Remove four pulley bolts (M6 x 12).

2. Remove water pump pulley.
3. Remove one water pump assembly nut (M8) and
bolt (M8 x 55).
4. Remove one water pump assembly nut (M8) and
bolt (M8 x 100).
Figure 223 Water pump wear plate (Generation
5. Remove one water pump assembly bolt (M8 x 16).
1 front covers only)
6. Remove two water pump assembly bolts (M8 x
40).
8. If applicable, remove three flat head hex socket
screws (M5) securing the water pump wear plate
to the rear half of the front cover and remove water
pump wear plate.

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168 FRONT COVER AND RELATED COMPONENTS

Vibration Damper, Damper Hub, and Wear Sleeve 1. Remove six M10 x 16 bolts securing the vibration
damper to the damper hub assembly and remove
the vibration damper.
2. Remove and discard three M12 x 40 bolts
securing the damper retaining plate.
3. Remove and discard damper retaining plate.

Figure 225 Removing the damper hub assembly

Figure 224 Vibration damper assembly
1. Vibration damper
2. Bolt, M10 x 16 (6) 4. Install two M10 x 80 bolts and washers through
3. Damper retaining plate H-bar puller (Table 21) and into the damper hub.
4. Dowel Install M10 x 80 bolt heads at equal lengths from
5. Bolt, M12 x 40 (3) the vibration damper mounting surface.
6. Damper hub assembly 5. Tighten H-bar center shaft to pull damper hub off
of crankshaft and remove damper hub.

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 FRONT COVER AND RELATED COMPONENTS 169

Figure 227 Removing front oil seal

Figure 226 Removing the wear sleeve with a
muffler chisel
1. Muffler Chisel NOTE: Be careful not to damage the crankshaft or
2. Vibration damper hub front oil seal mounting surface while removing the
3. Wear Sleeve front oil seal.
1. Remove front oil seal with a heel bar while oil
pump housing assembly is still attached to front
CAUTION: To prevent engine damage, do not cover. Discard the front oil seal.
damage or distort damper hub while removing wear
sleeve.
6. Split the wear sleeve with a muffler chisel to
remove it from the damper. Be careful not to
damage the vibration damper hub.

Gerotor Assembly Oil Pump and Front Oil Seal

Up to late Model Year 2006, all International® DT 466,
DT 570 and HT 570 Diesel Engines were equipped
with an 8 lobe gerotor oil pump.
Later in Model Year 2006, International® DT 466 (210
to 245 horsepower) Diesel Engines were equipped
with a 10 lobe gerotor oil pump.
NOTE: Removal procedures for the gerotor oil pump
assembly, show the 8 lobe gerotor oil pump. Removal
procedures for the 10 lobe gerotor oil pump are the
same as for the 8 lobe gerotor oil pump.
Figure 228 Oil pump housing mounting bolts
1. Bolt, M8 x 60 (2)
2. Dowels (2)
3. Bolt, M8 x 25 (4)

2. Remove two bolts (M8 x 60) retaining the oil pump

housing cover.

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170 FRONT COVER AND RELATED COMPONENTS

3. Remove four bolts (M8 x 25) retaining the oil pump 6. Remove outer rotor.
housing cover.

Figure 229 Oil pump housing, rotors, and oil

pump (housing) seal
Figure 230 Vibration damper key, washer seal,
1. Oil pump and rotor housing and inner rotor
2. Inner rotor
1. Vibration damper key
3. Outer rotor
2. Washer seal
4. Oil pump (housing) seal
3. Inner rotor

4. Remove oil pump housing cover and discard oil

pump (housing) seal. CAUTION: To prevent engine damage, do not
damage or distort the crankshaft keyway groove
CAUTION: To prevent engine damage, use during vibration damper key removal.
permanent marker to identify internal engine
components and their orientation. Do not use paint 7. Carefully tap the vibration damper key out of the
or temporary markers. crankshaft with a hammer and chisel.

5. Mark inner and outer rotors with a permanent 8. Remove washer seal and inner rotor from
marker, if oil pump is to be reused. Mark will crankshaft.
indicate rotor turning direction and orientation to
front cover.

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 FRONT COVER AND RELATED COMPONENTS 171

Front Engine Mount

Figure 231 Oil pump housing plate and seal Figure 232 Front engine mounting bracket

1. Oil pump (housing plate) seal 1. Bolt, M18 x 70 (2)

2. Oil pump housing plate 2. Bolt, M18 x 100 (2)

9. Remove oil pump housing plate and discard oil 1. Remove two upper bolts (M18 x 70).
pump (housing plate) seal. 2. Support engine mounting bracket and remove two
10. See disassembly of crankshaft oil pump drive lower bolts (M18 x 100).
(spline) (Crankshaft Disassembly, page 256) for 3. Remove front engine mounting bracket.
procedure relating to oil pump drive.

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172 FRONT COVER AND RELATED COMPONENTS

Front Cover (Front Half)

Generation 1 (Mounting Bolts)

3, 4
2
1
A A
5, 4

3, 4
A

5, 4

6
2 7 H06078

Figure 233 Front cover mounting bolts – front half (Generation 1)

1. Front cover (front half) 4. Hex flange nut, M8 (8) 6. Heavy hex flange bolt, M10 x 25
2. Hex flange bolt, M8 x 45 (6) 5. Hex flange bolt, M8 x 30 (4) (2) (PTO equipped engines only)
3. Hex flange bolt, M8 x 40 (4) 7. Dowel hole

CAUTION: To prevent engine damage, the oil pan 4. Remove front cover (front half) by sliding off the
and oil suction tube must be removed before the front two dowel pins.
cover can be removed.
5. Remove the oil and coolant gaskets and O-ring
1. Remove six hex flange bolts (M8 x 45). seal from the inside of the front cover, as required
and discard.
2. Remove four hex flange bolts (M8 x 40) and nuts
(M8).
3. Remove four hex flange bolts (M8 x 30) and nuts
(M8).

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 FRONT COVER AND RELATED COMPONENTS 173

Generation 2 (Mounting Bolts)

Figure 234 Front cover mounting bolts – front half (Generation 2)

1. M8 x 45 hex flange bolt (patch 4. M8 x 73 stud bolt (nut on back) 7. Seal assembly – M8 x 50 bolt
bolt) 5. M8 x 75 bolt – dog point (nut on and seal washer
2. M8 x 45 bolt (5) back) 8. Dowel hole
3. M8 x 50 special bolt (nut on 6. M8 x 50 bolt (nut on back) (6)
front) (3)

CAUTION: To prevent engine damage, the oil pan 4. Remove M8 x 73 stud bolt and nut (nut on back).
(Removing the Oil Pan, page206) and oil suction tube
5. Remove M8 x 45 mm hex flange patch bolt.
(Removing the Oil Suction Tube, page 207) must be
removed before the front cover can be removed. 6. Remove five M8 x 45 bolts.
1. Remove M8 x 75 bolt – dog point and nut (nut on 7. Remove front cover (front half) by sliding off the
back). two dowel pins.
2. Remove Seal Assembly – M8 x 50 bolt and seal 8. Remove the oil and coolant gaskets and O-ring
washer. seal from the inside of the front cover, as required
and discard.
3. Remove six M8 x 50 special bolts and nuts.

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174 FRONT COVER AND RELATED COMPONENTS

Idler Gears
NOTE: Before removing any gears from the gear
train, check the backlash between each gear and the
camshaft end play. See the inspection procedures
(Inspection, page177) in this section.

Figure 237 Lower Idler Gear Socket

Figure 235 Gear train locations

1. Remove M20 x 70 lower idler gear mounting bolt
1. Camshaft gear using Lower Idler Gear Socket (Table 21) and a
2. Upper idler gear 3/4 inch drive breaker bar.
3. Lower idler gear
4. Crankshaft gear 2. Remove lower idler gear.

Figure 236 Removing the lower idler gear

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 FRONT COVER AND RELATED COMPONENTS 175

3. Remove M16 x 65 upper idler gear mounting bolt

using a 16 mm 12 point impact socket (Table 21)
and a 1/2 inch drive breaker bar.
4. Remove upper idler gear.
NOTE: If required, Measure Camshaft End Play (page
267) after removing the upper idler gear.

Figure 238 Removing the upper idler gear

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176 FRONT COVER AND RELATED COMPONENTS

Front Cover (Rear Half)

NOTE: If the (rear half) of a Generation 1 front
cover assembly needs to be replaced, install a new
Generation 2 front cover assembly (front and rear
half). The (rear half) of the Generation 1 front cover
assembly is not available for service.
NOTE: Generation 1 (rear half) front covers include a
water pump wear plate.

2 1 5

4
2

3
5
H06079

Figure 239 Front cover mounting bolts – rear half (Generation 1)

1. Front cover assembly (rear half) 3. Flat head hex socket, M5 (3)
2. Special hex flange bolt, M8 x 20 4. Wear plate
(9) 5. Dowel pin locations

1. Remove the camshaft or camshaft assembly Pull cover straight outward to slide dowels out of
before removing front cover (rear half). See the crankcase. These dowels are retained in the
“Crankcase, Crankshaft, and Camshaft” section rear half of the front cover.
in this manual for removal procedure.
3. Remove the oil and coolant gaskets from the rear
2. Remove nine mounting bolts (M8 x 20) that secure half of the front cover and discard.
the rear half of the front cover to the crankcase.

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 FRONT COVER AND RELATED COMPONENTS 177

Inspection Checking Upper Idler Gear Backlash

Checking Lower Idler Gear Backlash

Figure 241 Checking upper idler gear backlash

Figure 240 Checking lower idler gear backlash 1. Dial indicator
2. Upper idler gear
1. Lower idler gear
2. Dial indicator

1. Mount a dial indicator on top of the crankcase.

1. Clamp a dial indicator onto the front cover. 2. Place the tip of the dial indicator as tangent as
possible to a gear tooth and zero dial indicator.
2. Place the tip of the dial indicator as tangent as
possible to a gear tooth, and zero dial indicator. 3. Place a screwdriver between the crankshaft and
the lower idler gear to keep the lower idler gear
3. Rock lower idler gear back and forth. Record the
from rotating.
reading on the dial indicator face. If the backlash
exceeds specifications, replace lower idler gear. 4. Rock upper idler gear back and forth. Record
the reading on the dial indicator. If the backlash
exceeds specifications, replace upper idler gear.

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178 FRONT COVER AND RELATED COMPONENTS

Checking Camshaft Gear Backlash Gerotor Oil Pump Clearance

Up to late Model Year 2006, all International® DT 466,
DT 570 and HT 570 Diesel Engines were equipped
with an 8 lobe gerotor oil pump.
Later in Model Year 2006, International® DT 466 (210
to 245 horsepower) Diesel Engines were equipped
with a 10 lobe gerotor oil pump.
NOTE: Inspection procedures for the gerotor oil
pump assembly show the 8 lobe gerotor oil pump.
Inspection procedures for the 10 lobe gerotor oil
pump are the same as for the 8 lobe gerotor oil pump.
Measuring Oil Pump Side Clearance

Figure 242 Checking camshaft gear backlash

1. Dial indicator
2. Camshaft gear

NOTE: Pressure exerted by the valve train must be

relieved before doing the following procedure.
1. Clamp a dial indicator on the front cover or the
cylinder head if the dial indicator stand is magnetic
2. Place the tip of the dial indicator as tangent as
possible to a gear tooth and zero dial indicator.
3. Place a screwdriver between the upper idler gear
and the lower idler gear to keep the upper idler Figure 243 Oil pump side clearance
gear from rotating. measurement
4. Rotate the camshaft gear back and forth. Record 1. Feeler gauge
reading on the dial indicator face. If the backlash 2. Oil pump and rotor housing
exceeds specifications, replace camshaft gear. 3. Outer rotor

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 FRONT COVER AND RELATED COMPONENTS 179

1. Coat outer rotor with oil and install rotor in oil pump 1. Place a straightedge (Table 21) across the oil
and rotor housing. pump mounting surface.
2. Check oil pump side clearance Specification 2. Check oil pump end clearance Specification
(Table 19) and choose the appropriate thickness (Table 19) and choose the appropriate thickness
feeler gauge (Table 21). feeler gauge (Table 21).
3. Insert feeler gauge between the oil pump and rotor 3. Slide feeler gauge between the straightedge and
housing and outer rotor. the oil pump inner and outer rotors.
4. Replace oil pump and rotor assembly if not within 4. Replace oil pump and rotor assembly if not within
specification. specification.

Measuring Oil Pump End Clearance

Figure 244 Oil pump end clearance

measurement
1. Straightedge
2. Feeler gauge
3. Outer rotor
4. Inner rotor

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180 FRONT COVER AND RELATED COMPONENTS

Installation
Front Cover
NOTE: If the (rear half) of a Generation 1 front
cover assembly needs to be replaced, install a new
Generation 2 front cover assembly (front and rear
half). The (rear half) of the Generation 1 front cover
assembly is not available for service.
Gaskets

2 3

H06072

Figure 245 Front cover gaskets – rear half, crankcase side

1. Front cover assembly (rear half, 2. Oil gasket
crankcase side) 3. Coolant gasket

1. Install a new oil gasket onto the crankcase side of 2. Install a new coolant gasket onto the crankcase
the front cover (rear half). side of the front cover (rear half).

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 FRONT COVER AND RELATED COMPONENTS 181

Mounting Bolts (Rear Half)

2 1 5

4
2

3
5
H06079

Figure 246 Front cover mounting bolts – rear half

1. Front cover assembly (rear half) 3. Flat head hex socket, M5 (3)
2. Special hex flange bolt, M8 x 20 4. Wear plate
(9) 5. Dowel pin

1. Position the rear half of the front cover onto the 2. Install the camshaft or camshaft assembly after
crankcase and install all nine mounting bolts installing front cover (rear half). See “Crankcase,
finger tight. Then tighten the mounting bolts to Crankshaft, and Camshaft” section in this manual
the special torque value (Table 20). for removal procedure.

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182 FRONT COVER AND RELATED COMPONENTS

Idler Gears

Figure 248 Installing the lower idler gear

Figure 247 Gears and timing marks mounting bolt

1. Camshaft gear
2. Upper idler gear 1. Install and hand tighten the lower idler gear and
3. Lower idler gear mounting bolt (M20 x 70) with timing marks facing
4. Crankshaft gear outward. Align single timing marks between the
crankshaft and lower idler gear.

NOTE: When installing the gears in the gear train,

the timing marks on the edge of each gear must be
correctly aligned and oriented (facing outward). Once
the gears are properly installed, the crankshaft will
require 34 revolutions to align the timing marks again.
• The upper idler gear and camshaft gear are
matched with one dimple on each gear
• The upper idler gear and lower idler gear are
matched with two dimples on each gear
• The lower idler gear and crankshaft gear are
matched with one dimple on each gear

Figure 249 Lower Idler Gear Socket

2. Tighten the M20 x 70 bolt to the special torque

value (Table 20) using Lower Idler Gear Socket
(Table 21).

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 FRONT COVER AND RELATED COMPONENTS 183

with those on the upper gaer. Tighten M16 x 65

bolt to the special torque value (Table 20), using
a 16 mm 12 point impact socket (Table 21).
4. Check gear backlash between upper idler gear
and camshaft gear. See Checking Camshft Gear
Backlash.
5. Check gear backlash between high-pressure
pump and upper idler gear (Table 19).
6. Check high-pressure pump end play.
7. Check camshaft end play.
NOTE: If equipped with an air compressor, check
gear backlash between air compressor drive gear
Figure 250 Installing the upper idler gear and lower idler gear.
mounting bolt
8. If a Generation 1 front cover (rear half) is reused,
install wear plate onto the front cover (rear half)
and insert three flat head hex socket screws (M5).
3. Install the upper idler gear and mounting bolt (M16
Tighten screws to the special torque value (Table
x 65) with timing marks facing outward. Align the
20).
single marks on the camshaft gear and upper idler
gear and the dual marks on the lower idler gear

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184 FRONT COVER AND RELATED COMPONENTS

Front Cover (Front Half)

Gaskets

1 2

H06080

Figure 251 Front cover gaskets – front half

1. Front cover (front half) 3. O-ring seal
2. Front cover gasket (coolant) 4. Front cover gasket (oil)

1. Install new front cover coolant and oil gaskets into 2. Install a new O-ring seal into the front half of the
the front half of the front cover. front cover

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 FRONT COVER AND RELATED COMPONENTS 185

Generation 1 (Mounting Bolts)

3, 4
2
1
A A
5, 4

3, 4
A

5, 4

6
2 7 H06078

Figure 252 Front cover mounting bolts – front half (Generation 1)

1. Front cover (front half) 3. Hex flange bolt, M8 x 40 (4), 5. Hex flange bolt, M8 x 30 (4)
2. Hex flange bolt, M8 x 45 (6) Note: Bolts marked A to be 6. Heavy hex flange bolt, M10 x 25
inserted from rear side of cover. (2) (PTO equipped engines only)
4. Hex flange nut, M8 (8) 7. Dowel hole

1. Position the forward half of the front cover onto the Thread all mounting bolts finger tight, then tighten
rear half of the front cover using the two dowels as bolts to the standard torque value (General
a guide. Torque Guidelines, page445).

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186 FRONT COVER AND RELATED COMPONENTS

Generation 2 (Mounting Bolts)

NOTE: Generation 2 front cover assemblies have
additional bolts to secure the front cover half to the
rear half.

Figure 253 Front cover mounting bolts – front half (Generation 2)

1. M8 x 45 hex flange bolt (patch 4. M8 x 73 stud bolt (nut on back) 7. Seal assembly – M8 x 50 bolt
bolt) 5. M8 x 75 bolt – dog point (nut on and seal washer
2. M8 x 45 bolt (5) back) 8. Dowel hole
3. M8 x 50 special bolt (nut on 6. M8 x 50 bolt (nut on back) (6)
front) (3)

1. Align dowel holes in front cover (front half) with 5. Install M8 x 73 stud bolt and nut (nut on back)
dowel pins in rear half of front cover, and install finger tight.
front cover (front half).
6. Install new M8 x 45 mm hex flange patch bolt
2. Install new M8 x 75 bolt – dog point and nut (nut finger tight.
on back) finger tight.
7. Install five M8 x 45 bolts finger tight.
3. Install new Seal Assembly – M8 x 50 bolt and seal
8. Tighten all mounting bolts to the standard torque
washer finger tight.
value (General Torque Guidelines, page445) .
4. Install six M8 x 50 special bolts and nuts finger
tight.

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 FRONT COVER AND RELATED COMPONENTS 187

Front Engine Mount

Figure 255 Oil pump housing plate and seal

Figure 254 Front engine mount 1. Oil pump (housing plate) seal
1. Bolt, M18 x 70 (2) 2. Oil pump housing plate
2. Bolt, M18 x 100 (2)

2. Place oil pump (housing plate) seal into front

1. Position front engine mount onto front cover cover recess. Align oil pump housing plate with
assembly. dowels.

2. Install two upper bolts (M18 x 70) finger tight.

3. Install two lower bolts (M18 x 100) finger tight.
4. Tighten all four bolts to the special torque value
(Table 20) .

Gerotor Oil Pump Assembly and Front Oil Seal

Up to late Model Year 2006, all International® DT 466,
DT 570 and HT 570 Diesel Engines were equipped
with an 8 lobe gerotor oil pump.
Later in Model Year 2006, International® DT 466 (210
to 245 horsepower) Diesel Engines were equipped
with a 10 lobe gerotor oil pump.
NOTE: Installation procedures for the gerotor oil
pump assembly show the 8 lobe gerotor oil pump.
Installation procedures for the 10 lobe gerotor oil Figure 256 Vibration damper key, washer seal,
pump are the same as for the 8 lobe gerotor oil pump. and inner rotor
1. If removed, install new oil pump drive (spline) onto 1. Vibration damper key
the crankshaft, (Crankshaft Assembly, page268). 2. Washer seal
3. Inner rotor

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188 FRONT COVER AND RELATED COMPONENTS

NOTE: If reusing the original gerotor oil pump

assembly, make sure the marks added during the
removal process are properly oriented for installation.
3. Slide oil pump inner rotor onto oil pump drive
(spline).
4. Install the washer seal with outer bevel oriented
towards the front.
CAUTION: To prevent engine damage, do not
mark or distort the crankshaft keyway groove
during vibration damper key installation.
5. Carefully tap the vibration damper key into place
on the crankshaft with a hammer.

Figure 258 Front oil seal installation

1. Press ram
2. Oil pump and rotor housing
3. Dowel pin (2)
4. Press table
5. Front oil seal
6. Front Seal and Wear Sleeve Installer

7. Place oil pump and rotor housing, new front oil

seal, and Front Seal and Wear Sleeve Installer
(Table 21) on press table.
8. Position oil pump housing on press table so
housing mating surface is level and supported.
Dowel pins should be recessed in press table
Figure 257 Applying Loctite® hydraulic sealant
openings.
to front oil seal
9. Position press ram on the center of the Front Seal
and Wear Sleeve Installer and carefully press the
6. Apply Loctite® hydraulic sealant to the outside front oil seal into the oil pump housing until seal is
edge of the front oil seal. fully seated.

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 FRONT COVER AND RELATED COMPONENTS 189

14. Align two oil pump and rotor housing dowels with
two front cover dowel holes and install oil pump
and rotor housing.

Figure 259 Oil pump housing, rotors, and oil

pump (housing) seal
1. Oil pump and rotor housing
2. Inner rotor
3. Outer rotor
4. Oil pump (housing) seal
Figure 260 Oil pump housing mounting bolt
locations
10. Install a new oil pump (housing) seal in the oil 1. Bolt, M8 x 60 (2)
pump and rotor housing groove. 2. Dowels (2)
3. Bolt, M8 x 25 (4)
11. Coat the outer rotor with clean engine oil.
CAUTION: To prevent engine damage, make sure
used oil pump inner and outer rotors rotate in the same 15. Install four M8 x 25 bolts finger tight.
direction as before removal. See marks added during
16. Install two M8 x 60 bolts finger tight.
removal for proper rotor orientation.
17. Tighten four M8 x 25 bolts and two M8 x 60 bolts
12. Install the outer rotor on the inner rotor.
to special torque (Table 20).
13. Lightly coat the inside sealing surface of the front
oil seal with clean engine oil.

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190 FRONT COVER AND RELATED COMPONENTS

POSE Dust Seal and Wear Sleeve NOTE: The chamfer (rounded edge) of the wear
sleeve outside diameter must face in, toward the
engine.
1. Apply Loctite® 569 Hydraulic Sealant (Table 21)
to the inside diameter of a new wear sleeve.

Figure 261 Wear sleeve with POSE dust seal Figure 262 Front seal and wear sleeve
installation
1. POSE dust seal
2. Wear sleeve 1. Press ram
3. Front of engine 2. Front Seal and Wear Sleeve Installer
3. POSE dust seal
4. Damper hub
NOTE: DT 466 engines equipped with an 8 lobe oil
pump use a wear sleeve without a POSE dust seal.
DT 466 engines equipped with a 10 lobe oil pump use 2. Center the damper hub, new wear sleeve (with
a wear sleeve with a POSE dust seal. All DT 570 and or without a POSE dust seal as appropriate for
HT 570 engines equipped with an 8 lobe oil pump use application), and Front Seal and Wear Sleeve
a wear sleeve with a POSE dust seal. Installer (Table 21) under press ram.

NOTE: If service kit contains more than one wear 3. Carefully press the new wear sleeve on the
sleeve, use sleeve that has the same width as the damper hub until sleeve is fully seated.
current wear sleeve. 4. Wipe any excess sealant off the outside diameter
CAUTION: A new front oil seal and wear sleeve (with a of the wear sleeve.
POSE dust seal) must be installed as a set for engines
equipped with a 10 lobe oil pump.

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 FRONT COVER AND RELATED COMPONENTS 191

Vibration Damper Hub and Damper Retaining

Plate WARNING: To prevent personal injury or
death, wear heat insulated gloves when handling
1. Mark damper hub with 100 °C (212 °F)
heated components.
Thermo-melt crayon (Table 21).

WARNING: To prevent personal injury or

death, damper hub must be completely seated on
the crankshaft.
3. Install heated vibration damper hub onto the
crankshaft. Use Heat Insulated Gloves (Table 21)
specifically designed for extremely hot objects.

Figure 263 Heating the vibration damper hub

2. Heat vibration damper hub on a hot plate (Table

21) . Do not heat to more than 212 °F.

WARNING: To prevent serious personal Figure 265 Damper retaining plate

injury, possible death, do not pick up the
vibration damper hub with exposed hands. Wear 1. Damper retaining plate
heat protective gloves due to the extremely hot 2. Dowel pin
vibration damper hub. 3. Bolt M12 x 40 (3)

CAUTION: To prevent engine damage, only use 15.2

mm (0.60) in thick damper retainer and Class 12.9
damper bolts.
4. Verify that new damper retainer is 15.2 mm (0.60)
in thick and new M12 x 40 damper bolts are Class
12.9.
5. Position new damper retaining plate and install
three new M12 x 40 bolts.
6. Tighten three M12 x 40 damper bolts to special
torque (Table 20).

Figure 264 Installation of vibration damper hub

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192 FRONT COVER AND RELATED COMPONENTS

7. Retighten three M12 x 40 damper bolts in

sequence to special torque (Table 20) several
times until each bolt has no movement.

Vibration Damper assembly

Three Rubber Vibration Damper Kits are available
for International® DT 570 and HT 570 Diesel
Engines. See (TSI-08-12-20 Rubber Vibration
Damper Replacement Kits, page480).
CAUTION: To prevent engine damage, verify damper
hub dowel pin is aligned with dowel hole of the
vibration damper assembly.

Figure 266 Vibration damper assembly

1. Vibration damper
2. Bolt, M10 x 16 (6)
3. Dowel pin

1. Align dowel hole in vibration damper with dowel

pin on damper hub and install six M10 x 16 bolts
finger tight.
2. Torque bolts to special torque (Table 20).

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 FRONT COVER AND RELATED COMPONENTS 193

Fan Drive

Table 18 Fan Drive Mounting Bolt Sizes

Fan drive mounting configuration Bolt size Torque Quantity
High-mount, Horton (20 in) M8 x 1.25 x 30 26 N·m (19 lbf·ft) 4
High-mount, Horton (18.3 in) M8 x 1.25 x 30 26 N·m (19 lbf·ft) 4
Mid-mount, Horton (16.2 in) M8 x 1.25 x 30 26 N·m (19 lbf·ft) 4
Low-mount (Horton 12.2 in) M8 x 1.25 x 30 26 N·m (19 lbf·ft) 4
High-mount (spin-on) M8 x 1.25 x 30 Standard 2
M8 x 1.25 x 65 Standard 2
Mid-mount (spin-on) M8 x 1.25 x 30 Standard 2
M8 x 1.25 x 65 Standard 2
Low-mount (bolt-on and spin-on) M8 x 1.25 x 65 Standard 4

NOTE: The table located at the back of this section

covers fan drive configurations diameters and ratios
(Table 19).
1. Install fan hub assembly.
NOTE: The standard fan hub assembly is serviced
as a unit. The assembly is made up of the following
nonserviceable items:
• Fan and pulley mounting hub
• Fan bearing hub
• Bearing assembly
• M10 x 70 bolt
• Fan bearing retainer
Figure 267 Torquing the fan drive mounting
bolts (typical)

2. Install the hex flange bolts required (Table 18)

and tighten to the standard torque value (General
Torque Guidelines, page 445), unless otherwise
noted (Table 20).

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194 FRONT COVER AND RELATED COMPONENTS

2 1 3 2 1

4 4

H05027

Figure 268 Spin-on fan drive (left) and bolt-on fan drive (right)
1. Fan pulley 4. Fan hub assembly 6. Spacer retainer washer
2. Bolt, M8 x 65 (4) (cross-hatched) 7. Bolt, M8 x 20 (6)
3. Fan spacer 5. Bolt, M10 x 20

3. Install the fan pulley and spacer as required for

application.

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 FRONT COVER AND RELATED COMPONENTS 195

Horton DriveMaster

Figure 269 Torquing the fan drive pulley bolts

4. Install six M8 x 20 hex flange bolts to the fan pulley

and tighten to the standard torque value (General
Torque Guidelines, page445) .

Figure 270 Horton DriveMaster (low mount

version)
1. Bearing retainer nut assembly (shoulder relief faces
engine)
2. Air channel inlet
3. Bracket assembly
4. Bolt, M8 x 30 (4)
5. Fan pulley
6. Air cartridge (Note: Horton service part only)

1. Install bracket assembly and four M8 X30 hex

flange bolts . Torque bolts to the standard torque
value (General Torque Guidelines, page445).
2. Slide fan pulley onto bracket with clutch mounting
flange facing front.
3. Install bearing nut, making sure bearing nut
shoulder relief is facing towards engine.
4. Tighten bearing retainer nut to the special torque
(Table 20).

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196 FRONT COVER AND RELATED COMPONENTS

Water Pump Assembly

Figure 272 Water pump assembly

1. Bolt, M8 x 55, nut M8 (1)
2. Bolt, M8 x 100, Nut, M8
3. Bolt, M8 x 16 (1)
Figure 271 Water pump wear plate (Generation 4. Bolt, M6 x 12 (4)
1 front covers only) 5. Bolt, M8 x 40 (2)

1. If applicable, install three flat head hex socket 5. Install one water pump assembly bolt (M8 x 100)
screws (M5) to secure the water pump wear plate from the raer half of the front cover. Thread nut
to the rear half of the front cover, if not done (M8) on finger tight.
previously during front cover installation.
6. Install one water pump assembly bolt (M8 x 55)
2. Tighten M5 hex socket screws to the special from the rear half of the front cover. Thread nut
torque (Table 20). (M8) on finger tight.
3. Install the water pump seal into the water pump 7. Install one water pump assembly bolt (M8 x 16)
seal recess. finger tight.
4. Position water pump assembly into front cover. 8. Install two water pump assembly bolts (M8 x 40)
finger tight.
9. Tighten all water pump bolts to the standard
torque value (General Torque Guidelines, page
445) .
10. Install water pump pulley and secure with
four pulley bolts (M6 x 12). Tighten bolts to
the standard torque value (General Torque
Guidelines, page445) .

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 FRONT COVER AND RELATED COMPONENTS 197

Water Supply Housing

Figure 275 Torquing the water supply housing

Figure 273 Water supply housing and coolant bolts
port seal

3. Tighten all bolts to the standard torque value

1. Position coolant port seal into machined recess at (General Torque Guidelines, page445) .
water supply housing.
Alternator Bracket

Figure 274 Water supply housing bolts

1. Bolt, M10 x 25 (4) Figure 276 Alternator bracket
1. Bolt, M10 x 120 (2)
2. Alternator bracket
2. Install water supply housing and secure with four 3. Bolt, M8 x 100 (2)
water supply housing bolts (M10 x 25).

1. Position alternator bracket to backside of front

cover and install two bolts (M10 x 120) and hex
flange nuts (M10) finger tight.
2. Install the two remaining bolts (M8 x 100) and hex
flange nuts (M8) finger tight.

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198 FRONT COVER AND RELATED COMPONENTS

1. Install M10 x 80 bolt through flat idler pulley

assembly and into the water supply housing.
Tighten bolt to the standard torque value (General
Torque Guidelines, page445).
2. Install M10 x 80 bolt through the automatic belt
tensioner assembly to the front cover assembly
and tighten to the special torque (Table 20).

Water Inlet Elbow, Water Outlet Tube, and

Thermostat
1. Install a water inlet gasket into the machined
recess at the front cover.

Figure 277 Torquing the alternator bracket bolts

3. Tighten all alternator bracket bolts to the standard

torque value (General Torque Guidelines, page
445) .
4. Install harness routing guide and secure guide
with an M8 bolt.

Flat Idler Pulley and Automatic Belt Tensioner

Figure 279 Water inlet elbow

2. Install water inlet (side port) elbow.

3. Install and tighten three hex flange bolts (M8 x
30) to the standard torque value (General Torque
Guidelines, page445) .
NOTE: The thermostat seal cannot be purchased
separately. It is only available with the thermostat
assembly.

Figure 278 Flat idler pulley and automatic belt

tensioner
1. Flat idler pulley assembly mounting bolt, M10 x 80
2. Automatic belt tensioner assembly mounting bolt,
M10 x 80

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 FRONT COVER AND RELATED COMPONENTS 199

5. Install water outlet tube assembly and secure with

two water outlet tube assembly bolts (M8 x 25) at
the cylinder head. Tighten to the special torque
value (Table 20) .

2 3 4 2

Figure 280 Thermostat assembly

1
4. Install a new thermostat and gasket into cylinder
head.
H05029

Figure 282 Water outlet tube assembly

connection at front cover
1. Front cover (front half)
2. Hex flange nut, M8 (4)
3. Water outlet tube assembly (bracket)
4. Washer (2)
5. Hex flange bolt, M8 x 40 (2)
6. Front cover (rear half)

6. Install nuts, bolts and washers to secure the water

outlet tube assembly at the front cover. Tighten
nuts and bolts to the special torque value (Table
20).
Figure 281 Water outlet tube assembly
1. Bolt, M8 x 25 (2)

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200 FRONT COVER AND RELATED COMPONENTS

Specifications

Table 19 Front Cover, Vibration Damper, Gerotor Oil Pump, Front Engine Mount, and Gear Train
Specifications
Camshaft gear end play 0.33 mm (0.013 in)
Camshaft gear-to-upper idler gear backlash 0.46 mm (0.018 in)
High-pressure pump end play 0.45 -1.22 mm
(0.018 - 0.48 in)
Lower idler gear-to-air compressor gear backlash 0.508 mm (0.020 in)
Lower idler gear-to-crankshaft gear backlash 0.36 mm (0.014 in)
Oil pump end clearance 0.05 -0.13 mm
(0.002-0.005 in)
Oil pump side clearance 0.36 - 0.48 mm
(0.014 - 0.019 in)
Upper idler gear-to-high-pressure oil pump gear backlash 0.48 mm (0.019 in)
Upper idler gear-to-lower idler gear backlash 0.48 mm (0.019 in)
Vibration damper face runout (max.) 1.52 mm (0.060 in)

Vibration damper maximum allowable member misalignment 1.50 mm (0.060 in)

Fan Drive Configurations Diameters and Ratios
Engine fan drive Fan CL to Crankshaft CL, Pulley Diameter Drive Ratio
configuration mm (in) OBD, mm (in)
466 high-mount, (Horton 508 (20) 242.8 (9.56) 0.894 : 1
DriveMaster)
570 high-mount, (Horton 508 (20) 242.8 (9.56) 1.08 : 1
DriveMaster)
570 high-mount, (Horton 508 (20) 219.4 (8.636) 1.2 : 1
DriveMaster)
570 high-mount, (Horton 465 (18.3) 201.2 (7.92) 1.3 : 1
DriveMaster)
570 high-mount, (Horton 465 (18.3) 201.2 (7.92) 1.3 : 1
DriveMaster)
466 high-mount, (Horton 465 (18.3) 219.4 (8.636) 1.2 : 1
DriveMaster)
466 high-mount, (Horton 465 (18.3) 219.4 (8.636) 0.99 : 1
DriveMaster)
466 mid-mount, (Horton 411 (16.2) 201.2 (7.92) 1.08 : 1
DriveMaster)
466 high-mount, (spin-on) 465 (18.3) 201.2 (7.92) 1.08 : 1
570 high-mount, (spin-on) 465 (18.3) 201.2 (7.92) 1.3 : 1
466 mid-mount, (spin-on) 411 (16.2) 201.2 (7.92) 1.08 : 1

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 FRONT COVER AND RELATED COMPONENTS 201

Table 19 Front Cover, Vibration Damper, Gerotor Oil Pump, Front Engine Mount, and Gear Train
Specifications (cont.)
466 low-mount, (spin-on) 310 (12.2) 201.2 (7.92) 1.08 : 1
466 low-mount, Horton 310 (12.2) 201.2 (7.92) 1.08 : 1
DriveMaster)
570 low-mount, (spin-on) 310 (12.2) 201.2 (7.92) 1.3 : 1
570 low-mount, (Horton 310 (12.2) 201.2 (7.92) 1.3 : 1
DriveMaster)
466 low-mount, (bolt-on) 310 (12.2) 201.2 (7.92) 1.08 : 1
570 low-mount, (bolt-on) 310 (12.2) 201.2 (7.92) 1.3 : 1
NOTE: The high-mount and mid-mount fan drives share the same part number, however the fan drive is
inverted depending upon application.

Special Torque

Table 20 Front Cover, Vibration Damper, Gerotor Oil Pump, Front Engine Mount, and Gear Train
Special Torques
Automatic belt tensioner assembly 50 N·m (37 lbf·ft)
Damper retaining plate bolts 163 N·m (120 lbf·ft)
Retorque all bolts until no
movement
End cover adapter (PTO equipped engines only) 52 N·m (38 lbf·ft)
Fan drive, high-mount, Horton DriveMaster (20, 18.3 in.) 26 N·m (19 lbf·ft)
Fan drive, mid-mount, Horton DriveMaster (16.2 in.) 26 N·m (19 lbf·ft)
Fan drive, low-mount, Horton DriveMaster (12.2 in.) 26 N·m (19 lbf·ft)
Fan spacer retaining bolt, M10 x 20 (bolt-on drive only) 52 N·m (38 lbf·ft)
Front cover mounting bolts (rear half) 26 N·m (19 lbf·ft)
Front engine mounting bracket bolts (4) 386 N·m (284 lbf·ft)
Horton DriveMaster bearing retainer nut 177 N·m (130 lbf·ft)
Lower idler gear mounting bolt 639 N·m (470 lbf·ft)
Oil pump and rotor housing M8 bolts 25 N·m (18 lbf·ft)
Upper idler gear mounting bolt 326 N·m (240 lbf·ft)
Viscous or rubber vibration damper mounting bolts 54 N·m (40 lbf·ft)
Water outlet tube assembly at cylinder head 33 N·m (24 lbf·ft)
Water outlet tube assembly at front cover 33 N·m (24 lbf·ft)
Wear plate (water pump) 7 N·m (60 lbf·in)

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202 FRONT COVER AND RELATED COMPONENTS

Special Service Tools

Table 21 Front Cover, Vibration Damper, Gerotor Oil Pump, Front Engine Mounts, and Gear Train
Special Service Tools
Dial indicator set Obtain locally
Feeler gauge Obtain locally
Front seal and wear sleeve installer ZTSE3004B
Heat Insulated Gloves Obtain locally
H-bar puller Obtain locally
Hot plate Obtain locally
Loctite® 569 Hydraulic Sealant Obtain locally
Lower Idler Gear Socket ZTSE4383
Slide hammer puller set ZTSE1879
Straightedge Obtain locally
Thermo-melt crayon, 100 °C (212 °F) Obtain locally
16 mm 12 point impact socket Obtain locally

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 OIL PAN AND OIL SUCTION TUBE 203

Table of Contents

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
.
Removing the Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206 .
Removing the Oil Suction Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207 .

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208 .

Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
.

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
.
Installing the Oil Suction Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208 .
Installing the Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209 .

300 Watt Oil Pan Heater (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210

.

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
.

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211

.

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211

.

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204 OIL PAN AND OIL SUCTION TUBE

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 OIL PAN AND OIL SUCTION TUBE 205

12

11 3

10

5
9

6
8
7 4

H06040

Figure 283 Oil pan and oil suction tube components

1. Oil suction tube gasket 6. Oil heating element assembly 10. Oil pan (typical)
2. Oil pan gasket (optional) 11. Bolt, M8 x 35 (2)
3. Bolt, M10 x 25 (1) 7. Plug (without oil pan heater) 12. Oil suction tube assembly
4. Bolt, M8 x 24 (18) 8. Oil drain plug (typical)
5. Heater element gasket 9. Oil drain plug gasket

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206 OIL PAN AND OIL SUCTION TUBE

Removal
Removing the Oil Pan

GOVERNMENT REGULATION: Engine

fluids (oil, fuel, and coolant) may be a hazard
to human health and the environment.
Handle all fluids and other contaminated
materials (e.g. filters, rags) in accordance Figure 284 Removing the oil pan mounting bolts
with applicable regulations. Recycle
or dispose of engine fluids, filters, and
other contaminated materials according to 1. Remove 18 (M8 x 24) oil pan mounting bolts.
applicable regulations.

WARNING: To prevent serious personal

injury, possible death, or damage to the engine or
vehicle, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent serious personal

injury, possible death, or damage to the engine or
vehicle, make sure the transmission is in neutral,
parking brake is set, and wheels are blocked
before doing diagnostic or service procedures on
engine or vehicle.
Figure 285 Removing the oil pan
WARNING: To prevent personal injury or
death, allow engine to cool before working with
components. 2. Lift the oil pan from the engine.

WARNING: To prevent personal injury or

death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing
and rags contaminated with engine fluids.

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 OIL PAN AND OIL SUCTION TUBE 207

1 2 3 6

4 (x 6)

4 5 4

4 4

H06031

Figure 286 RTV sealant locations

1. Front cover (front half) 3. Gasket 5. Crankcase
2. Front cover (rear half) 4. RTV sealant locations 6. Flywheel housing

3. Use a knife or scraper to cut through the RTV Removing the Oil Suction Tube
sealant under the oil pan gasket at six locations
on the crankcase mounting surface.

Figure 287 Removing the oil pan gasket

Figure 288 Removing the oil suction tube

4. Remove the oil pan gasket from the crankcase

mounting surface and discard. 1. Remove two (M8 x 35) mounting bolts from the oil
suction tube.

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208 OIL PAN AND OIL SUCTION TUBE

2. Remove mounting bolt (M10 x 25) from the oil Installation

suction tube bracket.
Installing the Oil Suction Tube

Figure 289 Removing the oil suction tube and

gasket Figure 290 Installing the oil suction tube and
gasket
1. Oil suction tube assembly
2. Gasket 1. Oil suction tube assembly
2. Gasket

3. Remove the oil suction tube assembly and gasket

from the front cover and discard gasket. 1. Place a new gasket onto the front cover and install
the oil suction tube assembly.

Cleaning and Inspection

Oil Pan
1. Remove any used RTV sealant from the
crankcase, oil pan, and oil pan gasket.
2. Clean the oil pan, front cover, flywheel housing
and crankcase mating surfaces thoroughly with a
suitable solvent.
3. Make sure that the oil suction tube is free of any
obstructions.
4. Check the oil pan and oil suction tube for cracks
and damage. Replace components as necessary. Figure 291 Installing the oil suction tube

5. Inspect oil pan heating element (if equipped) for

an open circuit. 2. Install two mounting bolts (M8 x 35) for the oil
suction tube and one mounting bolt (M10 x 25) to
hold down bracket.
3. Torque both bolts (M8 x 35) to the special torque
value (Table 23).

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 OIL PAN AND OIL SUCTION TUBE 209

4. Torque bracket bolt (M10 x 25) to the special

torque value (Table 23).

Installing the Oil Pan

1 2 3 6

4 (x 6)

4 5 4

4 4

H06031

Figure 292 RTV sealant locations – see inset (typical)

1. Front cover (front half) 4. Sealant, Wacker T-442, (6 6. Flywheel housing
2. Front cover (rear half) locations)
3. Gasket 5. Crankcase

1. Apply a circular dab of T-442 Wacker RTV mounting surface. These locations coincide with
sealant (Table 24) approximately 19 mm (0.75 in) gasket joints between the front cover halves,
in diameter to the six locations on the crankcase crankcase, and flywheel housing.

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210 OIL PAN AND OIL SUCTION TUBE

3. Install the oil pan onto the crankcase.

Figure 293 Installing the oil pan gasket

Figure 295 Installing oil pan mounting bolts

2. Before the RTV sealant dries (tack free), install

a new oil pan gasket on the crankcase mounting 4. Install 18 oil pan mounting bolts (M8 x 24).
surface. Make sure that the dowel on the gasket is Tighten all bolts to the special torque value (Table
aligned with the hole on the crankcase mounting 23).
surface.

300 Watt Oil Pan Heater (Optional)

An optional 300 Watt Oil Pan Heater is available for
service. See (1171848R1 300 Watt Oil Pan Heater
Kit, page495) for installation procedure.

Figure 294 Installing the oil pan

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 OIL PAN AND OIL SUCTION TUBE 211

Specifications

Table 22 Oil Fill Specifications

Dry engine (after rebuild and new filter) 34 L (36 quarts US)
Wet engine (after oil drain and filter change) 28 L (30 quarts US)

Special Torque

Table 23 Oil Pan and Oil Suction Tube Special Torques

Oil pan drain plug 68 N·m (50 lbf·ft)
Oil heating element assembly (optional) 68 N·m (50 lbf·ft)
Oil pan heater plug 68 N·m (50 lbf·ft)
Oil pan mounting bolts 32 N·m (24 lbf·ft)
Oil suction tube bracket, M10 x 25 63 N·m (46 lbf·ft)
Oil suction tube, M8 x 35 27 N·m (20 lbf·ft)

Special Service Tools

Table 24 Special Tools

Wacker T – 442 RTV sealant Obtain locally

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 POWER CYLINDERS 213

Table of Contents

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
.

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
.
Piston Cooling Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217 .
Old Piston Cooling Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217 .
New Piston Cooling Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218 .
Removing Piston and Connecting Rod Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218 .
Disassembling Piston and Connecting Rod Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219 .
Cylinder Sleeve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220 .

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
.
Pistons and Related Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221 .

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
.
Pistons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221 .
Top and Intermediate Compression Ring Grooves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222 .
Oil Control Ring Groove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222 .
Piston-to-Cylinder Sleeve Running Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223 .
Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223 .
Piston Pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224 .
Connecting Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224 .
Piston Pin Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224 .
Connecting Rod Cap Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224 .
Connecting Rod Bearing Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225 .
Bend and Twist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225 .
Bearing Fitting Procedures and Bearing Running Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225 .
Bearing Running Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226 .
Connecting Rod Side Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227 .
Checking Cylinder Sleeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227 .
Checking Counterbore Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229 .
Surface Gauge Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229 .
Depth Micrometer Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229 .
Checking Cylinder Sleeve Protrusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229 .

Reconditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
.
Resurfacing the Counterbore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232 .

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
.
Cylinder Sleeve Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234 .
Assembling Piston and Connecting Rod Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235 .
Installing Piston and Connecting Rod Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237 .
Torque Procedure for Connecting Rods with M12 Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241 .
Torque-to-yield Procedure for New Connecting Rod with M11 Bolts. . . . . . . . . . . . . . . . . . . . . .241 .
Piston Cooling Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242 .
Old Piston Cooling Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242 .
New Piston Cooling Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242 .

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214 POWER CYLINDERS

Engine Run-In Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243

.

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
.

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247

.

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247

.

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 POWER CYLINDERS 215

Description • Connecting rods have a fractured surface at the

cap and rod bolted joint. These are mated parts
A few changes were made for model year 2004: and are not interchangeable with other connecting
• Piston skirts for DT 466 and 570 cubic inch rods. It is important that serial numbers on the
displacements have a notch cast into each side connecting rod and connecting rod cap must
of the skirt for piston cooling tube clearance. match and appear together.

• The combustion bowl has been centered within Additional changes running changes were made after
the piston crown. The pistons are symmetrical, model year 2004:
and therefore do not require orientation. • New piston cooling tubes were released for
service.
• New connecting rod assemblies were released for
service.

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216 POWER CYLINDERS

Figure 296 Connecting rods, pistons, and rings

1. Cylinder sleeve 6. Piston skirt (570) 11. Connecting rod cap
2. Top compression ring 7. Piston pin 12. Piston, one-piece aluminum
3. Intermediate compression ring 8. Retaining ring (2) (466)
4. Oil control ring 9. Bearing shells (2) 13. Connecting rod bolt (2)
5. Piston crown (570) 10. Connecting rod

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 POWER CYLINDERS 217

Removal CAUTION: To prevent engine damage, keep the

fractured mating surfaces of the connecting rod and
cap clean and free of lint and debris. Do not allow
the mating surfaces to rest on any surface. Do not
GOVERNMENT REGULATION: Engine bump the mating surfaces or drop the connecting rod
fluids (oil, fuel, and coolant) may be a hazard or cap. This could cause chipping and wear on the
to human health and the environment. mating surface, resulting in improper mating during
Handle all fluids and other contaminated installation and possible engine damage.
materials (e.g. filters, rags) in accordance
with applicable regulations. Recycle CAUTION: If a carbon ridge has developed at the top
or dispose of engine fluids, filters, and of the cylinder sleeve, use a razor knife to scrape it
other contaminated materials according to off before removing the piston assemblies. Care must
applicable regulations. be taken not to damage the sleeve bore surface when
removing the carbon.
Piston Cooling Tubes
WARNING: To prevent personal injury or NOTE: Old piston cooling tubes and bolts can be
death, read all safety instructions in the “Safety reused or replaced with new piston cooling tubes and
Information” section of this manual. bolts.
Old Piston Cooling Tubes
WARNING: To prevent personal injury or
death, shift transmission to park or neutral, set NOTE: The crankshaft may need to be rotated to
parking brake, and block wheels before doing access some piston cooling tubes.
diagnostic or service procedures.

WARNING: To prevent personal injury or

death, allow engine to cool before working with
components.

WARNING: To prevent personal injury or

death, disconnect ground (-) cable from battery
before doing service or diagnostic procedures.

WARNING: To prevent personal injury or

death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing
and rags contaminated with engine fluids. Figure 297 Old piston cooling tube

1. Remove M6 x 16 patch type bolt from piston

cooling tubes.

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218 POWER CYLINDERS

Figure 298 Old piston cooling tube

2. Remove six old piston cooling tubes only if

Figure 300 O-ring (underside) of new piston
replacing with new.
cooling tube

New Piston Cooling Tubes 2. Remove and discard O-rings.

NOTE: The crankshaft may need to be rotated to
access some piston cooling tubes. Removing Piston and Connecting Rod Assembly

Figure 301 Loosening connecting rod bolts

Figure 299 New piston cooling tube
1. Piston cooling tube (6)
1. Loosen both connecting rod bolts two turns.
2. M6 x 12 bolt (6)
3. Mounting pad (6) 2. Rock the two bolts on the rod cap to loosen.
3. Repeat procedure for all other connecting rods.
1. Remove M6 x 12 bolt from piston cooling tubes 4. Rotate the engine to a vertical position with the
and bolts. front end up.

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 POWER CYLINDERS 219

Figure 302 Removing connecting rod cap and Figure 304 Removing piston and connecting
bolts rod assembly from cylinder sleeve

5. Unscrew the bolts completely. Remove the cap 8. Once the piston rings are free of the cylinder
and bolts as a unit. sleeve, remove the assembly from the top of the
6. Discard connecting rod cap bolts. crankcase.
9. For installation purposes, mark each piston,
connecting rod, and cap with the cylinder number
from which it was removed. Also mark the front
of each piston as it was installed in the engine.

Disassembling Piston and Connecting Rod

Assembly

WARNING: To prevent serious personal

injury or possible death, wear safety glasses
when removing piston pin retaining rings.

Figure 303 Pushing out piston and connecting

rod assembly

7. Do not push on rod fractured surface. Use a

hammer with a plastic or wooden handle or a
non-marring punch to push the piston out of the
cylinder sleeve. Figure 305 Removing piston pin retaining rings

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220 POWER CYLINDERS

1. Use pliers to remove the two piston pin retaining

rings.

Figure 308 Removing piston rings (DT 466

piston shown)
Figure 306 Removing piston pin
4. Use a piston ring expander tool (Table 34) to
remove the piston rings.
2. Remove the piston pin from the bore by hand.
Separate the piston from the connecting rod.
Mark the front of the piston pin with the cylinder
Cylinder Sleeve Removal
number from which it was removed.
NOTE: Before installing the puller, bar the engine over
so the crankshaft journal is located at the bottom (low
point) of its travel. This prevents possible damage
to the journal by the puller lifting jaws during puller
installation.
NOTE: When you remove the sleeve from puller,
mark the sleeve with its cylinder bore number. Also
mark the sleeve position in the engine block for the
purposes of inspection and assembly.
1. Position the cylinder sleeve puller in the sleeve
and spread the lifting jaws so the tangs grip the
bottom of the sleeve (Figure 309).

Figure 307 Removing piston skirt from crown

(570 engine only)
1. Skirt
2. Crown

3. For 570 engines only: Mark the orientation of the

piston skirt to the crown for installation purposes.
Remove the piston skirt from the crown. Figure 309 Removing cylinder sleeve from
crankcase

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 POWER CYLINDERS 221

2. With the lifting bridge firmly on the crankcase top 3. Use a suitable solvent and a non-metallic brush
deck, turn the forcing nut to break the cylinder to clean the connecting rods and caps, piston
sleeve loose from the crankcase. rings, pins, retainers, and steel piston crowns.
Thoroughly clean the connecting rod bolt holes
3. Lift sleeve and puller from the crankcase.
and threads.
4. Use a pick to remove the crevice seal at the lower
4. Clean crevice seal bore area of any scale,
counterbore area of each cylinder sleeve. Discard
deposits, or sealant (located in crankcase.)
crevice seal.

Cleaning Inspection
Pistons
Pistons and Related Components
CAUTION: To prevent engine damage, when
CAUTION: To prevent engine damage, do not use
replacing only the steel piston crown, the original
a caustic solvent or wire brushes, or bead blasting
orientation of the reused aluminum piston skirt to the
media to clean aluminum pistons.
sleeve must be maintained upon reassembly.
1. Soak aluminum pistons and skirts in a soap and
Inspect the pistons for scuffed or scored skirts
water solution. Use a non-metallic brush to clean
and worn ring lands. Replace damaged pistons
the pistons.
as required. For two-piece pistons, the aluminum
2. Scrub the piston ring grooves thoroughly. Make piston skirt or steel piston crown may be replaced
sure that the four oil drain holes in the oil ring individually.
grooves are not blocked.
CAUTION: To prevent engine damage, do not clean
the fractured mating surfaces of the connecting rods.

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222 POWER CYLINDERS

Top and Intermediate Compression Ring Grooves

Table 25 DT 466 Piston Ring Gauge Selection

Engine Rating Ring / Groove Type Gauge Diameter, mm (in)
225 bhp and below Top / keystone cross section 3.1 (0.122)
Intermediate / rectangular N/A
230 bhp and above Top / keystone cross section 3.1 (0.122)
Intermediate / keystone cross section 2.8 (0.110)

Table 26 DT 570 and HT 570 Piston Ring Gauge Selection

Engine Rating Ring / Groove Type Gauge Diameter, mm (in)
All 570 series engines Top / keystone cross section 3.2 (0.126)
Intermediate / rectangular N/A

If either measurement exceeds specifications, the

piston ring groove is worn, and the piston must be
replaced. For two-piece pistons, replace only the
steel piston crown.

Oil Control Ring Groove

Figure 310 Measuring ring grooves with piston

ring gauge pins

1. Install the piston ring gauge pins into the top

compression ring groove. Make sure that the
gauge pins are parallel.
Figure 311 Measuring side clearance of oil
2. Use an outside micrometer to measure the control ring groove
diameter of the piston over gauge pins. Record
the reading.
1. Place the edge of a new oil control ring in the
3. Repeat the procedure for the intermediate
groove. Roll the oil control ring entirely around the
compression ring groove, if its cross section
piston to ensure that the ring is free in its groove.
is keystone-shaped. If the ring groove has
a rectangular cross section, the height of the 2. With the edge of the oil control ring still in the
groove must be checked with gauge blocks. groove, use a feeler gauge to check the side

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 POWER CYLINDERS 223

clearance between the ring and the top of its cylinder sleeve, piston and rings. For two-piece
groove. Record the reading. pistons, replace the cylinder sleeve, aluminum
piston skirt, crown and rings.
If the measurement exceeds the specification, the
oil control ring groove is worn out. Replace the
piston. For two-piece pistons, replace only the
Piston Rings
steel piston crown.
CAUTION: To prevent engine damage, whenever a
piston is removed from a cylinder, replace the piston
Piston-to-Cylinder Sleeve Running Clearance rings. Faulty piston rings cannot always be detected
by visual inspection. Therefore, if the rings are
replaced, the cylinder sleeves need to be replaced as
well.
1. Inspect the new piston rings for cleanliness. Use
a suitable solvent to clean the piston rings if
necessary.

Figure 312 Measuring piston skirt diameter

1. With the piston at room temperature, use an

outside micrometer to measure the piston skirt
diameter. Place the micrometer 90 degrees from
the piston pin bore. For one-piece pistons (466
engine), measure at 28.58 mm (1.125 in) from the
bottom of the piston. For two-piece pistons (570 Figure 313 Checking piston ring end gap
engine), measure at 3.00 mm (0.118 in) from the
bottom of the piston skirt. Record the reading.
2. Push the piston ring down into the cylinder bore.
2. Subtract the measurement from the inside
Make sure that the piston ring is perpendicular to
diameter of the cylinder sleeve (Checking
the cylinder wall.
Cylinder Sleeves, page 227). The result is the
running clearance between the piston and the 3. Use a feeler gauge to measure the end gap
cylinder sleeve. between the ends of each piston ring.
If the running clearance is not within the Discard any piston ring that does not meet
specification for the one-piece piston, replace the specifications.

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224 POWER CYLINDERS

Piston Pins Connecting Rods

1. Inspect piston pins for corrosion, nicks, and Piston Pin Bushing
obvious wear. Do not use pins with nicks or
heavy scratches with the two-piece steel crown.
Engine failure will result. Install new piston pins.

Figure 315 Measuring piston pin bushing inside

diameter
Figure 314 Measuring piston pin outside
diameter
Use a telescoping gauge and an outside micrometer
to measure the inside diameter of the piston pin
2. Use an outside micrometer to measure the bushing at two locations that are 90 degrees apart.
outside diameter of each piston pin at two places. Record the readings.
3. If the outside diameter is less than minimum
Specification (Table 31), install new piston pin.
Connecting Rod Cap Bolts
4. Measure each piston pin bore.
1. Inspect the connecting rod cap bolts for nicks and
5. Calculate piston pin clearance. Subtract the thread damage. Replace the bolts as required.
outside diameter of the piston pin from the inside
2. Lubricate the threads of the connecting rod cap
diameter of the piston pin bore.
bolts with clean engine oil. Install the cap without
NOTE: Piston pin clearance = (inside diameter the bearing shells on the connecting rod and
of the piston pin bore) – (outside diameter of the install the bolts by hand. Match serial numbers
piston pin) on the connecting rod and cap (on same side of
fractured rod).
6. If piston pin clearance in piston exceeds
Specifications (Table 31), install new connecting If resistance is met, clean the bolt holes in the
rod. connecting rod and try installing new bolts. If
the new bolts do not turn in freely, replace the
connecting rod. The threads in the bolt holes
cannot be tapped.
3. Tighten the connecting rod cap bolts to the special
torque value (Table 33).

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 POWER CYLINDERS 225

Connecting Rod Bearing Bore 3. Use a telescoping gauge and an outside

micrometer to measure the inside diameter of
1. Inspect the finished surface of the connecting
the connecting rod bearing bore at the edge of
rod bearing bore for nicks, burrs, and scoring.
each side of the bore. Record the readings.
Replace connecting rod as required.
If the difference between the two measurements
exceeds the bore taper specification, replace the
connecting rod assembly.

Bend and Twist

Engine component wear patterns can often be
identified and used to diagnose a problem. Some
common examples of connecting rod wear patterns
include the following:
• A shiny surface on the edge of the piston pin
bushing usually indicates that a connecting rod
is bent or a piston pin hole is not positioned
properly in relation to the piston skirt and piston
Figure 316 Connecting rod bearing bore for ring grooves.
out-of-round • Abnormal wear on the connecting rod bearing
may indicate that a connecting rod is bent or the
bearing bore is too tapered.
2. Use an inside micrometer to measure the inside
diameter of the connecting rod bearing bore at • A twisted connecting rod will not create an
three locations that are 60 degrees apart. Record easily identifiable wear pattern, although
the readings. severely twisted connecting rods will disturb
the action of the entire piston and connecting rod
If the difference between measurement B and assembly and may be the cause of excessive oil
the average of measurements A and C exceeds consumption.
the specification for out-of-round, replace the
connecting rod. If any of these conditions exist, use a suitable
alignment fixture to check the connecting rod for
bends and twists. Follow the instructions of the
alignment fixture manufacturer. If a bend or twist
exceeds the specification, replace the connecting
rod.

Bearing Fitting Procedures and Bearing Running

Clearance
CAUTION: To prevent engine damage, do not attempt
to reduce journal-to-bearing running clearance by
reworking the bearing cap or the bearings. Grind the
crankshaft to the next available under size or replace
crankshaft.

Figure 317 Measuring connecting rod bearing

bore taper

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226 POWER CYLINDERS

3. Remove the connecting rod cap. Wipe the oil

from the face of the bearings in the cap and the
exposed portion of the crankshaft.
4. Place a piece of undamaged Plastigage® across
the full width of the connecting rod bearing, about
6 mm (0.25 in) from the center of the connecting
rod cap.
CAUTION: To prevent engine damage, do not
torque-to-yield connecting rod cap bolts while doing
this measurement procedure.
CAUTION: To prevent engine damage, when torquing
connecting rod bolts use a torque wrench that is
known to be accurate. Correct torque of connecting
Figure 318 Effects of bearing crush rod cap bolts is important.
1. Diameter at open ends after bearing crush load 5. Install the connecting rod cap bolts and tighten to
2. Diameter at open ends before bearing crush load 109 N·m (80 lbf·ft).
NOTE: Do not turn the crankshaft. This will smear the
NOTE: Connecting rod bearings must fit tightly in the Plastigage® making it unusable.
connecting rod bore. When bearings are inserted
in the connecting rod and cap, they protrude slightly
above the parting surface. This protrusion is required
to achieve bearing crush. Bearing crush forces the
ends inward at the parting line when a load is applied
by tightening the bolts. Some snap may be lost in
normal use, but bearing replacement is not required
because of a nominal loss of snap.

When the connecting rod bearing is installed and the

connecting rod cap bolts are tightened, the bearing is
compressed, ensuring a positive contact between the
backside of the bearing and the machined surface of
the connecting rod bore.
Bearing Running Clearance
Figure 319 Measuring Plastigage® with scale
1. Install new bearings in the connecting rod and
cap.
6. Remove the connecting rod cap. The Plastigage®
CAUTION: To prevent engine damage, install
material will adhere to the bearing shell or the
connecting rod cap and connecting rod with matching
crankshaft. Do not remove the Plastigage®.
serial numbers on the same side. If the rod cap is
reversed or not installed on its matching connecting 7. Use the Plastigage® paper scale to measure the
rod, the fractured mating surfaces will be damaged. widest point of the flattened material. Numbers
This can loosen the rod cap. A new connecting rod in the graduated marks on the scale indicate the
assembly must be installed. running clearance in thousandths of an inch or
millimeters.
2. Match serial numbers on the connecting rod
and rod cap (on same side of fractured rod) NOTE: If running clearance is not to specification, it
and install the connecting rod and cap on the may be necessary to grind the crankshaft and install
crankshaft. See Installing Piston and Connecting an undersized bearings. Check running clearance
Rod Assembly (page237). again before condemning the crankshaft.

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 POWER CYLINDERS 227

8. Remove the Plastigage® material. Repeat the Telescoping Gauge Method

test for each connecting rod bearing.

Connecting Rod Side Clearance

Figure 321 Checking cylinder sleeve inside

diameter with telescoping gauge

Figure 320 Measuring connecting rod side

clearance

Place a feeler gauge between the connecting rod and

crankshaft journal. This is the connecting rod side
clearance.
If there is too little side clearance, the connecting
rod may be damaged or the bearing may be out
of position. If there is too much clearance, the
connecting rod or crankshaft may be damaged.

Checking Cylinder Sleeves

1. Inspect the inside surface of the cylinder sleeves
for scuffing, scoring and polishing. Inspect
Figure 322 Measuring telescoping gauge
the outside surface for cavitation. Replace the
cylinder sleeves with piston rings as required.
2. To check the cylinder sleeves for wear (taper), use a. Use a telescoping gauge and an outside
one of the following methods: micrometer to measure the inside
diameter of each cylinder sleeve at the
top of piston ring travel and below the
area of piston ring travel. Record the
readings.
b. Subtract the lower reading from the
higher reading. The result is the cylinder
sleeve taper.
If the result exceeds the specification,
replace the cylinder sleeve.

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228 POWER CYLINDERS

Dial Bore Gauge Method Feeler Gauge Method

Figure 324 Checking cylinder sleeve piston ring

end gap

Figure 323 Checking cylinder sleeve inside a. Install a top compression ring squarely
diameter with dial bore gauge above the top of the piston ring travel
area. Use a feeler gauge to measure
the piston ring end gap. Record the
a. Use a dial bore gauge to measure the measurement.
inside diameter of the each cylinder
b. Move the top compression ring squarely
sleeve at the top of piston ring travel
below the bottom of the piston ring travel
and below the area of piston ring travel.
area. Use a feeler gauge to measure
Record the readings.
the piston ring end gap. Record the
b. Subtract the lower reading from the measurement.
higher reading. The result is the cylinder
Every increase of 0.07 mm (0.003 in)
sleeve taper.
between the measurements equals a
If the result exceeds the specification, 0.025 mm (0.001 in) increase in cylinder
replace the cylinder sleeve. sleeve inside diameter. If the cylinder
sleeve is worn beyond the specification,
replace the cylinder sleeve.

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 POWER CYLINDERS 229

Checking Counterbore Depth Depth Micrometer Method

Use one of the following methods to check the depth NOTE: Clean counterbore surface and remove
of the crankcase counterbore: existing shims if any before measuring counterbore
depth.

Surface Gauge Method

NOTE: Clean counterbore surface and remove
existing shims if any before measuring counterbore
depth.

Figure 326 Checking counterbore depth with

depth micrometer

Figure 325 Checking counterbore depth with

surface gauge 1. Place a depth micrometer onto the counterbore
ledge. Record the counterbore depth reading.
2. Take counterbore depth measurements at four
1. Place the indicator tip of the surface gauge on the evenly spaced locations around the counterbore
crankcase. Zero the dial indicator. ledge.
2. Move the indicator tip onto the counterbore ledge. 3. Compare the counterbore depth variation
Record the counterbore depth reading on the dial between the four measurements with
indicator. specifications.
3. Take counterbore depth measurements at four If the maximum variation between the four
evenly spaced locations around the counterbore measurements exceeds the specification,
ledge. resurface the counterbore.
4. Compare the counterbore depth variation
between the four measurements with those
listed in specifications (Table 32). Checking Cylinder Sleeve Protrusion

If the maximum variation between the four CAUTION: To prevent engine damage, do not apply
measurements exceeds the specification, holding adapters to the "fire dam" ridge of the cylinder
resurface the counterbore. sleeve. Clamping forces should not be applied to this
ridge as internal cracking could develop adjacent to
the shim land.

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230 POWER CYLINDERS

1 2 3

6
4

5
H06089
Figure 328 Installing the holding adapters
Figure 327 Cylinder sleeve clamping details
1. Fire dam (highest point on cylinder sleeve) 3. Install the cylinder sleeve holding adapters (Table
2. Clamping tool (washer) 34) with 10.9 or higher grade bolts and hardened
3. Clamping bolt washers. Tighten bolts in two stages:
4. Crankcase
A. 55 N·m (40 lbf·ft)
5. Cylinder sleeve
6. Shim pack B. 110 N·m (80 lbf·ft)

1. Clean the cylinder sleeve, cylinder sleeve crevice

bore, and crankcase counterbore surface.
CAUTION: To prevent engine damage, do not
"torque-to- yield" the holding adapter bolts (as
when installing cylinder head bolts). This will
prevent stretching the bolts and risking the
indentation of tooling marks on the cylinder
sleeve.
2. Install the cylinder sleeve in the cylinder bore
without the crevice seal.

Figure 329 Measuring cylinder sleeve protrusion

4. Place the indicator tip of a surface gauge on the

cylinder sleeve flange. Zero the dial indicator.
5. Move the surface gauge until the indicator
tip slides off the flange to the surface of the
crankcase. Record the cylinder sleeve protrusion
reading on the dial indicator.

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 POWER CYLINDERS 231

6. Take cylinder sleeve protrusion readings from

three evenly spaced locations around the cylinder
sleeve. Average the three readings to determine
the cylinder sleeve protrusion.
If the cylinder sleeve protrusion does not meet
the specification, remove the cylinder sleeve and
install the necessary amount of shims to meet the
specification.
NOTE: Shims are available as a package consisting
of the following:

Table 27 Cylinder Sleeve Shim Sizes

Shim size (mm) Shim size (in)
0.05 0.002
Figure 330 Checking cylinder sleeve protrusion 0.10 0.004
1. Cylinder sleeve protrusion 0.25 0.010
2. Top surface of crankcase 0.51 0.020
3. Cylinder sleeve flange
4. Shim to suit 0.81 0.032
5. Counterbore

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232 POWER CYLINDERS

Reconditioning feeler gauge. Use a hex head wrench to lock the

tool bit in place.
Resurfacing the Counterbore
The following steps will require the use of the cylinder
sleeve counterbore tool kit. See piston, piston ring,
and connecting rod special service tools (Table 34).

Figure 332 Counterboring tool components

1. Driver unit and adapter plate
2. Cutting head
3. Washer (2)
4. Mounting bolt (2)
5. Spacer (2)
Figure 331 Setting tool bit
6. Locking plate (2)
7. Feeler gauge

1. To set the tool bit for the counterbore cutting head

(Table 34), place a 0.20-0.25 mm (0.008-0.010 in)
2. Install the cutting head on the driver unit and
feeler gauge on the outside diameter of the cutting
adapter plate of the counterboring tool.
head. Push the tool bit out until it touches the

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 POWER CYLINDERS 233

5. To set the depth of the cut, use one of the following

methods:
Graduated Marks on Tool
a. Loosen the locking screw and turn the
adjusting nut counterclockwise until it
contacts the housing of the driver unit.
b. Back off the adjusting nut by the amount
of the desired cut. Each graduated mark
equals 0.03 mm (0.001 in).
c. Tighten the locking screw.
Feeler Gauge
a. Loosen the locking screw on the upper
turn knuckle and insert the correct size of
feeler gauge between the turn knuckles.
Figure 333 Positioning counterboring tool b. Rotate the upper turn knuckle until the
feeler gauge is barely held between the
1. Turn knuckles turn knuckles.
2. Locking screws
3. Mounting bolt (2) c. Tighten the locking screw and remove the
4. Washer (2) feeler gauge.
5. Spacer (2) CAUTION: To prevent engine damage, do not rotate
6. Locking plate (2) the handle counterclockwise when the tool bit is in
contact with the counterbore ledge as damage to the
tool bit could result as well.
3. Pull the plunger and lift up on the handle to raise
the cutting head. Mount the counterboring tool on 6. To cut the counterbore, rotate the handle smoothly
the crankcase. Install the washers and mounting in a clockwise direction until the driver unit turns
bolts finger tight, then tighten the bolts to 45 N·m freely and is bottomed out between the adjusting
(33 lbf·ft). nut and the top of the driver unit housing.
4. To lower the cutting head, loosen the locking 7. Remove the counterboring tool and clean the
screws and the turn knuckles. Pull the plunger up counterbore area. Check the depth of the
to the desired height. Tighten the turn knuckles counterbore (Checking Counterbore Depth, page
and locking screws. 229).
NOTE: Do not remove more than 0.05 mm (0.002 in)
of material at any one attempt.

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234 POWER CYLINDERS

Installation
Cylinder Sleeve Installation

Figure 335 Lubrication of cylinder sleeve bore

4. Apply clean engine oil to the lower crankcase

counterbore and crevice seal bore, then carefully
install the cylinder sleeve.
Figure 334 Lubricate cylinder sleeve crevice
seal

1. Lubricate the crevice seal with clean engine oil

and install into cylinder sleeve groove (without
twisting).
NOTE: Each cylinder sleeve has one crevice seal.
2. If required, ensure the proper shim(s) are
installed in the crankcase counterbore necessary
to bring the cylinder sleeve protrusion within
Figure 336 Installation of cylinder sleeve
specifications.
3. Make sure the crevice seal is properly aligned in
the groove. 5. After installation, check cylinder sleeve protrusion
(Checking Cylinder Sleeve Protrusion, page229).
6. Check cylinder sleeve bore dimensions and
sleeve taper per specifications (Table 32).
If the cylinder sleeve is not measuring up to
specifications, check for an improperly aligned
crevice seal.

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 POWER CYLINDERS 235

Assembling Piston and Connecting Rod

Assembly

Figure 337 Installing piston rings (466 piston

shown) Figure 338 Installing piston skirt on crown (570
engine only)
1. Skirt
NOTE: Make sure that the top side of both
2. Crown
compression rings (marked with a dot) are facing
up. The oil control ring may be installed with either
side facing up, if new.
2. For 570 engines only: Install the piston skirt on
1. Use a piston ring expander tool (Table 34) to install the crown. Make sure that the oil jet cutouts on
the piston rings. Install the oil control ring first, the skirt are facing away from the crown.
then intermediate compression ring, and finally
3. Lubricate the piston pin bore with clean engine oil.
the top compression ring.
CAUTION: To prevent engine damage, orientation of
a reused piston skirt is very important due to wear
patterns. Install the skirt on the crown using the
original skirt orientation.
NOTE: New piston skirts may be oriented in either
direction due to piston skirt symmetry.

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236 POWER CYLINDERS

Figure 340 Installing piston pin

CAUTION: To prevent engine damage, do not mix

connecting rods with M12 bolts and connecting rods
with M11 bolts in the same engine. If one or more
connecting rods must be replaced make sure all
connecting rods in each engine are the same type.

Figure 339 Piston and connecting rod

orientation
1. Crankcase
2. CAM SIDE stamp
3. Arrow stamp
4. Piston
5. Connecting rod
6. Camshaft bore

NOTE: One piece pistons are stamped CAM SIDE or

with an arrow.
• Install piston with CAM SIDE over short leg of the
connecting rod.
• Install piston with arrow stamp (on left side of
Figure 341 Connecting rod cap with M12
piston) over short leg of the connecting rod.
connecting rod cap bolts (protrusion points to
front of engine)

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 POWER CYLINDERS 237

5. Use pliers to install the piston pin retaining rings.

Installing Piston and Connecting Rod Assembly

CAUTION: To prevent engine damage, do not allow
the connecting rod or connecting rod cap fractured
mating surfaces to contact any surface other then
its matched fractured surface. Contacting any
other surface can cause misalignment of the mating
surface, resulting in connecting rod bearing and
engine failure.
NOTE: Turn crankshaft so connecting rod journals 1
and 6 are at Bottom Dead Center (BDC). Install piston
and connecting rod assemblies 1 and 6 first. Then
repeat the procedure for piston and connecting rod
assemblies 2 and 5. Finish with piston and connecting
rod assemblies 3 and 4.
Figure 342 Connecting rod cap with M11 1. Install connecting rod bearings into connecting
connecting rod cap bolts (protrusion points to rods and connecting rod caps dry (without oil).
front of engine) 2. Lubricate piston rings with clean engine oil.
Stagger piston ring gaps approximately 120
degrees from each other.
4. Align the bores in the connecting rod and piston
and install the piston pin. 3. Install the piston ring compression tool (Table 34)
over the piston rings.
WARNING: To prevent serious personal 4. Lubricate the cylinder sleeve and connecting rod
injury or possible death, wear safety glasses bearing shell with clean engine oil.
when installing retaining rings.
CAUTION: To prevent engine damage, install each
piston with the arrow to the front of the engine and the
CAM SIDE mark toward the cam side of the engine.
CAUTION: To prevent engine damage, make sure
that the longer side of the connecting rod bolted joint
is oriented opposite the camshaft side of the engine.
5. Carefully install the piston and connecting rod
assembly without rod cap into the cylinder sleeve
with the arrow on the piston crown pointing to
the front of the engine. Use a wooden or plastic
handle to carefully push the assembly into the
cylinder sleeve. Do not scratch the cylinder wall.

Figure 343 Installing piston pin retaining rings

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238 POWER CYLINDERS

Figure 344 Installing the piston ring

compression tool

Figure 346 Matching serial number on

connecting rod and connecting rod cap
1. Connecting rod
2. Connecting rod cap
3. Serial number

CAUTION: To prevent engine damage, install

connecting rod cap and connecting rod with matching
serial numbers on the same side. If the rod cap is
reversed or not installed on its matching connecting
rod, the fractured mating surfaces will be damaged.
This can loosen the rod cap. A new connecting rod
Figure 345 Installing the piston and connecting
assembly must be installed.
rod assembly
The fractured mating surfaces of each rod and cap
pair are precisely matched. Always keep each cap
6. Carefully guide the piston and connecting rod with its respective rod. If unsure, match the serial
assembly onto the crankshaft connecting rod number on each connecting rod and connecting rod
journal. cap.

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 POWER CYLINDERS 239

Figure 347 An offset indicates incorrect rod cap

assembly

The rod cap can only be correctly installed on the

connecting rod if it is oriented in the correct direction.
Figure 348 Connecting rod cap with M12
If the rod cap is reversed during assembly of the
connecting rod cap bolts (protrusion points to
connecting rod, an obvious offset will be seen at
front of engine)
the mating surfaces. If the connecting rod assembly
is installed on the crankshaft in this manner, the
connecting rod must be replaced. Also check the
crankshaft journal fillets for damage. Such damage
will require replacement of the crankshaft.
7. Lubricate the inside diameter of the connecting
rod cap bearing.

Figure 349 Connecting rod cap with M11

connecting rod cap bolts (protrusion points to
front of engine)

NOTE: Each rod end cap has a protrusion for correct

orientation in the engine during installation. The
protrusion must face toward the front of the engine.

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240 POWER CYLINDERS

8. Carefully install connecting rod cap over the

crankshaft journal and install two new M11 or
M12 connecting rod cap bolts, depending on
connecting rod version, finger tight.

Figure 350 Installing the connecting rod cap

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 POWER CYLINDERS 241

Torque Procedure for Connecting Rods with M12

Bolts
CAUTION: To prevent engine damage, follow the
connecting rod torque procedure for the specific
connecting rods in the engine.

Figure 352 Connecting rod cap with M11

connecting rod cap bolts (protrusion points to
front of engine)

NOTE: If doing a bearing fit procedure (Bearing Fitting

Procedures and Bearing Running Clearance, page
225), do not torque-to-yield connecting rod cap bolts.
Figure 351 Connecting rod cap with M12 Tighten new M11 connecting rod cap bolts to 109 N·m
connecting rod cap bolts (protrusion points to (80 lbf·ft)
front of engine)
1. For final assembly, tighten new M11 connecting
rod cap bolts to 41 N·m (30 lbf·ft).
NOTE: If doing a bearing fit procedure, (Bearing
Fitting Procedures and Bearing Running Clearance,
page 225) tighten new M12 connecting rod cap bolts
to 109 N·m (80 lbf·ft).
For final assembly, tighten new M12 connecting rod
cap bolts to 163 N·m (120 lbf·ft).

Torque-to-yield Procedure for New Connecting

Rod with M11 Bolts
CAUTION: To prevent engine damage, follow the Figure 353 Torque-to-yield marks for M11 bolts
connecting rod torque procedure for the specific 1. Connecting rod bolt with permanent marker spot
connecting rods in the engine. (before torque-to-yield)
2. Connecting rod bolt with permanent marker spot
(after torque-to-yield)
3. Permanent marker spot on connecting rod cap

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242 POWER CYLINDERS

CAUTION: To prevent engine damage, use

permanent marker to identify internal engine
components and their orientation. Do not use paint
or temporary markers.
2. Using a permanent marker, mark each connecting
rod bolt and put another mark on a 15 mm 12 point
socket directly in line with the mark on each rod
bolt.
3. Mark the surface of the connecting rod cap 90°
clockwise from each mark on the rod bolt.
4. Align mark on socket with mark on the rod bolt and
install socket on the rod bolt.
5. Torque-to-yield each M11 connecting rod cap bolt Figure 355 Old piston cooling tube
by rotating bolt exactly 90 degrees clockwise (1/4
turn). The mark on the socket and bolt should
be aligned with the mark on the surface of the CAUTION: To prevent engine damage, the piston
connecting rod cap. cooling tubes use a special patch type mounting bolt.
Do not substitute.

Piston Cooling Tubes NOTE: Piston cooling tubes are self aligning.

Old Piston Cooling Tubes 1. Place piston cooling tubes onto crankcase
mounting pad.
NOTE: The crankshaft may need to be rotated to
access some piston cooling tubes. 2. When installing the piston cooling tube bolts (M6
x 16), do A or B below:
A. Install new piston cooling tube mounting
bolts (patch type).
B. Remove oil residue, and apply Loctite®
#242 to the threads of existing piston
cooling tube mounting bolts (patch type),
and install M6 x 16 bolts.
3. Tighten M6 x 16 bolts to the special torque value
(Table 33).

New Piston Cooling Tubes

Figure 354 Old piston cooling tube NOTE: The crankshaft may need to be rotated to
access some piston cooling tubes.
CAUTION: To prevent engine damage, the correct
piston cooling tubes must be installed.
NOTE: The non-knurled piston cooling tube is
required for DT 466 engines. The knurled piston
cooling tube is required for DT 570 and HT 570
engines.

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 POWER CYLINDERS 243

Figure 358 Installation of new piston cooling

Figure 356 New piston cooling tubes
tube
1. New piston cooling tube (non-knurled) – DT 466
1. Piston cooling tube (6)
engines
2. M6 x 12 bolt (6)
2. New piston cooling tube (knurled) – DT 570 and HT
3. Crankcase mounting pad (6)
570 engines

NOTE: The new piston cooling tubes are self aligning.

2. Position piston cooling tubes on crankcase
mounting pads.
CAUTION: To prevent engine damage, the piston
cooling tubes use a special patch type mounting bolt.
Do not substitute.
3. When installing the piston cooling tube bolts (M6
x 16), do do A or B below:
A. Install new piston cooling tube mounting
bolts (patch type).
B. Remove oil residue, and apply Loctite®
#242 to the threads of existing piston
cooling tube mounting bolts (patch type),
and install M6 x 12 bolts.
Figure 357 O-ring (underside) of new piston 4. Tighten M6 x 16 bolts to the special torque value
cooling tube (Table 33).

1. Put a new O-ring on each piston cooling tube. Engine Run-In Procedure

WARNING: To prevent personal injury or

death, shift transmission to park or neutral, set
parking brake, and block wheels before doing
diagnostic or service procedures.
If new pistons or piston rings have been installed, do
the following engine run-in procedure:

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244 POWER CYLINDERS

1. Run the engine at low idle with no load for 5 • Excessive vibration
minutes. Check for leaks in the water, lube oil,
• Loose mounting
fuel and air induction systems.
3. Shut the engine off and correct any condition to
2. Check the turbocharger for any of the following
prevent damage to the engine or turbocharger.
conditions:
4. Start the engine and drive the vehicle (unloaded)
• Unusual noise
for 25 minutes in city mode, then drive the
• Oil leaks vehicle (unloaded) for an additional 15 minutes in
highway mode.
• Air leaks
5. Return to idle and check for leaks.
• Excessive exhaust smoke

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 POWER CYLINDERS 245

Specifications

Table 28 Connecting Rod Specifications

Bend (max.) 0.06 mm (0.003 in)
Center-to-center distance between connecting rod bearing bore and 219.4 - 219.5 mm (8.638 - 8.642 in)
piston pin bushing bore
Connecting rod bearing bore inside diameter 85.130 - 85.156 mm (3.3516 -
3.3526 in)
Connecting rod bearing inside diameter (installed) 80.05 - 80.10 mm (3.1518 - 3.1536
in)
Connecting rod bearing bore out-of-round (max.) 0.02 mm (0.00078 in)
Connecting rod bearing bore taper (max.) 0.02 mm (0.00078 in)
Connecting rod bearing running clearance 0.030 - 0.107 mm (0.0012 - 0.0042
in)
Connecting rod side clearance on crankshaft 0.13 - 0.48 mm (0.005 - 0.019 in)
Piston pin bushing inside diameter 46.393 - 46.401 mm (1.8265 -
1.8268 in)
Twist (max.) 0.05 mm (0.002 in)

Table 29 Piston Specifications

466 piston configuration
Piston material Aluminum alloy
Piston rings
225 bhp and below Top ring - keystone cross section
Intermediate - rectangular cross
section
230 bhp and above Top ring - keystone cross section
Intermediate - keystone cross
section
570 piston configuration
Piston crown Steel crown, two-piece articulated
Piston skirt Aluminum alloy
Piston rings
All 570 series engines Top ring – keystone cross section
Intermediate – rectangular cross
section
466 and 570 piston specifications

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246 POWER CYLINDERS

Table 29 Piston Specifications (cont.)

Running clearance between piston and cylinder sleeve 466 piston: 0.076 - 0.128 mm
(0.0030 - 0.0050 in)
570 piston: 0.063 - 0.115 mm
(0.0025 - 0.0045 in)
Skirt diameter 466 piston: 116.44 - 116.49 mm
(4.584 - 4.586 in)
570 piston: 116.48 - 116.51 mm
(4.586 - 4.587 in)
Top compression ring groove width, 466 measure over 0.122 gauge 115.90 - 115.68 mm (4.563 -
pins 4.554 in)
Top compression ring groove width, 570 measure over 0.126 gauge 116.74 - 116.50 mm (4.596 -
pins 4.587 in)
Intermediate compression ring groove width (keystone shaped ring) 115.92 - 115.73 mm (4.564 -
measure over 0.110 gauge pins 4.556 in)
Intermediate compression ring groove width (rectangular shaped 3.05 - 3.03 mm (0.120 - 0.119 in)
ring), 466
Intermediate compression ring groove width (rectangular shaped 3.05 - 3.03 mm (0.120 - 0.119 in)
ring), 570
0.076 - 0.026 mm (0.0030 -
Oil control ring, side clearance, 466
0.0010 in)
0.080 - 0.030 mm (0.0031 -
Oil control ring, side clearance, 570
0.0012 in)

Table 30 Piston Ring Specifications

Intermediate compression ring end gap 1.65 - 1.90 mm (0.065 - 0.075 in)
Oil control ring end gap 0.35 - 0.66 mm (0.014 - 0.026 in)
Top compression ring end gap 0.35 - 0.66 mm (0.014 - 0.026 in)

Table 31 Piston Pin Specifications

Clearance in piston 466 piston: 0.0165 - 0.0292 mm (0.00065 -
0.00115 in)
0.035 - 0.048 mm (0.0014 - 0.0019 in)
570 skirt (vertical plane): 0.0165 - 0.0292 mm
(0.00065 - 0.00115 in)
570 skirt (horizontal plane): 0.0280 - 0.0574 mm
(0.00114 - 0.00226 in)
570 crown: 0.038 - 0.053 mm (0.0015 - 0.0021 in)
Diameter 46.352 - 46.357 mm (1.8249 - 1.8251 in)
Length 96.57 - 96.82 mm (3.802 - 3.812 in)

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 POWER CYLINDERS 247

Table 32 Cylinder Sleeve Specifications

Allowable variation of counterbore depth between four points (max.) 0.03 mm (0.001 in)
Counterbore depth before adding shims (max.) 10.49 mm (0.413 in)
Counterbore depth (including shims- if any) 8.84 - 8.89 mm (0.348 - 0.350
in)
Cylinder sleeve protrusion 0.05 - 0.13 mm (0.002 - 0.005
in)
Cylinder sleeve taper, at top of ring travel (max.) 0.10 mm (0.004 in)
Flange thickness 8.94 - 8.96 mm (0.352 - 0.353
in)
Inside diameter 114.50 - 116.60 mm (4.590 -
4.591 in)

Special Torque

Table 33 Connecting Rod Special Torque

Connecting rod bolts (verify connecting rod type) See Torque Procedures for
Connecting Rod with M12
Bolts (page241) or M11 Bolts
(page241).
Piston cooling tube bolts, M6 x 12 13 N·m (115 lbf·in)
Piston cooling tube bolts, M6 x 16 13 N·m (115 lbf·in)

Special Service Tools

Table 34 Piston, Piston Ring, and Connecting Rod Special Service Tools
Counterbore cutting head ZTSE25144A
Cylinder bore gauge Obtain locally
Cylinder sleeve counterbore tool kit ZTSE2514
Cylinder sleeve holding adapters (set of 3) ZTSE4672
Cylinder sleeve puller ZTSE2536
Dial indicator set Obtain locally
EGR water coolant supply plate ZTSE4648
Piston ring compressor tool ZTSE4396
Piston ring expander Obtain locally
Piston ring gauge pins (set of 3) ZTSE4653
Telescoping gauge set Obtain locally

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 CRANKCASE, CRANKSHAFT, AND CAMSHAFT 249

Table of Contents

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
.
Crankcase Ventilation System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253 .
Oil Level Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255 .
Crankcase Ladder (DT 466 series – 225 hp and 245 hp @ 2600 rpm) and all 570 ratings. . . . . . .256 .
Crankshaft Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256 .
Cam Gear from Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257 .
Camshaft Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258 .
Camshaft Bushings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259 .
Coolant Heater (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 .

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261

.
Cleaning the Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261 .
Crankcase Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261 .
Crankshaft and Main Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262 .
Checking Camshaft Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262 .
Checking Camshaft Lobes and Journals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263 .

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
.
Coolant Heater (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263 .
Camshaft Bushings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263 .
Camshaft Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266 .
Cam Gear on Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267 .
Checking Camshaft End Play. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267 .
Crankshaft Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268 .
Bearing Fitting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269 .
Main Bearings and Caps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270 .
Torque Procedure for Torque-to-Yield Main Bearing Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271 .
Crankcase Ladder (DT 466 series – 225 hp and 245 hp @ 2600 rpm) and all 570 ratings. . . . . . .272 .
Oil Level Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274 .
Crankcase Ventilation System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274 .

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
.

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278

.

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278

.

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250 CRANKCASE, CRANKSHAFT, AND CAMSHAFT

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 CRANKCASE, CRANKSHAFT, AND CAMSHAFT 251

7
6

5
4
3
2
1
10

11
12
13
9 14
8

15
16

18
17
19

25

29 28 27 26

41 21
44 17
43 20
42 22
40 23
45 22
39 24
38
37

36
35 30
31
34 32
33 H06087

Figure 359 Crankcase, Crankshaft, and Camshaft

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252 CRANKCASE, CRANKSHAFT, AND CAMSHAFT

1. Camshaft gear assembly 17. Clamp, 1/2 in. diameter (3) 32. Bolt, M12 x 35 (14)
2. Bolt, M8 x 20 (2) 18. Vent and drain tube assembly 33. Bearing cap bolt, M15 x 162 (14)
3. Camshaft thrust plate 19. Nut, M10 34. Spacer (14)
4. Key, 1/2 x 1/2 20. Reducer hose 35. Main bearing cap (7)
5. Roller tappet assembly (12) 21. Check valve 36. Main bearing, lower (7)
6. Roller tappet guide (6) 22. Clamp (3) 37. Oil pump drive (spline)
7. Camshaft 23. Rubber elbow 38. Crankshaft gear
8. Front camshaft bushing 24. Bolt, M8 x 16 39. Crankshaft
9. Intermediate camshaft bushings 25. Drain hose elbow 40. Main bearing, upper (6)
(2) 26. Oil level gauge assembly (Figure 41. Tee assembly, M12
10. Rear camshaft bushing 361) 42. Bolt, piston cooling tube (6)
11. Camshaft seal ring, rear 27. Fitting assembly, M12 43. Piston cooling tube assembly (6)
12. O-ring, #214 28. O-ring seal (see “Power Cylinders”)
13. Breather assembly 29. Main bearing, upper (#7 thrust) 44. Block heater assembly (option)
14. Hose, 1 in. I.D. 30. Crankcase ladder (DT 570 >300 45. Slotted pin, 5/32 x 5/16
15. Clamp, 1 in. diameter (2) bhp)
16. Bolt, M8 x 35 (2) 31. Bolt, M10 x 25 (10)

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 CRANKCASE, CRANKSHAFT, AND CAMSHAFT 253

Removal parking brake, and block wheels before doing

diagnostic or service procedures.
Crankcase Ventilation System

WARNING: To prevent personal injury or

death, allow engine to cool before working with
GOVERNMENT REGULATION: Engine components.
fluids (oil, fuel, and coolant) may be a hazard
to human health and the environment. WARNING: To prevent personal injury or
Handle all fluids and other contaminated death, disconnect ground (-) cable from battery
materials (e.g. filters, rags) in accordance before doing service or diagnostic procedures.
with applicable regulations. Recycle
or dispose of engine fluids, filters, and
other contaminated materials according to WARNING: To prevent personal injury or
applicable regulations. death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).

WARNING: To prevent personal injury or WARNING: To prevent personal injury or

death, read all safety instructions in the “Safety death, do not let engine fluids stay on your skin.
Information” section of this manual. Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing
and rags contaminated with engine fluids.
WARNING: To prevent personal injury or
death, shift transmission to park or neutral, set

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254 CRANKCASE, CRANKSHAFT, AND CAMSHAFT

4 1 2 3 4
15
5

6
14 Breather assembly
Side view
7

8 Black side
Gray side
Side View 5 9 10 9
9

Flow
direction

13 9 12 11
H17017

Figure 360 Crankcase ventilation system

1. Breather assembly 6. Nut, M10 12. Rubber elbow
2. Clamp, 25.4 mm (1 in) diameter 7. Vent and drain tube assembly 13. Fitting assembly, M12
(2) 8. Reducer hose 14. Drain hose elbow
3. Hose, 25.4 mm (1 in) I.D. 9. Clamp (3) 15. O-ring, #214
4. Bolt, M8 x 35 (2) 10. Check valve
5. Clamp, 1/2 in. diameter (3) 11. Bolt, M8 x 16

NOTE: Have an oil pan handy before disconnecting 2. Remove clamp and rubber elbow on the
the oil drain hose. It is possible for a column of oil to crankcase side of the check valve. Leave fitting
be maintained above the check valve, as the check assembly in crankcase unless evidence of leaking
valve does require a certain amount of pressure to is occurring from fitting O-ring.
allow passage of oil back to the crankcase.
3. Remove the bolt (M8 x 16) securing the vent and
To remove the crankcase ventilation system as an drain tube assembly to the crankcase, located at
assembled unit, do the following steps. the end of the vent tube.
1. Move clamp (1/2 in) out of way and remove 4. Remove two bolts (M8 x 35) securing the breather
reducer hose from vent and drain tube assembly. assembly to the valve cover.
Allow tube and reducer hose to drain. Reconnect
reducer hose and clamp.

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 CRANKCASE, CRANKSHAFT, AND CAMSHAFT 255

5. Remove the nut (M10) securing the vent and drain

tube to the intake manifold.
6. Carefully pull breather assembly out of valve
cover.
7. Remove breather and tubing assembly and place
in solvent wash tank.

Oil Level Gauge

4
5

7 6

H06082

Figure 361 Oil level gauge assembly

1. Bolt, M6 x 40 4. Oil filler tube 7. Oil dipstick tube seal
2. Nut, M6 5. Tube clamp
3. Cushioned clamp 6. Oil level gauge tube

1. Remove the oil filler tube bolt (M6 x 40) and nut 3. If necessary, remove oil level gauge tube from
(M6) at the fuel filter bracket. crankcase by using a brass drift and hammer.
2. Remove the tube clamp at the crankcase and
discard oil dipstick tube seal.

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256 CRANKCASE, CRANKSHAFT, AND CAMSHAFT

Crankcase Ladder (DT 466 series – 225 hp and Crankshaft Disassembly

245 hp @ 2600 rpm) and all 570 ratings
NOTE: Before removing the crankshaft, it may
be necessary to remove the piston assemblies
(Removing Piston and Connecting Rod Assembly,
page218).

Figure 362 Crankcase ladder hardware

NOTE: Refer to the following for information

regarding the removal or installation of these related Figure 364 Main bearing cap identification
components: stamps

• Oil pan (Removing the Oil Pan, page206)

• Oil suction tube (Removing the Oil Suction Tube, 1. Verify that the main bearing caps and crankcase
page207) are numbered. You may have to degrease
accordingly to gain access to the stamped
1. Remove 14 crankcase ladder bolts (M12 x 35) and numbers.
spacers.
2. Loosen all the main bearing bolts (M15 x 162).
2. Remove 10 crankcase ladder bolts (M10 x 25).

Figure 365 Removing the main bearings

Figure 363 Removing the crankcase ladder

3. Remove the crankcase ladder.

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 CRANKCASE, CRANKSHAFT, AND CAMSHAFT 257

3. Lift up both bolts until about half the threads are 8. Remove the oil pump drive first to access the
exposed. Use both bolts to rock main bearing cap crankshaft gear.
free from crankcase.
9. Be careful not to damage the crankshaft during
4. Discard all of the removed main bearing bolts. gear removal.
These are not reusable due to the permanent
stretch they received from “torque-to-yield”.

Figure 366 Removing the crankshaft assembly

Figure 368 Removing the number seven upper
thrust bearing
5. Place an appropriately sized sling around the
middle of the crankshaft and attach it to a hoist or
crane. Lift crankshaft out of crankcase and place
10. Remove upper main bearing shells by pushing
on workbench.
them out of main bearing saddle with your thumbs.
6. Visually inspect the crankshaft gears for chipping Mark the upper shells with bearing number and
or wear. Replace as required. orientation. Set aside each upper bearing shell
with the lower shells until a proper inspection can
7. Place a chisel between the gear teeth and strike
be done.
the chisel with a hammer to split the gear.

Cam Gear from Camshaft

NOTE: If removing the whole camshaft assembly, skip
to next procedure.
1. Install gear puller making sure claws are positively
engaged with cam gear and the threaded shaft is
aligned with camshaft.

Figure 367 Removing oil pump drive spline

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258 CRANKCASE, CRANKSHAFT, AND CAMSHAFT

1. Remove the two camshaft thrust plate bolts (M8 x

20).

Figure 369 Removing camshaft gear

2. Using a socket or wrench apply force to tool until

gear is just about off. Use both hands to remove Figure 371 Removing the camshaft assembly
cam gear and tool.

2. Carefully remove the camshaft assembly from the

Camshaft Disassembly crankcase.

NOTE: Use this procedure to remove the cam gear

and camshaft as a unit.

Figure 370 Removing camshaft thrust plate

bolts

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 CRANKCASE, CRANKSHAFT, AND CAMSHAFT 259

Camshaft Bushings

Figure 372 Camshaft Bushing Puller (installer)

1. Puller screw 6. Extension tube 10. Backup nut
2. Pulling nut 7. Puller screw extension
3. Thrust bearing 8. Camshaft bearing (not part of
4. Pulling plate tool)
5. Pulling spacer 9. Expanding collet

NOTE: Although the inside diameter of each camshaft

bushing is the same, the outside diameters and widths
are different depending on bearing location. The
bearing diameters have changed from previous
designs and this determines how bushing are
removed and installed.

Table 35
Bushing Outside Width
Location Diameter (nominal)
(nominal)
Front 65.5 mm (2.50 in) 25.4 mm
(1.00 in)
Rear 65.5 mm (2.50 in) 17.8 mm
(0.70 in)
Intermediate 63.0 mm (2.48 in) 17.8 mm
(0.70 in)

Remove the front and rear bushings (1) first. The rear
bearing and camshaft seal ring must be removed from
the rear of the crankcase. It is recommended that the
intermediate bushings be removed according to the
following illustration.

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260 CRANKCASE, CRANKSHAFT, AND CAMSHAFT

4
3

1 2 2 1

H06092

Figure 373 Pulling direction for camshaft bushing removal

1. Front and rear bushings 3. Rear half of engine 5. Camshaft seal ring
2. Intermediate bushings 4. Front half of engine

1. Assemble the correct expanding collet size and Coolant Heater (if equipped)
backup nut onto the expanding mandrel.
1. Make sure coolant has been drained out of the
2. With the collet collapsed, install the collet engine or at least drained to a level below the
assembly into the camshaft bushing. Tighten coolant heater, if simply servicing the heater.
the backup nut onto the expanding mandrel until
2. Loosen 5/32 in hex socket head cap screw
the collet fits the camshaft bearing.
sufficient to remove the coolant heater from the
3. Assemble the puller screw and extension, if crankcase.
necessary. Install the puller screw onto the
3. Clean out coolant heater cavity at crankcase.
expanding mandrel.
4. Hold the end of the puller screw with a wrench
to keep it from turning. Tighten the pulling nut
against the thrust bearing and the pulling plate
until the camshaft bushing is removed.

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 CRANKCASE, CRANKSHAFT, AND CAMSHAFT 261

Cleaning and Inspection b. Clean cross drillings using a nylon brush

(Table 40) with soap and water.
Cleaning the Crankcase
c. Use filtered compressed air to blow out oil
CAUTION: To prevent engine damage, the oil cooler
galleries and cross drillings.
must be replaced if there was a bearing failure. Debris
from a bearing failure cannot be removed from the oil d. Clean all threaded holes with an appropriately
cooler. sized tap (Table 40).
NOTE: The best way to clean the crankcase during 4. Install a new main oil gallery cup plug as follows:
engine overhaul is in a chemical bath or hot tank.
a. Clean the mating surfaces of the plug and
This removes all carbonaceous material and mineral
crankcase.
deposits that collect in the cooling passages. If the
hot tank is not available, use the following cleaning b. Apply Loctite® 262 to the outside edge of the
procedure. cup plug.
1. Clean all old gasket material from the surfaces of c. Use an arbor to drive the cup plug in. The
the crankcase, if any. arbor must be approximately 6 mm (1/4 in)
smaller in diameter than the plug that is being
installed.
d. Recess the cup plug 3.2 mm (1/8 in).
5. Install new plugs in the rear of the crankcase.

WARNING: To prevent personal injury or

death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).
6. Inspect the piston cooling tubes for damage and
blockage as follows:
a. Inspect both ends of the tube. Verify that
the flanged end next to the bearing saddle is
intact and the orifice end protruding from the
crankcase is not broken. Replace any tubes
that are damaged.
b. Hold tube under running water in a sink.
Figure 374 Removing crankcase plugs Water should stream out of tube end. If not,
blockage will have to be physically removed
by compressed air or piston oil tube must be
2. Remove the main oil gallery cup plug, located at replaced.
the rear of the crankcase by using a hammer and
chisel. Knockout main oil gallery cup plug.
Crankcase Ventilation
WARNING: To prevent personal injury or 1. Place breather and tubing assembly (Figure 360)
death, wear safety glasses with side shields. into a solvent parts cleaner and disassemble.
Limit compressed air pressure to 207 kPa (30 psi).
2. Thoroughly clean all hoses, clamps, tubing,
3. With the plugs removed from the crankcase, clean check valve and breather assembly. Run solvent
the crankcase as follows: through each end of the check valve to confirm
a. Use a nylon brush (Table 40) with soap and directional flow.
water to clean oil galleries.

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262 CRANKCASE, CRANKSHAFT, AND CAMSHAFT

WARNING: To prevent personal injury or

death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).
3. Blow dry with filtered compressed air.
4. Inspect all rubber hoses for cracking or
deformation. Replace components as necessary.

Crankshaft and Main Bearings

Perform the following steps:
1. Clean the bearing inserts and caps thoroughly
in solvent and dry with filtered compressed air .
Do not scrape gum or varnish deposits from
Figure 375 Inspecting the crankshaft journals
bearing shells.
2. Clean all the internal oil passages of the
crankshaft using a stiff nylon brush (Table 40). 6. Measure the diameter of each journal using a
Loosen all dirt, sludge and deposits which may micrometer. Measure each journal at two points,
have accumulated. Flush the oil passages with a right angles to each other. Move the micrometer
suitable non-caustic solvent. over the entire width of the journal.
NOTE: If journals exceed maximum out-of-round
WARNING: To prevent personal injury or specification, crankshaft must be reground or
death, wear safety glasses with side shields. replaced. The crankshaft can be ground to the
Limit compressed air pressure to 207 kPa (30 psi). following undersizes:
3. Blow passages dry with filtered compressed air . • 0.25 mm (0.010 in)
4. Inspect the crankshaft journals (main and rod) • 0.51 mm (0.020 in)
for scratches, grooves and scoring. Use dye
penetrant methods to check for cracks. • 0.76 mm (0.030 in)

5. Inspect all bearing inserts. Replace bearings that Checking Camshaft Assembly
are scored, chipped or worn. 1. Use a soft bristle brush and a suitable solvent to
clean the camshaft and cam gear.
2. Inspect the cam gear for worn and damaged teeth.
Replace the gear assembly, if necessary.
3. Inspect the camshaft for scuffed, scored
and cracked lobes. Replace the camshaft if
necessary.
4. Inspect the camshaft thrust plate for wear, cracks,
and distortion. Use an outside micrometer to
measure the thickness of the thrust plate. If the
thrust plate is too worn or damaged, replace the
thrust plate.

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 CRANKCASE, CRANKSHAFT, AND CAMSHAFT 263

Checking Camshaft Lobes and Journals 3. Tighten the 5/32 in hex socket head cap screw to
the special torque value (Table 39).
4. Replenish coolant level if only servicing coolant
heater.

Camshaft Bushings
1. Identify each camshaft bushing according to its
outside diameter.

Table 36
Bushing Outside Width
Location Diameter (nominal)
(nominal)
Front 65.5 mm (2.50 in) 25.4 mm
(1.00 in)
Rear 65.5 mm (2.50 in) 17.8 mm
(0.70 in)
Figure 376 Checking camshaft lobes and Intermediate 63.0 mm (2.48 in) 17.8 mm
journals for wear (0.70 in)

2. Lubricate each new camshaft bushing and

1. Use an outside micrometer to measure across crankcase bushing bore with clean engine oil.
each camshaft lobe from A-D and B-C. Subtract
measurement B-C from measurement A-D. This
is the cam lobe lift.
If any measurement exceeds the specification,
replace the camshaft.
2. Use an outside micrometer to measure the
diameter of each camshaft journal.
If any measurement exceeds the specification
(Table 38), replace the camshaft.

Installation
Coolant Heater (if equipped) Figure 377 Camshaft bushing installation tool
1. If servicing a leaky coolant heater, replace O-ring
on heater assembly. 3. Install new camshaft bearing onto the expanding
2. Place nonpetroleum base lubricant around O-ring collet. Tighten collet by turning adjusting nut until
area and install into crankcase. Orient electrical the bushing is held securely in place.
connector so that it is facing downward (6 o’clock
position).

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264 CRANKCASE, CRANKSHAFT, AND CAMSHAFT

4. Mark the bearing oil hole location on the backup

nut of the installation tool to help align the oil hole
in the bushing with the oil hole in the crankcase.
Repeat this step for each bushing.
CAUTION: To prevent engine damage, camshaft
bushings must be installed in the proper order due
to differing outside diameters. Both intermediate
cam bushings have an outer diameter that is slightly
smaller than bushings used in the front and rear
positions.

Cam bearings oil holes must align with oil holes in

cylinder block.

Figure 378 Marking oil hole location on bushing

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 CRANKCASE, CRANKSHAFT, AND CAMSHAFT 265

4
3

2 1 1 2

H06093

Figure 379 Pulling direction for camshaft bushing installation

1. Intermediate bushings 3. Rear half of engine 5. Camshaft seal ring
2. Front and rear bushings 4. Front half of engine

5. Install the rear intermediate bushings through

the rear of the crankcase. Pull the bushing into
place from the front of the crankcase by turning
the pulling nut on the puller screw. Remove the
installation tool and inspect the oil hole alignment.
6. Install the front intermediate bushing through
the front of the crankcase. Pull the bushing into
place from the rear of the crankcase by turning
the pulling nut on the puller screw. Remove the
installation tool and inspect oil hole alignment.

Figure 380 Paint marks indicating oil hole

alignment

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266 CRANKCASE, CRANKSHAFT, AND CAMSHAFT

Figure 381 Pulling in the front bushing Figure 382 Installing camshaft assembly

7. Install the front bushing through the front of the 1. Rotate crankcase to a vertical position.
crankcase. Pull the bushing into place from the 2. Lubricate all camshaft journals and bushings with
rear of the crankcase by turning the pulling nut on clean engine oil.
the puller screw. Remove the installation tool and
inspect the oil hole alignment. 3. Install the camshaft assembly in the crankcase.
8. Install the rear bushing through the rear of the
crankcase. Pull the bushing into place from the
front of the crankcase by turning the pulling nut
on the puller screw. Remove the installation tool
and inspect the oil hole alignment.
9. Install camshaft seal ring in rear of crankcase.

Camshaft Assembly
NOTE: Use this procedure to install the cam gear and
camshaft as a unit.

Figure 383 Torquing camshaft thrust plate bolts

4. Install the two camshaft thrust plate bolts (M8 x

20). Tighten the bolts to the special torque value
(Table 39).

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 CRANKCASE, CRANKSHAFT, AND CAMSHAFT 267

Cam Gear on Camshaft 3. Use heat resistant gloves to install the heated
cam gear onto the camshaft. The cam gear
WARNING: To prevent serious personal should slide onto the camshaft with only slight
injury or possible death, wear heat resistant hand pressure. Hold the cam gear (while
gloves when handling heated components. thoroughly seated) until it cools onto the camshaft
(approximately 30 seconds).
NOTE: Heated gear should easily slide onto camshaft.
Do not tap into place to avoid camshaft end play
issues. If gear does not slide easily, reheat gear and
try again.
Checking Camshaft End Play

Figure 384 Heating the camshaft gear

CAUTION: To prevent engine damage, do not heat

the cam gear above 177 °C (350 °F). This will turn the
Figure 386 Checking camshaft end play
gear blue and reduce wear resistance. Do not use any
gear turned blue. 1. Dial indicator set
2. Camshaft
1. If the camshaft gear was removed from the
camshaft, heat the cam gear on a hot plate (Table
40) or other controlled heat source to 149-177 °C
1. Mount magnetic base of a dial indicator set (Table
(300-350 °F).
40) on a flat engine surface.
2. Pull camshaft assembly forward prior to sliding
2. Place the tip of the dial indicator on the end of the
heated gear onto camshaft.
camshaft and zero the dial indicator.
3. Use a screwdriver to pry the camshaft gear back
and forth. Record the reading on the dial indicator.
If the end play exceeds the specification, remove
the cam gear and pull the camshaft forward.
Repeat the procedure.

Figure 385 Installing cam gear on camshaft

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268 CRANKCASE, CRANKSHAFT, AND CAMSHAFT

Crankshaft Assembly
1. Rotate the engine so the main bearing saddles
are facing up. Clean the bearing saddles with a
lint-free cloth. The supports must be free of oil. Do
not lubricate the back side of the bearing inserts.

WARNING: To prevent serious personal

injury or possible death, wear heat resistant
gloves when handling heated components.
2. With gears removed, heat the crankshaft gear and
oil pump drive spline, using a hot plate (Table 40),
to 188-202 °C (370-395 °F).
3. Position the slotted locating pin (5/32 x 5/16) onto
the crankshaft. Figure 388 Installing the number seven thrust
bearing

7. Install the thrust bearing into the number seven

upper bearing saddle. Make sure the locking
tangs on the bearings are snapped into the
crankcase.
8. Install the remaining six upper bearing inserts into
the saddles. Make sure the locking tangs on the
bearings are snapped into the crankcase.
9. Apply Prussian Blue® to the crankshaft main
bearing journals.

Figure 387 Installing crankshaft gear

1. Slotted pin, 5/32 x 5/16
2. Crankshaft
3. Oil pump drive spline
4. Crankshaft gear

4. Using gloves specifically designed for extremely

hot objects, install heated crankshaft gear first,
aligning the slotted pin with hole in crankshaft Figure 389 Installing the crankshaft assembly
gear. Press the gear into place holding against
crankshaft shoulder.
10. Using an appropriate lifting sling, carefully lower
5. Slide the hot oil pump drive (splined) up against
the crankshaft onto the main bearing inserts in the
the crankshaft gear (no orientation required).
crankcase.
6. Hold oil pump drive and crankshaft gear in
NOTE: Do not install the main bearing caps and lower
place until cool enough to sufficiently hold onto
bearing inserts at this time.
crankshaft.
11. Rotate the crankshaft 180 degrees (1/2 turn).

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 CRANKCASE, CRANKSHAFT, AND CAMSHAFT 269

12. Carefully remove the crankshaft and inspect the Bearing Fitting Procedure
upper bearing inserts for an even transfer of bluing
1. Install a new bearing insert into the bearing cap,
agent from the journals to the bearings.
as required. The bearing surface of the bearing
NOTE: If voids appear in the bluing transfer, caps must be free of oil. Do not lubricate the
crankcase integrity is considered questionable. backside of the bearing inserts. Make sure the
locking tangs on the bearing inserts are snapped
13. If the crankcase is not damaged and is free of
into the bearing cap notch.
distortion and burrs around upper bearing insert
seats, then clean all Prussian Blue® from the
bearings and crankshaft journals.

Figure 392 Main bearing cap identification

stamps

2. Align each main bearing cap with its identification

Figure 390 Lubricating the upper main bearing stamp.
inserts
3. Check bearing clearance as follows:
a. Clean the bearing surface and the exposed
14. Lubricate the upper main bearing inserts with half of the crankshaft journal. Make sure
clean engine oil. these surfaces are free of oil.
b. Install the lower inserts and bearing caps. Oil
the threads of new main bearing bolts with
clean engine oil.
c. Torque bolts in the following steps in a circular
pattern.
NOTE: This two step torque procedure to
177 N·m (130 lbf·ft), simply checks bearing
fit and will not permanently stretch the
new main bearing bolts. Do not follow the
torque-to-yield procedure until final assembly.

Figure 391 Installing the crankshaft assembly 1. Tighten each main bearing bolt to 136
N·m (100 lbf·ft) using the recommended
torque sequence (Figure 395).
15. Using an appropriate lifting sling, carefully lower
the crankshaft onto the main bearings.

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270 CRANKCASE, CRANKSHAFT, AND CAMSHAFT

2. Tighten each main bearing bolt to 177 i. If the bearing clearance is not within
N·m (130 lbf·ft) using the recommended specifications, the crankshaft must be
torque sequence (Figure 395). replaced or reground and undersize bearings
installed.
d. Remove one bearing cap and insert at a time.
Leave the remaining caps tight while checking
the fit of the bearing with the cap removed.
Main Bearings and Caps
e. Wipe oil from all contact surfaces of the
CAUTION: To prevent engine damage, use new main
exposed journal, bearing insert and cap that
bearing cap bolts whenever the bearing caps are
is removed.
serviced.
f. Place a piece of Plastigage® across the full
NOTE: The thrust bearing located at number 7 is
width of the bearing surface on the crankshaft
found only in the upper half. All seven lower bearings
journal (or bearing insert) approximately 6
share the same part number.
mm (¼ in) off center. Install the bearing cap
and tighten the cap bolt to 177 N·m (130 1. Clean the Plastigage® from main bearing and or
lbf·ft). crankshaft journal surfaces.
NOTE: Do not turn the crankshaft. 2. Coat all bearing surface journals with clean
engine oil.
NOTE: In chassis service only: When
bearing oil clearance is checked, the 3. Apply clean engine oil to main bearing bolts
crankshaft will have to be supported and held (threads and under head).
against the upper main bearing halves to get
4. Place the No. 1 through No. 7 main bearing caps
a correct Plastigage® reading. Use a jack at
with the lower bearing inserts installed.
the crankshaft counterweight nearest to each
main bearing being checked to apply local NOTE: Make sure the main bearings are installed with
support. Failure to support the crankshaft will the arrow pointing to the cam side and numbered from
result in inaccurate readings. the front of the engine to the rear.
g. Remove the bearing cap and insert.
h. Do not disturb the Plastigage®. Use the scale
on the Plastigage® envelope to measure the
widest point of the flattened Plastigage®.
This reading indicates the bearing clearance
in thousandths of an inch or millimeters.

Figure 394 Installing the main bearing caps

5. Align and seat each of the main bearing caps.

Figure 393 Measuring widest point of flattened

Plastigage®

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 CRANKCASE, CRANKSHAFT, AND CAMSHAFT 271

Torque Procedure for Torque-to-Yield Main

Bearing Bolts

12 8 4 1 5 9 13

#7
Main
6 5 4 3 2 1
Cap

11 7 3 2 6 10 14

H06083
Figure 395 Recommended main bearing bolt torque sequence

1. Torque new bolts for main bearing caps 1 Check crankshaft end play using a dial
through 7. indicator as follows:
a. Tighten each main bearing bolt to 136 N·m 1. Mount the dial indicator onto crankcase
(100 lbf·ft) using the recommended torque with indicator tip on crankcase flange
sequence. face.
2. Lightly pry the crankshaft forward and
zero indicator.
3. Pry crankshaft rearward and record dial
indicator reading. Repeat to ensure an
accurate reading.
4. If end play exceeds specifications,
replace thrust bearing and recheck
crankshaft end play. If end play is less
than specified, loosen the thrust bearing
cap, reposition, torque and check end
play again.
b. Tighten each main bearing bolt to 177 N·m
(130 lbf·ft) using the recommended torque
sequence.

Figure 396 Checking crankshaft end play

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272 CRANKCASE, CRANKSHAFT, AND CAMSHAFT

Figure 397 Crankshaft main bearing bolt

1. Head of bolt with mark, position 1
Figure 398 Installing the crankcase ladder
2. Head of bolt with mark, position 2 (bolt stretches)
3. Main cap surface
4. Mark (permanent marker)
1. Install crankcase ladder onto crankcase.

c. Use a permanent marker to add a mark

on each bolt head and another mark 90°
clockwise on the main cap. Also mark the
socket to match the bolt marking.
d. Rotate each crankshaft main bearing bolt
(Figure 397) 90 degrees (1/4 turn).

Crankcase Ladder (DT 466 series – 225 hp and

245 hp @ 2600 rpm) and all 570 ratings
NOTE: The crankcase ladder is symmetrical;
therefore, it does not matter which way it is installed.

Figure 399 Crankcase ladder hardware

2. Install 14 crankcase ladder spacers and bolts

(M12 x 35) to the 14 inboard bolt holes finger
tight.
3. Install 10 crankcase ladder bolts (M10 x 25) to the
10 outboard bolt holes finger tight.

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 CRANKCASE, CRANKSHAFT, AND CAMSHAFT 273

8 4 1 5 9

12 8 4 1 5 9 13

11 7 3 2 6 10 14

7 3 2 6 10
H06084

Figure 400 Recommended crankcase ladder torque sequence

4. Using the recommended crankcase ladder torque

sequence, tighten the inboard bolts (M12 x 35) to
the special torque value (Table 39).
5. Using the recommended crankcase ladder torque
sequence, tighten the outboard bolts (M10 x 25)
to the special torque value (Table 39). These bolts
are indicated by the circled numbers in the above
illustration.

Figure 401 Torquing the crankcase ladder bolts

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274 CRANKCASE, CRANKSHAFT, AND CAMSHAFT

Oil Level Gauge

4
5

7 6

H06082

Figure 402 Oil level gauge assembly

1. Bolt, M6 x 40 4. Oil filler tube 7. Oil dipstick tube seal
2. Nut, M6 5. Tube clamp
3. Cushioned clamp 6. Oil level gauge tube

1. If removed earlier, install the oil level gauge tube Crankcase Ventilation System
by first applying Loctite® #277 around entire
1. If fitting assembly (M12) was leaking at the
circumference of tube and casting. Drive tube
crankcase, replace O-ring. Tighten fitting to
into crankcase until bead of tube is seated in
the standard torque value (General Torque
chamfer of crankcase boss.
Guidelines, page445) .
2. Install a new oil dipstick tube seal between oil filler
CAUTION: To prevent engine damage, do not use
tube and crankcase oil tube flange.
any type of impact tools to seat the (M8 x 35) bolts.
3. Install the tube clamp at the crankcase. Using impact tools will cause thread damage.
4. Install the oil filler tube bolt (M6 x 40) and nut (M6) 2. Install a new O-ring onto breather assembly and
at the fuel filter bracket. push into valve cover grommet.

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 CRANKCASE, CRANKSHAFT, AND CAMSHAFT 275

4 1 2 3 4
15
5

6
14 Breather assembly
Side view
7

8 Black side
Gray side
Side View 5 9 10 9
9

Flow
direction

13 9 12 11
H17017

Figure 403 Crankcase ventilation

1. Breather assembly 6. Nut, M10 11. Bolt, M8 x 16
2. Clamp, (1 in) diameter (2) 7. Vent and drain tube assembly 12. Rubber elbow
3. Hose, (1 in) I.D. 8. Reducer hose 13. Fitting assembly, M12
4. Bolt, M8 x 35 (2) 9. Clamp (3) 14. Drain hose elbow
5. Clamp, 1/2 in diameter (3) 10. Check valve 15. O-ring, #214

3. Position drain hose elbow and one inch hose 6. Attach bottom of vent tubing to crankcase and
onto breather assembly. Secure with clamps, see secure with bolt (M8 x 16).
illustration.
7. Combine rubber elbow, clamps, check valve, and
4. Place appropriate hose clamps onto vent and reducer hose, making sure check valve is oriented
drain tube assembly. Position vent and drain tube correctly. Connect to drain side of tubing and
assembly into breather assembly hoses. clamp.
5. Align vent and drain tubing assembly bracket with 8. Tighten all hardware to the standard torque value
intake manifold stud. Thread nut (M10) onto stud (General Torque Guidelines, page445) and move
finger tight. clamps into their sealing positions.

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276 CRANKCASE, CRANKSHAFT, AND CAMSHAFT

Specifications

Table 37 Crankshaft Specifications

Type Steel forged, induction hardened, grindable
Main Bearing journal diameter
Standard size 107.95 ± 0.015 mm (4.250 ± 0.0006 in)
0.254 mm (0.010 in) undersized 107.70 ± 0.015 mm (4.240 ± 0.0006 in)
0.508 mm (0.020 in) undersized 107.44 ± 0.0152 mm (4.230 ± 0.0006 in)
0.762 mm (0.030 in) undersized 107.19 ± 0.0152 mm (4.220 ± 0.0006 in)
Damper mounting area runout (maximum) 0.03 mm (0.001 in)
Flywheel mounting surface runout (maximum) 0.05 mm (0.002 in)
Main bearing journal maximum out-of-round 0.05 mm (0.002 in)
Main bearing journal taper (maximum per inch) 0.071 mm (0.0028 in)
Main bearing thrust face runout (TIR maximum) 0.03 mm (0.001 in)
Main bearing width (except rear thrust) 34.19 ± 0.13 mm (1.346 ± 0.005 in)
Number of main bearings 7
Rear oil seal journal runout (maximum) 0.08 mm (0.003 in)
Thrust taken by No. 7 rear upper main bearing
Thrust bearing journal length 34.404 ± 0.038 mm (1.3545 ± 0.0015 in)
Connecting rod journal diameter
Standard Size 80.0 ± 0.0152 mm (3.1500 ± 0.0006 in)
0.0254 mm (0.010 in) undersized 79.7 ± 0.0152 mm (3.1400 ± 0.0006 in)
0.508 mm (0.020 in) undersized 79.5 ± 0.0152 mm (3.1300 ± 0.0006 in)
0.762 mm (0.030 in) undersized 79.2 ± 0.0152 mm (3.1200 ± 0.0006 in)
Center line of main bearing bore to head deck 368.3 ± 0.05 mm (14.50 ± 0.002 in)
Connecting rod bearing to crankshaft running 0.030 - 0.107 mm (0.0012 - 0.0042 in)
clearance
Connecting rod bearing width 40.01 mm (1.575 in)
Connecting rod journal maximum out-of-round 0.0064 mm (0.00025 in)
Connecting rod journal taper (maximum per inch) 0.0069 mm (0.00027 in)
Crankshaft end play 0.15-0.31 mm (0.006 - 0.012 in)
Crankshaft end play maximum wear limit 0.51 mm (0.020 in)
Crankshaft flange outside diameter 155.58 mm (6.125 in)
Crankshaft gear backlash 0.08-0.41 mm (0.003 - 0.016 in)
Main bearing to crankshaft running clearance 0.046 - 0.127 mm (0.0018 - 0.0050 in)
Connecting rod to crankshaft side clearance 0.30 ± 0.11 mm (0.012 ± 0.005 in)
Standard size to 0.51 mm (0.020 in) undersized 34.404 ± 0.03 mm (1.3545 ± 0.010 in)

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 CRANKCASE, CRANKSHAFT, AND CAMSHAFT 277

Table 38 Crankcase Specifications

Cap attachment 2 bolts per cap
Coolant heater rating 1250 W, 120 V
Counterbore depth in crankcase 8.865 ± 0.025 at 132 mm (0.349 ± 0.001
at 5.189 in)
Crankcase deck flatness 0.08 mm (0.003 in)
Crankcase main bearing bore diameter 116.421 ± 0.0127 mm (4.4583 ± 0.0005 in)
Cylinder sleeve counterbore maximum allowable depth 9.25 mm (0.364 in)
Main bearing type Precision replaceable
Material Steel-backed copper, lead, tin
Maximum allowable variation of counterbore depth (between 0.025 mm (0.001 in)
four points)
Piston cooling tube dia. (spray hole) DT 466 1.91 - 2.06 mm (0.075 - 0.081 in)
Piston cooling tube dia. (spray hole) DT 570, HT 570 2.26 - 2.41 mm (0.089 - 0.095 in)
Roller tappet outside diameter 28.435 - 28.448 mm (1.1195 -1.1200 in)
Sleeve protrusion above crankcase 0.05 - 0.13 mm (0.002 - 0.005 in)
Tappet bore diameter 28.51 - 28.55 mm (1.123 - 1.124 in)
Thrust taken by No. 7 rear upper main bearing
Camshaft
Bushing I.D. (installed) 58.03 - 58.12 mm (2.285-2.288 in)
Cam lobe lift, exhaust 6.91 mm (0.272 in)
Cam lobe lift, intake 6.68 mm (0.263 in)
Camshaft end play 0.18 - 0.33 mm (0.007 - 0.013 in)
Camshaft journal diameter 57.95 - 58.98 mm (2.282 - 2.283 in)
Camshaft radial clearance 0.05 - 0.17 mm (0.002 - 0.007 in)
Maximum permissible cam lobe wear 0.25 mm (0.010 in)
Service bushings furnished to size Yes
Thrust plate thickness (new) 6.96 - 7.01 mm (0.274 - 0.276 in)
Camshaft bushing bore diameter in crankcase
Front 65.51 - 63.55 mm (2.501 - 2.502 in)
Intermediate front 63.01 - 63.04 mm (2.481 - 2.482 in)
Intermediate rear 63.01 - 63.04 mm (2.481 - 2.482 in)
Rear 65.51 - 63.55 mm (2.501 - 2.502 in)

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278 CRANKCASE, CRANKSHAFT, AND CAMSHAFT

Special Torque

Table 39 Crankcase, Crankshaft and Camshaft Special Torques

Camshaft thrust plate bolts 26 N·m (19 lbf·ft)
Crankcase ladder, M12 x 35 122 N·m (90 lbf·ft)
Coolant heater bolt 4.5 - 5.1 N·m (40 - 45 lbf·in)
Crankcase ladder, M10 x 25 63 N·m (46 lbf·ft)
Crankshaft main bearing cap bolt torque and sequence (Torque Procedure for
Torque-to-Yield Main Bearing
Bolts, page271)

Special Service Tools

Table 40 Crankcase, Crankshaft and Camshaft Special Service Tools

Cam gear puller ZTSE4411
Camshaft bushing puller ZTSE2893B
Dial indicator set Obtain locally
Hot plate Obtain locally
Nylon brush ZTSE4389
Plastigage®. Obtain locally
Prussian Blue® Obtain locally
Tap, cylinder head bolt holes ZTSE4671
Tap set ZTSE4386
Stiff nylon brush ZTSE4392

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 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION 279

Table of Contents

Component Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281

.

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283
.
Oil System Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283 .
Secondary Filtration Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .286 .
Disassembling the Oil System Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287 .
Disassembling the Secondary Filtration Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289 .

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290 .

Cleaning the Oil System Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290 .
Checking the Cooler Heat Exchanger for Leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290 .
External. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290.
Internal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292
.

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293
.
Assembling the Oil System Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293 .
Assembling the Secondary Filtration Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295 .
Secondary Filtration Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296 .
Oil System Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296 .
Priming the Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298 .
Alternate Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298 .

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299
.

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299

.

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299

.

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280 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION

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 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION 281

Component Exploded View

4
3
2 5
1 6
7

19

18

17

16 9

14 13 12 11 10

15

H13003

Figure 404 Oil system module assembly

1. Oil supply tube fitting and O-ring 8. Oil seal 15. Bolt, M8 x 20 (8)
2. O-ring gasket 9. Plug assembly, M18 (coolant) 16. Cooler heat exchanger (23 or 33
3. Regulator valve assembly 10. Coolant seal (2) plates)
4. Hex flange screw, M8 x 20 (2) 11. Oil seal 17. Bypass valve
5. Oil thermal valve assembly 12. O-ring gasket 18. O-ring gasket
6. Oil cooler housing 13. Lube adapter (not serviceable) 19. Plug assembly, M12
7. Coolant seal 14. Bolt, M8 x 25 (3)

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282 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION

Figure 405 Secondary filter components

1. Stud assembly
2. O-ring
3. Cover
4. O-ring gasket
5. Filter element
6. Filter header

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 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION 283

Removal
Oil System Module

GOVERNMENT REGULATION: Engine

fluids (oil, fuel, and coolant) may be a hazard
to human health and the environment.
Handle all fluids and other contaminated
materials (e.g. filters, rags) in accordance
with applicable regulations. Recycle
or dispose of engine fluids, filters, and
other contaminated materials according to
applicable regulations.
Figure 406 Coolant drain plug

WARNING: To prevent personal injury or

death, read all safety instructions in the "Safety 1. Place a coolant drain pan under the oil system
Information" section of this manual. module.
2. Remove the coolant drain plug (M18) at the
WARNING: To prevent personal injury or bottom of the oil system module. Open radiator
death, shift transmission to park or neutral, set cap to allow system to drain faster.
parking brake, and block wheels before doing
diagnostic or service procedures. 3. Remove and discard coolant drain plug O-ring .
4. Install a new O-ring on the coolant drain plug.
WARNING: To prevent personal injury or
5. After coolant has drained, install coolant drain
death, allow engine to cool before removing
plug in the oil system module.
components.
6. Tighten coolant drain plug to special torque (Table
42).
WARNING: To prevent personal injury or
death, wear safety glasses with side shields. 7. Recycle or dispose of coolant according to
Limit compressed air pressure to 207 kPa (30 psi). applicable regulations.

WARNING: To prevent personal injury or

death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing
and rags contaminated with engine fluids.

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284 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION

Figure 408 VGT oil supply tubing

Figure 407 Removing the oil filter

9. Remove the VGT oil supply tube fitting from the
1. Oil system module assembly oil system module assembly.
2. Oil cooler
3. Oil filter
4. Gasket

8. Place an oil drain pan under oil filter. After

waiting for oil to cool down, remove, drain, and
discard oil filter. Dispose or recycle oil and filter
in accordance with local regulations.

Figure 409 VGT oil supply tubing O-ring

10. Remove the VGT oil supply tube O-ring and

discard.

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 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION 285

1 2 3 4

11 10 5 9 8 7 6 5
H13035

Figure 410 Oil system module and secondary filter assembly

1. Oil system module assembly 5. O-ring (2) 8. Oil cooler drain tube
2. Bolt, M8 x 30 (8) 6. Secondary filtration filter 9. Support bracket bolt, M8 x 16
3. Hose, 1 in O.D. assembly 10. Bolt, M8 x 20 (8)
4. Hose clamp (2) 7. Bolt, M8 x 25 (6) 11. Oil filter (spin-on)

11. Remove oil cooler drain tube support bracket bolt 14. Remove the complete oil system module including
(M8 x 16) at lower end. the oil cooler and filter header as a unit (less oil
filter) and place onto a clean workbench.
12. Pull oil cooler drain tube (lower end) out of oil
cooler module and discard O-ring.
13. Remove eight oil system module assembly bolts
(M8 x 30).

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286 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION

1. Remove six bolts (M8 x 25) securing secondary

1 filter assembly to crankcase.

H13022

Figure 411 Oil and coolant seal locations

1. Coolant seal
2. Oil seal H13036

Figure 412 Secondary filtration gasket seals

15. Remove and discard the oil and coolant seals.
16. Cap the open end of the VGT oil supply tube and
fitting. 2. Remove assembly and discard secondary
filtration gasket seals.
3. Pull oil cooler drain tube (upper end) out of front
Secondary Filtration Assembly cover assembly. Remove O-ring from tube and
NOTE: Remove only if evidence of external leakage discard.
has occurred or oil cooler drain tube requires
servicing.

Oil in secondary filter drains back into crankcase,

therefore no additional draining procedures are
required.

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 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION 287

Disassembling the Oil System Module

NOTE: Perform the following disassembly procedures
as required for your particular repair situation. Do
not disassemble any components unless component
failure or leakage has been detected.

Figure 415 Separating cooler heat exchanger

from oil cooler housing

CAUTION: To prevent oil cooler heat exchanger

damage, do not use power tools to remove or install
bolts. Bolts will be damaged if removed to quickly.
Figure 413 Removing the regulating valve 4. Remove eight bolts (M8 x 20) and separate cooler
heat exchanger from the oil cooler housing.
1. Using a 24 mm or 15/16 in wrench, remove the NOTE: Bolts are thread-forming fasteners. These
regulating valve from the oil system module. bolts may be removed and reinstalled or replaced
Remove and discard both O-ring seals. with standard machined bolts.
2. Remove two bolts (M8 x 20) retaining the oil CAUTION: To prevent engine damage, when
thermal valve assembly. removing the cooler heat exchanger from its base
housing, do not use excessive force against the
aluminum cooler plate to separate from base. Do
not apply any force to the fins of the cooler heat
exchanger.

2 H13030

Figure 416 Separation of cooler heat exchanger

Figure 414 Removing the oil thermal valve from oil cooler housing base
1. Cooler heat exchanger
3. Remove the oil thermal valve from the oil system 2. Oil cooler housing base
module. Remove O-ring and discard.

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288 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION

5. Using a small hammer and a piece of wood, apply 8. Remove the lube adapter to provide access to
just enough force (at large arrow) to break the the oil bypass valve, which is pressed into the
coolant and oil gasket bonds. housing. Discard the two O-ring gaskets.

2 3

H13028

Figure 417 Oil and coolant seals

Figure 419 Removing the oil bypass valve
1. Oil seal
1. Oil bypass valve
2. Coolant seal (2)
2. Hooked shaped tool (tool size shown not to scale)
3. Oil system module casting

6. Discard one oil seal two coolant seals.

7. Remove the three bolts (M8 x 25) retaining the 9. Remove the oil bypass valve (only if determined
lube adapter to the oil cooler housing. to be defective) by inserting a hook shaped tool
(make locally) and depressing the check valve,
NOTE: Bolts are thread-forming fasteners. These
while catching the valve seat. The use of a Slide
bolts may be removed and reinstalled, or may be
Hammer (Table 43) threaded completely through
replaced with standard machined bolts.
valve is an alternative method.

Figure 418 Lube adapter assembly and gaskets

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 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION 289

Disassembling the Secondary Filtration Filter 2. Lift cover off of filter header and discard O-ring
gasket.

Figure 420 Secondary filter components

1. Stud assembly
2. O-ring Figure 421 Secondary filter removed
3. Cover 1. Filter removed
4. O-ring gasket 2. Filter header
5. Filter element
6. Filter header
3. Lift out filter and dispose of properly.

1. Remove stud assembly from the top of the

secondary filtration filter and O-ring.

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290 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION

Cleaning and Inspection

Cleaning the Oil System Module
CAUTION: To prevent engine damage, the oil cooler
must be replaced if there was a bearing failure. Debris
from a bearing failure cannot be removed from the oil
cooler.
CAUTION: To prevent engine damage, do not attempt
to clean the assembled oil system module in solvent.
Solvent will be trapped in the oil cooler, regulator valve
assembly, and oil thermal valve assembly. Failure to
1
follow this caution could result in engine damage.

The following items should be removed:

2
• Oil cooler
H13031
• Regulator valve assembly
• Oil thermal valve assembly Figure 422 Oil supply tube fitting
1. Direction of oil flow
The oil system module housing and lube adapter can
2. Oil supply wire mesh screen
be cleaned in solvent and blown dry with clean filtered
compressed air.
1. Immerse the disassembled oil cooler housing and
lube adapter into a suitable solvent. WARNING: To prevent personal injury or
death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).
WARNING: To prevent personal injury or
death, wear safety glasses with side shields. 6. Inspect screen for damage or particle obstruction.
Limit compressed air pressure to 207 kPa (30 psi). Clean or replace oil supply tube fitting screen as
necessary.
2. Flush and drain the oil cooler housing and
lube adapter to remove any residue. Dry all 7. Install a new O-ring onto fitting and thread into oil
components with filtered compressed air. filter header. Tighten to the special torque value
(Table 42).
3. Check the oil cooler housing for blocked orifices
and damaged threads. Replace oil cooler housing
if required.
Checking the Cooler Heat Exchanger for Leakage
4. Remove any debris that may be blocking the filter
External
bypass valve.
CAUTION: To prevent engine damage, do not allow
5. Remove turbocharger oil supply fitting (M18) on
water to enter oil side of cooler heat exchanger
top of oil filter header and discard O-ring seal.
assembly.
1. Remove the eight bolts (M8 x 20) securing cooler
heat exchanger to the oil system module, if not
done so already.
2. Fasten Oil Cooler Test Plate (Table 43) to cooler
heat exchanger.
3. Make sure oil port valve is closed.

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 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION 291

4. Immerse cooler heat exchanger and test plate

combination into a suitably sized container of
clean tap water (large shop sink).
5. Open coolant valve and allow water to fill coolant
side of the cooler heat exchanger.

Figure 424 Checking cooler heat exchanger for

external leakage
1. Test plate set
2. Air pressure regulator
3. Coolant port (closed)
4. Oil port
Figure 423 Checking cooler heat exchanger for
external leakage
CAUTION: To prevent engine damage, do not allow
1. Test plate set water to enter oil side of cooler heat exchanger
2. Air pressure regulator assembly.
3. Coolant port
9. Connect an air pressure regulator between the
4. Oil port (closed)
test plate oil port and the shop air supply.
10. Immerse cooler heat exchanger and test plate
6. Connect an air pressure regulator between the combination into a suitably sized container of
test plate coolant port and the shop air supply. clean tap water (large shop sink).
7. Apply approximately 172-276 kPa (25-40 psi) of 11. Apply approximately 172-276 kPa (25-40 psi) of
air pressure to the test plate while the assembly air pressure to the test plate while the assembly
is immersed in water. is immersed in water.
8. Observe exterior of cooler heat exchanger and 12. Observe exterior of cooler heat exchanger and
test plate surfaces for signs of leakage. If test test plate surfaces for signs of leakage. If test
plate fittings leak, lift out of water, tighten fittings plate fittings leak, lift out of water, tighten fittings,
then continue to look for leaks at cooler heat then continue to look for leaks at cooler heat
exchanger. Air bubbles evident at any external exchanger. Air bubbles evident at any external
location indicate a leak from the coolant passage. location indicate a leak from the oil passage.
Replace the cooler heat exchanger. Replace the cooler heat exchanger.

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292 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION

Internal
WARNING: To prevent personal injury or
death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).
1. Connect an air pressure regulator between the
test plate oil port and the shop air supply.
2. Open coolant valve and allow water to fill coolant
side of cooler heat exchanger.
3. Immerse cooler heat exchanger and test plate
combination into a suitably sized container of
clean tap water (large shop sink).
4. Apply approximately 172-276 kPa (25-40 psi) of
air pressure to the test plate while the assembly
is immersed in water.
5. Observe coolant port valve for air bubbles.
Bubbles at this point indicate a leak path between
the oil and coolant fluid passages. Replace the
Figure 425 Checking cooler heat exchanger for cooler heat exchanger.
internal leakage
1. Test plate set
2. Air pressure regulator
3. Coolant port (open)
4. Oil port

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 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION 293

Installation
Assembling the Oil System Module
NOTE: Do the following assembly procedures as
required for your particular situation. Not all of these
components may have been removed.

20 mm (25/32 in)

2
Figure 427 Lube adapter assembly and gaskets

2. Install small and large diameter O-rings into the

grooves of the oil lube adapter. Fasten the oil
lube adapter to the oil cooler header using three
1 bolts (M8 x 25). Tighten bolts to the special torque
value (Table 42).
3

H13029

Figure 426 Installing the oil bypass valve

1. Oil system module casting
2. Deep socket
3. Oil bypass valve
Figure 428 Installing the oil thermal valve

NOTE: Measure socket outside diameter. Do not go

by the socket bolt size stamped on the socket. 3. Install the oil thermal valve assembly into the oil
system module with a new O-ring. Tighten two
1. Install oil filter bypass valve (only if removed) by
bolts (M8 x 20) to the special torque value (Table
placing a deep socket with a physical outside
42).
diameter of < 20 mm (25/32 in) but > 16 mm (5/8
in). Tap socket and bypass valve into oil system 4. Install two new O-rings onto the oil pressure
module casting, until oil bypass valve has been regulator valve. Only lubricate the bottom O-ring
thoroughly seated. with clean engine oil.

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294 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION

6. Install one new oil seal and two new coolant seals
to the oil cooler housing seal grooves.
CAUTION: To prevent oil cooler heat exchanger
damage, do not use power tools to remove or install
bolts. Bolts will be damaged if removed to quickly.

Figure 429 Installing the oil pressure regulating

valve

5. Install the oil pressure regulator valve into the oil

system module and tighten to the special torque
value (Table 42).
Figure 431 Bolt torque sequence for cooler heat
exchanger

7. Position the new cooler heat exchanger on the oil

cooler housing and finger tighten eight new M8 x
20 bolts.
8. Tighten M8 x 20 bolts (1 and 2) to 20 N·m (15
lbf·ft).
9. Tighten all eight M8 x 20 bolts to special torque
value (Table 42) in the following sequence: 3, 4,
5, 6, 7, 8, 1, 2.

Figure 430 Oil and coolant seals

1. Oil seal
2. Coolant seal (2)

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 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION 295

Assembling the Secondary Filtration Filter

Figure 433 Secondary filter components

1. Stud assembly
2. O-ring
Figure 432 Secondary filter installation 3. Cover
1. Filter element 4. O-ring Gasket
2. Filter header 5. Filter element
6. Filter header

1. Install a new secondary oil filter.

2. Place a new O-ring gasket onto filter cover.
3. Position cover onto filter header.
4. Place a new O-ring onto stud assembly and
thread into top of secondary filter cover and
tighten to the special torque value (Table 42).

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296 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION

Secondary Filtration Assembly Oil System Module

1. If oil cooler drain tube was removed for any
reason, install new O-rings onto each end of the 1
tube assembly.
2. Install oil cooler drain tube into front cover
assembly.

H13022

Figure 435 Oil and coolant seal locations

1. Coolant seal
2. Oil seal

H13036 1. Position oil and coolant gasket seals onto the oil
cooler housing and begin working the seals into
Figure 434 Secondary filtration gasket seals the seal recesses at intersections and mid-points.
Do not work the seal from one end to the other, or
seal may stretch resulting in difficult installation.
3. If secondary filtration filter assembly was 2. Ensure that the machined surface of the
removed, install new oil gasket seals to assembly. crankcase is clean and free of debris, old seals
4. Secure secondary filter assembly to crankcase or damage that could affect the new seals of the
with six bolts (M8 x 25). Make sure oil cooler oil system module.
drain tube bracket is secured by upper left side 3. Position oil system module onto the crankcase
bolt. Do not torque upper left mounting bolt until mounting surface and install eight mounting bolts
oil system module and oil cooler drain tube have (M8 x 20). Tighten these bolts to the special
been installed. Tighten bolts to the special torque torque value (Table 42).
value (Table 42).

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 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION 297

1 2 3 4

11 10 5 9 8 7 6 5
H13035

Figure 436 Oil system module and secondary filter assembly

1. Oil system module assembly 5. O-ring (2) 8. Oil cooler drain tube assembly
2. Bolt, M8 x 30 (8) 6. Secondary filtration filter 9. Support bracket bolt, M8 x 16
3. Hose, 1 in O.D. assembly 10. Bolt, M8 x 20 (8)
4. Hose clamp (2) 7. Bolt, M8 x 25 (6) 11. Oil filter (spin-on)

4. Make sure a new O-ring has been installed onto (M8 x 16) through bracket and into crankcase.
the oil cooler drain tube. Slide tube into front side Torque both oil cooler drain tube bracket bolts to
of oil cooler and position a support bracket bolt the special torque value (Table 42).

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298 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION

10. Refill cooling system.

Priming the Lubrication System

Preferred Method
When the engine has been assembled, lubricate the
engine with oil before starting. This will aid internal
components with the proper lubrication requirements
during the critical initial startup phase. The following
procedure is the preferred method to use when
priming the lubrication system.
1. If engine was completely disassembled and
rebuilt, remove the plug assembly (M12) (Figure
404) and pressurize the lubrication system with
Figure 437 Installing oil supply tube sufficient oil to fill the oil filter and charge the
entire lubrication system.

5. Connect the oil supply tube fitting to the filter 2. Install plug assembly (M12 and tighten to the
header. Tighten nut on the tube to the special special torque (Table 42).
torque value (Table 42). 3. Check the oil level before starting engine.
6. Fill oil filter with the proper grade and viscosity of
engine oil. See the DT 466, DT 570 and HT 570
Alternate Method
Engine Operation and Maintenance Manual.
CAUTION: To prevent engine damage, make sure
7. Lubricate new oil filter gasket with clean engine
that all moving internal components of the engine
oil.
have been well oiled during assembly, if using this
8. Fasten Spin oil filter onto header until the gasket procedure.
initially makes contact. Using an Oil Filter Wrench
1. Crank the engine – but do not start the engine
with a band width of 38 mm (1.5 in) or greater,
(ensure CMP sensor is disconnected) – until
(Table 43) tighten filter an additional one full turn.
the oil pressure gauge indicates sufficient oil
NOTE: Do not overtighten filter. A damaged filter may pressure.
fracture or leak.
2. After oil pressure is evident in the lubrication
9. If not already installed, install coolant drain plug system, reconnect CMP sensor connector and
(M18) and tighten to the special torque (Table 42). start engine.

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 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION 299

Specifications

Table 41 Oil System Module and Secondary Filter Specifications

Cooler heat exchanger, DT 466 23 plates
Cooler heat exchanger, HT 570 33 plates
Cooler heat exchanger, all engines with front drive axle 33 plates
Oil pressure regulating valve, opening pressure 380 kPa (55 psi) @ 38° C (100° F)
Oil filter bypass valve, opening pressure 345 kPa (50 psi)
Oil thermal valve, opening temperature 111° C (232° F)

Special Torque

Table 42 Oil System Module and Secondary Filter Special Torques

Coolant drain plug, M18 24 N·m (18 lbf·ft)
Lube adapter bolts 29 N·m (21 lbf·ft)
Oil system module mounting bolts 26 N·m (19 lbf·ft)
Oil pressure regulator valve 68 N·m (50 lbf·ft)
Oil thermal valve assembly 29 N·m (21 lbf·ft)
Cooler heat exchanger mounting bolts, M8 29 N·m (21 lbf·ft)
Oil cooler drain tube bracket bolt 26 N·m (19 lbf·ft)
Oil supply tube fitting (turbocharger) 24 - 26 N·m (17 - 19 lbf·ft)
Plug assembly, M12 5 N·m (46 lbf·in)
Secondary filter mounting bolts 26 N·m (19 lbf·ft)
Secondary filter stud assembly 20 N·m (15 lbf·ft)

Special Service Tools

Table 43 Oil System Module and Secondary Filter Special Tools

Air Pressure Regulator Obtain locally
Oil Cooler Test Plate ZTSE4654
Oil Filter Wrench ZTSE1879
Slide Hammer Puller Set Obtain locally

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300 OIL SYSTEM MODULE ASSEMBLY AND SECONDARY FILTRATION

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 ENGINE ELECTRICAL 301

Table of Contents

Sensor Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303

.

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306
.
Sensor Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306 .
Injector Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 .
ECM, IDM, EGR Drive Module, and Intake Air Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313 .
Valve Cover Gasket with Pass-Through Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317 .

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .319

.
Checking Wiring Harness and Electrical Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .319 .

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320
.
Valve Cover Gasket with Pass-Through Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320 .
ECM, IDM, EGR Drive Module, and Intake Air Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .321 .
Injector Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327 .
Sensor Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .328 .

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .334

.

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302 ENGINE ELECTRICAL

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 ENGINE ELECTRICAL 303

Sensor Identification NOTE: This long CKP sensor, used with

International® DT 466, DT 570, and HT 570
For a more detailed description of the electrical
diesel engines, is the Camshaft Position (CMP)
sensors, see (Engine and Vehicle Sensors, page 47)
sensor used with other International® diesel engines.
in the “Engine Systems” section in this manual.

Figure 440 Engine Oil Temperature (EOT) sensor

and Engine Coolant Temperature (ECT) sensor

The EOT sensor is a thermistor type sensor. The EOT

Figure 438 Camshaft Position (CMP) sensor
sensor is installed in the rear of the front cover, left of
the high-pressure oil pump assembly.
The CMP sensor is a magnetic type sensor. It The ECT sensor is a thermistor type sensor. The
responds to a rotating actuator positioned on the ECT sensor is installed in the water supply housing
camshaft gear. The CMP sensor is installed in the (Freon® compressor bracket), left of the flat idler
front cover, above and to the right of the water pump pulley assembly, as viewed from the front of the
pulley. engine.
NOTE: This short CMP sensor, used with
International® DT 466, DT 570, and HT 570 diesel
engines, is the Crankshaft Position (CKP) sensor
used with other International® diesel engines.

Figure 441 Manifold Absolute Temperature

Figure 439 Crankshaft Position (CKP) sensor (MAT) sensor

The CKP sensor is a magnetic pickup sensor. The The MAT sensor is a thermistor type sensor. The MAT
CKP sensor is installed on the top left of the flywheel sensor is installed to the right of the MAP sensor in the
housing. intake manifold.

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304 ENGINE ELECTRICAL

Figure 442 Engine Oil Pressure (EOP) sensor

Figure 444 Brake Control Pressure (BCP)
sensor
The EOP sensor is a variable capacitance sensor.
The EOP sensor is installed on the left of the
crankcase below and left of the fuel filter housing. The BCP sensor is a variable capacitance sensor. The
BCP sensor is installed forward of the engine Brake
shutoff valve in the high-pressure rail.

Figure 443 Injection Control Pressure (ICP)

sensor Figure 445 Engine Fuel Pressure (EFP) sensor

The ICP sensor is a variable capacitance sensor. The The EFP sensor is a variable capacitance sensor. The
ICP sensor is installed left of the engine Brake shutoff EFP sensor is installed in the rear of the fuel filter
valve in the high-pressure rail. assembly (crankcase side).

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 ENGINE ELECTRICAL 305

Figure 448 Water In Fuel (WIF) sensor

Figure 446 Manifold Absolute Pressure (MAP)
sensor
The Water In Fuel sensor detects water in the fuel.
The WIF sensor is installed at the base of the fuel filter
The MAP sensor is a variable capacitance sensor. housing.
The MAP sensor is installed left of the MAT sensor
in the intake manifold.

Figure 449 Injection Pressure Regulator (IPR)

valve

Figure 447 Exhaust Back Pressure (EBP) sensor The IPR valve is a pulse width modulated valve that
regulates the injection control pressure. The valve is
located on the rear of the high-pressure oil pump.
The EBP sensor is a variable capacitance sensor. The
EBP sensor is installed in a bracket mounted on the
water supply housing (Freon® compressor bracket).

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306 ENGINE ELECTRICAL

Removal Sensor Wiring Harness

GOVERNMENT REGULATION: Engine

fluids (oil, fuel, and coolant) may be a hazard
to human health and the environment.
Handle all fluids and other contaminated
materials (e.g. filters, rags) in accordance
with applicable regulations. Recycle
or dispose of engine fluids, filters, and
other contaminated materials according to
applicable regulations.

WARNING: To prevent personal injury or

death, read all safety instructions in the “Safety Figure 450 Disconnecting the VGT connector
Information” section of this manual.

WARNING: To prevent personal injury or 1. Disconnect the wiring harness connector from the
death, shift transmission to park or neutral, set VGT actuator.
parking brake, and block wheels before doing
diagnostic or service procedures.

WARNING: To prevent personal injury or

death, disconnect the main battery negative
terminal before disconnecting or connecting
electrical components.

WARNING: To prevent personal injury or

death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing
and rags contaminated with engine fluids.
CAUTION: To prevent engine damage, make sure
the key is in the OFF position before unplugging the
connector or relay for the ECM, IDM, and EGR drive
module. Failure to turn the key to the OFF position Figure 451 Disconnecting the CMP sensor
will cause a voltage spike and damage the electrical
components.
CAUTION: To prevent engine damage, do not tug on 2. Disconnect the wiring harness connector from the
wiring harnesses; if resistance is felt, find the problem CMP sensor.
and free connectors or clips.

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 ENGINE ELECTRICAL 307

Figure 452 Disconnecting the ECT sensor

Figure 454 Disconnecting the EGR control valve
3. Disconnect the wiring harness connector from the connector
ECT sensor.
5. Disconnect the wiring harness connector from the
EGR control valve.

Figure 453 Disconnecting the EBP sensor

4. Disconnect the wiring harness connector from the

EBP sensor.
Figure 455 Disconnecting the EOT sensor

6. Disconnect the wiring harness connector from the

EOT sensor.

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308 ENGINE ELECTRICAL

Figure 456 Disconnecting the MAP sensor

Figure 458 Disconnecting the IPR valve

7. Disconnect the wiring harness connector from the connector
MAP sensor.

9. Disconnect wiring harness connector from the IPR

valve.

Figure 457 Disconnecting the MAT sensor

Figure 459 Disconnecting the EOP sensor

8. Disconnect the wiring harness connector from the
MAT sensor.
10. Disconnect the wiring harness connector from the
EOP sensor.

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 ENGINE ELECTRICAL 309

Figure 462 Disconnecting the fuel pressure

sensor
Figure 460 Disconnecting the block heater

13. Disconnect the wiring harness connector from the

11. Disconnect the block heater cable (optional). fuel pressure sensor (optional).

Figure 463 Disconnecting the WIF sensor

Figure 461 Disconnecting the fuel heater
connector 14. Disconnect the wiring harness connector from the
WIF sensor.
12. Disconnect the wiring harness connector from the
fuel heater (optional).

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310 ENGINE ELECTRICAL

Figure 464 Disconnecting the CKP sensor

15. Disconnect the wiring harness connector from the

CKP sensor.
16. Disconnect two additional, three wire connectors
for the BCP sensor connector and brake shutoff
valve connector to the valve cover gasket
(optional).

Figure 465 BCP, Brake shutoff valve, and injector locations

1. Injector connector (6) 3. Brake shutoff connector
2. BCP sensor connector (optional) (optional)

17. Disconnect one, three wire ICP connector from 19. Disconnect one IDM connector. This is the one of
valve cover gasket. three IDM connectors in the most forward position
on the IDM.
18. Disconnect wiring harness at EGR drive module.
20. Disconnect two ECM engine connectors. These
are the two connectors towards the rear of the
ECM.

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 ENGINE ELECTRICAL 311

Figure 466 12 wire engine connector

21. Disconnect one, 12 wire engine connector.

Figure 467 Intake air heater relay connectors (2)

1. Injector shield ground nut
2. Top relay connector
3. Bottom relay connector

22. Disconnect two intake air heater relay connectors.

23. Remove injector shield ground nut.
24. Remove the sensor harness by disconnecting
harness at the various tie down locations.
• If removing complete harness; sensor and
injector harnesses, continue with injector
harness removal before attempting to remove
the sensor harness.

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312 ENGINE ELECTRICAL

Injector Wiring Harness

WARNING: To prevent serious personal

injury, possible death, or damage to the engine or
vehicle, disconnect the main negative battery
terminal before removing or installing any
electrical components.
CAUTION: To prevent engine damage, make sure
the key is in the OFF position before unplugging the
connector or relay for the ECM, IDM, and EGR drive
module. Failure to turn the key to the OFF position
will cause a voltage spike and damage the electrical
components.
CAUTION: To prevent engine damage, do not tug on
any wiring harnesses while trying to remove them. If Figure 468 Disconnecting the No. 6 fuel injector
resistance is felt, find the source of resistance and connector
free up any connectors or clips that are caught before
proceeding. If necessary, remove the valve cover to
gain clearance for injector harness. 1. Disconnect six, four wire injector connectors from
valve cover gasket.
• If only removing the injector harness, separate it
from the sensor harness and remove from various
tie down locations.
• If removing both the sensor and injector
harnesses together, it is assumed the sensor
harness removal procedure was followed by
removing both harnesses at the various tie down
locations.

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 ENGINE ELECTRICAL 313

ECM, IDM, EGR Drive Module, and Intake Air

Heater

WARNING: To prevent serious personal

injury, possible death, or damage to the engine or
vehicle, disconnect the main negative battery
terminal before removing or installing any
electrical components.
CAUTION: To prevent engine damage, make sure
the key is in the OFF position before unplugging the
connector or relay for the ECM, IDM, and EGR drive
module. Failure to turn the key to the OFF position
will cause a voltage spike and damage the electrical
components.
CAUTION: To prevent engine damage, do not tug on
Figure 470 ECM and sensor harness locations
any wiring harnesses while trying to remove them. If
resistance is felt, find the source of resistance and 1. ICP sensor connector
free up any connectors or clips that are caught before 2. EGR drive module
proceeding. 3. IDM connector
4. ECM chassis connectors (2)
5. Intake air heater relay connections (2)
6. CKP sensor
7. ECM engine connectors (2)

Disconnecting the sensor wiring harness at the

drive modules.
1. Disconnect the ICP connector from the valve
cover connection.
2. Disconnect the EGR drive module.
3. Disconnect the IDM connector.
4. Disconnect two ECM chassis connectors.
5. Disconnect two intake air heater relay connectors.
6. Disconnect the CKP sensor.
Figure 469 ECM, IDM, EGR drive module, and
tube assembly overview 7. Disconnect two ECM engine connectors.

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314 ENGINE ELECTRICAL

Injector wiring harness at ECM and IDM drive

modules

Figure 472 Intake air heater and relay wiring

harness
Figure 471 Injector harness locations
1. Intake air heater mounting nuts (2)
1. Injector connectors (6) 2. Intake air heater wiring harness tie downs
2. Injector shield ground stud connection 3. Intake air heater mounting nut stud bolts (2)
3. IDM connectors (2) 4. Intake air heater and relay bracket mounting bolt

8. Disconnect six injector connectors from the valve

cover gasket.
9. Disconnect the injector shield ground stud
connection.
10. Disconnect two IDM connectors.
11. Disconnect two ECM engine connectors.
12. Disconnect two ECM chassis connectors.

Intake Air Heater Wiring Harness Assembly

13. Disconnect intake air heater cable at starter
solenoid.

Figure 473 Intake air heater – dual element

1. Inlet and EGR mixer
2. Intake air heater cable locations
3. Intake air heater element

See (TSI-05-12-35 New 1500 Watt Single Grid Intake

Air Heater Production Option, page466).

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 ENGINE ELECTRICAL 315

14. Disconnect Inlet Air Heater (IAH) cable(s).

15. Pull up on intake air heater wiring harness to
disengage two tie down locations from ECM /
IDM bracket.

Figure 475 ECM, IDM, and EGR drive module

Figure 474 Intake air heater relay bracket assembly (side view)

1. Heater relay bracket bolt, M6 x 20 and nut, M6 1. Module assembly mounting stud bolts (2)
2. Heater relay bracket nuts, M8 (2)

18. Remove two module assembly to engine

mounting stud bolts on right side (M8 x 45/19).
16. Remove two intake air heater mounting nuts (M8)
and heater relay bracket bolt (M6 x 20) and nut 19. Remove two module assembly mounting bolts on
(M6). left side (M8 x 45).
17. Remove intake air heater bracket with harness
assembly.
NOTE: Heater relay bracket and heater wiring
harness are removed as an assembly. There is no
need to disconnect the air heater wiring harness
connectors from the air heater relays.

Figure 476 ECM, IDM, and EGR drive module

assembly

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316 ENGINE ELECTRICAL

20. Remove module assembly.

NOTE: The ECM, IDM, and EGR drive module can
be removed as a single unit and disassembled on a
workbench, or they can be replaced individually on
the engine. It will be disassembled on a workbench
for illustrative purposes.

Figure 479 ECM / IDM bracket

22. Remove four bolts (M8 x 40) and four M8 nuts

Figure 477 EGR drive module, IDM, and ECM and special lockwashers securing the ECM / IDM
assembly bracket to both modules then remove bracket.

Figure 478 EGR drive module

21. Remove two bolts (M6 x 16) securing EGR drive

module to the ECM / IDM bracket and lift off. Figure 480 Removing IDM from ECM

23. Both IDM and ECM modules can now be

separated.

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 ENGINE ELECTRICAL 317

Valve Cover Gasket with Pass-Through

Connectors

WARNING: To prevent serious personal

injury, possible death, or damage to the engine or
vehicle, disconnect the main negative battery
terminal before removing or installing any
electrical components.
CAUTION: To prevent engine damage, make sure
the key is in the OFF position before unplugging the
connector or relay for the ECM, IDM, and EGR drive
module. Failure to turn the key to the OFF position
will cause a voltage spike and damage the electrical
components.
CAUTION: To prevent engine damage, do not tug on Figure 482 Disconnecting the BCP sensor
any wiring harnesses while trying to remove them. If
resistance is felt, find the source of resistance and
free up any connectors or clips that are caught before 2. Disconnect the wiring harness connector from the
proceeding. BCP sensor (optional).
NOTE: When removing, disconnecting, or installing
the brake shutoff valve, ICP and BCP sensors, the
valve cover must be removed.

Figure 483 Brake shutoff valve connector

Figure 481 Disconnecting the ICP sensor 3. Disconnect the wiring harness connector from the
Brake shutoff valve (optional).

1. Disconnect the wiring harness connector from the

ICP sensor.

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318 ENGINE ELECTRICAL

4. Disconnect the wiring harness connector from

each of the six injectors.
5. Disconnect from the valve cover gasket.
6. Release valve cover harness by unclipping from
the high-pressure oil manifold.

Figure 484 Injector connector

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 ENGINE ELECTRICAL 319

Cleaning and Inspection 3. Check each wiring harness connector for

corrosion (green or gray and white deposits
Checking Wiring Harness and Electrical
on the terminals), female connector sleeves that
Connectors
are spread open, and terminals that are pushed
1. Check the connector pins on all electrical back relative to the other terminals in the same
components. If any pins are bent, replace connector. Replace damaged connectors and
component. terminals as necessary.
2. Check each wiring harness for worn flexible 4. Inspect vibration isolator grommets for wear. If
conduit, and heat damage to wiring. Repair or worn, install new grommets.
replace each wiring harness as necessary.

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320 ENGINE ELECTRICAL

Installation 3. Connect (6) injectors connectors.

Valve Cover Gasket with Pass-Through
Connectors

WARNING: To prevent serious personal

injury, possible death, or damage to the engine or
vehicle, disconnect the main negative battery
terminal before removing or installing any
electrical components.
CAUTION: To prevent engine damage, make sure
the key is in the OFF position before unplugging the
connector or relay for the ECM, IDM, and EGR drive
module. Failure to turn the key to the OFF position
will cause a voltage spike and damage the electrical
components.
CAUTION: To prevent engine damage, do not tug on Figure 486 Connecting the ICP sensor
any wiring harnesses while trying to remove them. If
resistance is felt, find the source of resistance and
free up any connectors or clips that are caught before 4. Connect the ICP sensor connector to the valve
proceeding. cover gasket connection.

Figure 485 Injector connector

Figure 487 Connecting the BCP sensor

1. Install the valve cover harness by connecting

harness to the high-pressure oil manifold. 5. Connect the BCP sensor connector to the valve
cover gasket connection.
2. Install valve cover gasket.

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 ENGINE ELECTRICAL 321

ECM, IDM, EGR Drive Module, and Intake Air

Heater

WARNING: To prevent serious personal

injury, possible death, or damage to the engine or
vehicle, disconnect the main negative battery
terminal before removing or installing any
electrical components.
CAUTION: To prevent engine damage, make sure
the key is in the OFF position before unplugging the
connector or relay for the ECM, IDM, and EGR drive
module. Failure to turn the key to the OFF position
will cause a voltage spike and damage the electrical
components.
Figure 488 Connecting brake shutoff valve CAUTION: To prevent engine damage, do not tug on
any wiring harnesses while trying to remove them. If
resistance is felt, find the source of resistance and
6. Connect the brake shutoff valve connector to the free up any connectors or clips that are caught before
valve cover gasket connection. proceeding.
NOTE: When removing, disconnecting, or installing NOTE: The ECM, IDM, and EGR drive modules can
the brake shutoff valve, ICP and BCP sensors, the be assembled as a single unit on a workbench or
valve cover must be removed. they can be installed individually on the crankcase. It
will be assembled here on a workbench for illustrative
purposes.

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322 ENGINE ELECTRICAL

1
3

8 4

5
7

H09061

Figure 489 ECM / IDM module assembly

1. Injector Drive Module (IDM) 4. Vibration isolation grommet (8) 8. Electronic Control Module
2. Hex socket head screws, M8 x 5. Spiral lockwasher (4) (ECM)
40 (4) 6. Vibration isolation bushing (4)
3. ECM / IDM bracket 7. Nut, M8 (4)

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 ENGINE ELECTRICAL 323

3. Install four hex socket head screws (M8 x 40),

lockwashers and nuts (M8) to secure the IDM
/ ECM bracket assembly to the IDM and hand
tighten. These screws will be torqued later when
mounting assembly onto crankcase.

Figure 490 Installing the IDM onto the ECM

Figure 492 EGR drive module

1. Lay the IDM over the ECM as shown.

4. Install the EGR drive module with two bolts (M6 x
16) and hand tighten. Bolts will be torqued later
when mounting to crankcase.

Figure 493 ECM, IDM and EGR drive modules

Figure 491 IDM / ECM bracket assembly
assembled

2. Lay the IDM / ECM bracket assembly over the

IDM.

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324 ENGINE ELECTRICAL

NOTE: If your engine has the intake air heater feature,

then continue with the following steps.

Intake Air Heater Wiring Harness Assembly

Figure 494 Installing the ECM, IDM, and EGR Figure 495 Intake air heater relay bracket
drive module assembly to crankcase
1. Heater relay bracket bolt, M6 x 20 and nut, M6
2. Heater relay bracket nuts, M8 (2)
5. Install ECM, IDM, and EGR drive module
assembly to the crankcase with two mounting
stud bolts (M8 x 45/19) on right side. 8. If applicable, install the intake air heater and
bracket assembly over the two ECM / IDM
Install two bolts (M8 x 45) on left side to secure assembly mounting stud bolts (M8 x 45/19).
ECM, IDM, and EGR drive module assembly to
crankcase. 9. Place injector shield ground wire onto top stud.
Install a nut (M8) onto each stud and torque
6. Torque module assembly mounting bolts (M8 x to the standard torque value (General Torque
45) and stud bolts (M8 x 45/19) to the special Guidelines, page445).
torque value (Table 44).
10. Secure bracket to crankcase with an M6 x 20 bolt
7. Torque both EGR drive module bolts (M6 x 16) and M6 nut. Tighten to the standard torque value
to the standard torque value (General Torque (General Torque Guidelines, page445).
Guidelines, page445).

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 ENGINE ELECTRICAL 325

12. Install intake air heater cable at starter solenoid.

See (TSI-05-12-35 New 1500 Watt Single Grid Intake
Air Heater Production Option, page466).
13. Connect Inlet Air Heater (IAH) cable(s). Slide
boots over the connections.

Injector harness at ECM, IDM, and EGR drive

module

Figure 496 Intake air heater and relay wiring

harness
1. Intake air heater mounting nuts, M6 (2)
2. Harness routing anchor points (2)
3. Heater relay bracket nuts, M8 (2)
4. Heater relay bracket bolt, M6 x 20 and nut, M6

11. Position intake heater harness assembly into Figure 498 Injector harness locations
place.
1. Injector connectors (6)
2. Injector shield ground connection
3. IDM connectors (2)

14. Connect two ECM engine connectors.

15. Connect two IDM connectors.
16. Connect the injector shield ground connection.
17. Connect six injector connectors to the valve cover
gasket.

Figure 497 Intake air heater – dual element

1. Inlet and EGR mixer
2. Intake air heater cable locations
3. Intake air heater element

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326 ENGINE ELECTRICAL

Sensor harness at ECM, IDM, and EGR drive 22. Connect the IDM connector.
module
23. Connect the EGR drive module.
24. Connect the ICP connector to the valve cover
gasket.

Figure 499 Sensor harness locations

1. ICP sensor connector
2. EGR drive module
3. IDM connector
Figure 500 ECM, IDM, EGR drive module, and
4. ECM chassis connectors (2)
tube assembly overview
5. Intake air heater relay connections
6. CKP sensor
7. ECM engine connectors (2)
25. Install injector wiring harness underneath the
EGR mixer duct and place harness snaps into
anchor locations along the top side of the intake
18. Connect two ECM engine connectors.
manifold.
19. Connect the CKP sensor.
26. Install all wiring harness snaps securing the
20. Connect two intake air heater relay connectors. sensor and injector wiring harnesses to the
engine.
21. Connect two ECM chassis connectors.

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 ENGINE ELECTRICAL 327

Injector Wiring Harness

WARNING: To prevent serious personal

injury, possible death, or damage to the engine or
vehicle, disconnect the main negative battery
terminal before removing or installing any
electrical components.
CAUTION: To prevent engine damage, make sure
the key is in the OFF position before unplugging the
connector or relay for the ECM, IDM, and EGR drive
module. Failure to turn the key to the OFF position
will cause a voltage spike and damage the electrical
components.
CAUTION: To prevent engine damage, do not tug on
any wiring harnesses while trying to remove them. If Figure 501 Connecting the No. 6 fuel injector
resistance is felt, find the source of resistance and connector
free up any connectors or clips that are caught before
proceeding. If necessary, remove the valve cover
to gain clearance for the installation of the injector 1. Connect six, four wire injector drive connectors to
harness. the valve cover gasket.
2. Slide ground eyelet over injector shielded ground
stud (Figure 471). Install nut and tighten.

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328 ENGINE ELECTRICAL

Sensor Wiring Harness 1. Position the sensor harness by connecting the

harness at various tie down locations.
WARNING: To prevent serious personal 2. Connect two intake air heater relay connectors at
injury, possible death, or damage to the engine or the intake air heater relays.
vehicle, disconnect the main negative battery
terminal before removing or installing any
electrical components.
CAUTION: To prevent engine damage, make sure
the key is in the OFF position before unplugging the
connector or relay for the ECM, IDM, and EGR drive
module. Failure to turn the key to the OFF position
will cause a voltage spike and damage the electrical
components.
CAUTION: To prevent engine damage, do not tug on
any wiring harnesses while trying to remove them. If
resistance is felt, find the source of resistance and
free up any connectors or clips that are caught before
Figure 503 12 wire engine connector
proceeding.

3. Connect one, 12 wire connector engine to the

chassis connection point.

Figure 502 Intake air heater relay connectors (2)

1. Injector ground stud
2. Top relay connector
3. Bottom relay connector

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 ENGINE ELECTRICAL 329

Figure 504 BCP, brake shutoff valve, and injector locations

1. Injector connector (6) 3. Brake shutoff valve connector
2. BCP sensor connector (optional) (optional)

4. Connect two ECM engine connectors.

5. Connect one IDM connector.
6. Connect one connector at EGR drive module.
7. Connect one, three wire ICP connector to the
valve cover gasket.
8. Connect two additional, three wire connectors for
the BCP sensor connector and brake shutoff valve
connector to the valve cover gasket (optional).
9. Connect wiring harness at EGR drive module.
10. Connect the ECM, IDM, and EGR drive module
assembly ground.
11. Connect two ECM engine module connectors.
12. Connect three IDM Module connectors. Figure 505 Connecting to the CKP sensor

13. Connect the engine harness by connecting the

harness at the various tie down locations. 14. Connect the wiring harness to the CKP sensor.

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330 ENGINE ELECTRICAL

Figure 506 Connecting to the WIF sensor

Figure 508 Connecting to the fuel heater

15. Connect the wiring harness at the WIF sensor.

17. Connect the wiring harness at the fuel heater

(optional).

Figure 507 Connecting to the fuel pressure

sensor

16. Connect the wiring harness to the fuel pressure

sensor (optional). Figure 509 Connecting to the block heater

18. Install the block heater cable connections

(optional).

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 ENGINE ELECTRICAL 331

Figure 510 Connecting to the EOP sensor Figure 512 Connecting to the MAT sensor

19. Connect the wiring harness connector to the EOP 21. Connect the wiring harness connector to the MAT
sensor. sensor.

Figure 513 Connecting the MAP sensor

Figure 511 Connecting to the IPR valve
22. Connect the wiring harness connector to the MAP
sensor.
20. Connect wiring harness connector to the IPR
valve solenoid.

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332 ENGINE ELECTRICAL

Figure 516 Connecting to the EBP sensor

Figure 514 Connecting to the EOT sensor 25. Connect the wiring harness connector to the EBP
sensor.
23. Connect the wiring harness connector to the EOT
sensor.

Figure 517 Connecting to the CMP sensor

Figure 515 Connecting to the EGR control valve

24. Connect the wiring harness connector at the EGR 26. Connect the wiring harness connector to the CMP
control valve. sensor.

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 ENGINE ELECTRICAL 333

Figure 518 Connecting to the ECT sensor

Figure 519 Connecting to the VGT harness

27. Connect the wiring harness connector to the ECT

sensor. 28. Connect the VGT harness at the VGT.

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334 ENGINE ELECTRICAL

Special Torque

Table 44 Engine Electrical Special Torques

ECM / IDM mounting bolts (2), M8 x 45 20 N·m (15 lbf·ft)
ECM / IDM mounting stud bolts (2), M8 x 45/19 20 N·m (15 lbf·ft)
Engine coolant temperature (ECT) sensor 15-20 N·m (11-15 lbf·ft)
Engine oil pressure (EOP) sensor 9-14 N·m (79-124 lbf·in)
Engine oil temperature (EOT) sensor 15-20 N·m (11-15 lbf·ft)
Injection control pressure (ICP) sensor and Brake Control (BCP) sensor 20-30 N·m (15-22 lbf·ft)
Intake Manifold Air Pressure (MAP) sensor 10-20 N·m (88-176 lbf·in)
Intake Manifold Air Temperature (MAT) sensor 10-20 N·m (88-176 lbf·in)

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 FUEL SYSTEM 335

Table of Contents

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337
.

Low-pressure Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337

.

High-pressure Oil System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338

.

Periodic Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340

.
Fuel Strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340 .
Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341
.

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342
.
Low-pressure Fuel Supply Pump and Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342 .
Fuel Filter Header Assembly and Intake Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343 .
High-pressure Hose Assembly – Generation 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .345 .
High-pressure Hose Assembly with 70 and 90 Degree Elbows – Generation 2. . . . . . . . . . . . . . . . . . .345 .
High-pressure Pump and IPR Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .346 .
High-pressure Oil Rail Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .346 .
Fuel Injector Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .348 .

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350
.
Fuel Filter Header Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350 .

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352
.
Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352 .
High-pressure Oil Rail Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353 .
High-pressure Oil Pump and IPR Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .356 .
IPR Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .356 .
High-pressure Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .356 .
High-pressure Hose Assembly – Generation 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .357 .
High-pressure Hose Assembly with 70 and 90 Degree Elbows – Generation 2. . . . . . . . . . . . . . . . . . .357 .
Fuel Filter Header Assembly and Intake Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .359 .
Low-pressure Fuel Supply Pump and Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .360 .
Priming Fuel System after Out of Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .362 .

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363
.

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363

.

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .364

.

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336 FUEL SYSTEM

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 FUEL SYSTEM 337

Description

Low-pressure Fuel System

Figure 520 Low-pressure fuel system

1. Cylinder head 5. Low-pressure fuel supply pump 10. Fuel filter cover
2. Fuel injector assembly (6) 6. Primer pump assembly 11. Fuel filter assembly
3. Low-pressure fuel rail (cast in 7. Water drain valve 12. Fuel piping from tank(s)
intake manifold) 8. Drain valve (strainer) 13. Fitting (service port)
4. Transfer pump outlet tube 9. Transfer pump inlet tube 14. Fuel inlet ports (4)
assembly assembly

The low-pressure fuel system draws fuel from the strainer. Fuel then passes through the low-pressure
fuel tank with a low-pressure fuel pump. Fuel first fuel pump, tubing, and through the fuel filter. Fuel
enters the fuel filter header, is heated by the optional finally passes through the intake manifold and cylinder
fuel heater (if necessary) and passes through the fuel head and is delivered to each fuel injector.

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338 FUEL SYSTEM

High-pressure Hose Assembly

The high-pressure hose assembly was modified as a
production running change from (high-pressure hose
– generation 1 to high-pressure Hose with 70 and 90
Degree Elbows – generation 2).
See removal and installation procedures for
(High-pressure Hose – Generation 1 and
High-pressure Hose with 70 and 90 Degree
Elbows – Generation 2), listed in the Table of
Contents in this section.

High-pressure Oil System

Figure 521 High-pressure oil system

1. High-pressure oil manifold 5. High-pressure hose 8. Fuel inlet port (4)
2. Fuel injector assembly (6) 6. Oil inlet from high-pressure oil
3. High-pressure pump assembly manifold
4. Oil inlet from front cover reservoir 7. Oil outlet (2)

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 FUEL SYSTEM 339

The high-pressure oil system draws oil from the front oil manifold, and sent to the oil inlet on top of each
cover reservoir into the high-pressure oil pump. The fuel injector. High-pressure oil increases fuel pressure
high-pressure oil pump pressurizes this oil which is inside the injectors, which deliver high-pressure fuel to
forced through the high-pressure hose, high-pressure each cylinder.

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340 FUEL SYSTEM

Periodic Service

GOVERNMENT REGULATION: Engine

fluids (oil, fuel, and coolant) may be a hazard
to human health and the environment.
Handle all fluids and other contaminated
materials (e.g. filters, rags) in accordance
with applicable regulations. Recycle
or dispose of engine fluids, filters, and
other contaminated materials according to
applicable regulations.

WARNING: To prevent personal injury or Figure 522 Removing the fuel strainer
death, read all safety instructions in the "Safety
Information" section of this manual.
2. Use a 24 mm or 15/16 inch open end wrench to
remove the fuel strainer from fuel filter assembly.
WARNING: To prevent personal injury or
death, shift transmission to park or neutral, set
parking brake, and block wheels before doing
diagnostic or service procedures.

WARNING: To prevent personal injury or

death, disconnect the main battery negative
terminal before disconnecting or connecting
electrical components.

WARNING: To prevent personal injury or

death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).

WARNING: To prevent personal injury or

death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing Figure 523 Strainer and heater assembly
and rags contaminated with engine fluids.
1. Fuel strainer
2. Heater assembly (optional)
WARNING: To prevent personal injury or 3. Fuel bowl O-ring
death, do not smoke and keep fuel away from
flames and sparks.
Fuel Strainer 3. Remove strainer for cleaning or replacement and
discard fuel bowl O-ring.
1. Loosen drain valve below strainer and drain fuel
into a suitable container. Dispose of properly. 4. Clean all debris from fuel bowl or heater bowl.
5. Place new or cleaned strainer into fuel bowl.
6. Coat fuel bowl threads and a new O-ring with
clean fuel. Thread fuel bowl into fuel filter header

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 FUEL SYSTEM 341

assembly and torque to the special torque value

(Table 47).

Fuel Filter

Figure 525 Fuel filter element

2. Unthread housing cover and fuel filter as an

assembly.
3. Pull fuel filter from housing cover and discard
O-ring gasket.
4. Place a new O-ring gasket onto housing cover.

Figure 524 Water drain valve 5. Install a new fuel filter onto housing cover.
6. Lubricate housing cover threads and O-ring
gasket with diesel fuel.
1. Open water drain valve and drain fuel into a
suitable container. 7. Thread fuel filter and housing cover in as an
assembly. Torque to the special value (Table 47).

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342 FUEL SYSTEM

Removal
Low-pressure Fuel Supply Pump and Tubing

Figure 528 Removing the transfer pump outlet

tube assembly

3. Remove the transfer pump outlet tube assembly.

Cap all pump openings to the fuel filter and
low-pressure fuel supply pump.

Figure 526 Water drain valve

1. Open water drain valve and drain fuel into a

suitable container.

Figure 529 Removing the low-pressure fuel

pump
1. Low-pressure fuel supply pump
2. Seal

Figure 527 Removing the transfer pump inlet 4. Remove three mounting bolts (M6 x 16)
tube assembly and the low-pressure fuel supply pump from
high-pressure oil pump. Discard seal.
5. Check the low-pressure fuel supply pump tappet
2. Remove the transfer pump inlet tube assembly. for cracks, burrs and straightness. Replace
low-pressure fuel supply pump if necessary.

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 FUEL SYSTEM 343

6. Check all fuel lines for kinks, obstructions, or

other damage. Replace individual fuel lines as
necessary.

Fuel Filter Header Assembly and Intake Manifold

1. Drain fuel filter assembly (Figure 526), if not done
so already.
2. Drain fuel bowl by performing the following steps:
a. Have a suitable container handy to catch
draining fuel. Open drain valve completely.
In most cases, the portion of fuel below the
fuel strainer will pour out.
b. Turn primer pump assembly knob
counterclockwise to unlock. Pump primer
knob approximately 3-4 times to force fuel Figure 531 Strainer and heater assembly
through strainer. 1. Fuel strainer
c. Turn primer pump assembly knob clockwise 2. Heater assembly (optional equipment)
to lock. 3. Fuel bowl O-ring

3. Remove strainer for cleaning or replacement and

discard fuel bowl O-ring.

Figure 530 Removing fuel bowl and strainer

d. Use a 24 mm or 15/16 inch open end wrench

to remove the fuel strainer from fuel filter Figure 532 Fuel filter assembly mounting bolts
assembly.
1. Bolts, M8 x 100

4. Remove three mounting bolts (M8 x 100) and fuel

filter assembly from intake manifold.

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344 FUEL SYSTEM

6. Remove the plug assembly (M12) from each end

of the intake manifold and discard O-ring seal.
You may also need to remove the rear engine
lifting eye to gain access to remove the rear plug.

Figure 533 Removing the fuel filter outlet gasket

5. Discard the fuel filter outlet gasket between fuel

filter assembly and intake manifold.
Figure 535 Removing the fuel valve assembly
(air bleed and pressure test port)

7. Remove the fuel valve assembly (air bleed and

pressure test port), located at the front end of the
intake manifold. Discard O-ring seal.

Figure 534 Removing the fuel rail plug assembly

(2)

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 FUEL SYSTEM 345

High-pressure Hose Assembly – Generation 1

Figure 537 High-pressure hose assembly

Figure 536 Removal of high-pressure oil hose connections (typical)
assembly
1. High-pressure oil hose
2. High-pressure oil hose nut (2)
1. Remove the high-pressure oil hose assembly 3. Elbow jam nut (2)
between the high-pressure pump assembly and 4. 70 degree elbow
cylinder head. 5. Swivel nut (2)
6. 90 degree elbow
2. Remove and discard O-ring at each fitting.
3. If necessary, remove high-pressure hose fitting
located at cylinder head. 2. Remove high-pressure oil hose swivel nuts from
70 and 90 degree elbows. Use one wrench to
hold the high-pressure oil hose nut in place while
High-pressure Hose Assembly with 70 and 90 loosening its corresponding swivel nut using
Degree Elbows – Generation 2 another wrench. Remove the high-pressure
hose.
1. Remove the conduit cover from the high-pressure
hose assembly.

Figure 538 High-pressure oil elbow (typical)

1. O-ring seal (#14) (2)
2. Back-up ring
3. Elbow jam nut
4. Elbow

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346 FUEL SYSTEM

3. Loosen jam nuts on each elbow. High-pressure Oil Rail Assembly

4. Remove 70 and 90 degree elbows. 1. Remove valve cover. See (Valve Cover, page120)
in the “Cylinder Head and Valve Train” section of
5. Remove and discard each elbow back-up ring and
this manual.
O-rings.

High-pressure Pump and IPR Valve

Figure 541 Removing the injector harness

connector

Figure 539 Removing the high-pressure pump 2. Disconnect the injector harness connector at the
assembly top of each injector.

WARNING: To prevent personal injury or

1. Remove two bolts (M8 x 100) behind pump and death, get assistance to remove and install the
two (M8 x 30) bolts securing the high-pressure high-pressure oil rail assembly.
pump to the front cover. Remove pump assembly
and discard seal. 3. Remove 12 bolts (M8 x 90) securing
high-pressure oil rail to cylinder head.

Figure 542 Removing the high-pressure oil rail

Figure 540 Removing the IPR valve

4. Remove all bolts and lift high-pressure oil rail

2. Use an IPR removal / installation tool (Table 48) up just enough to drain as much oil out of
to remove the IPR valve. Check inlet screen for high-pressure oil rail before lifting it away from
restrictions. Remove O-rings and discard. cylinder head.

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 FUEL SYSTEM 347

5. Clean outside of high-pressure oil rail using

appropriate solvent.

Figure 544 Injector oil inlet adapter installed in

high-pressure oil rail
Figure 543 High-pressure oil rail 1. Injector oil inlet adaptor
2. Backup ring
3. Injector oil inlet seal
6. Remove oil inlet O-ring from recess in cylinder 4. Oil inlet tube
head and discard O-ring. 5. Internal O-ring (not serviceable)

NOTE: It is not necessary to remove an injector oil

inlet adaptor to install a new backup ring and injector
inlet seal.
7. Remove and discard backup ring and injector
inlet seal from injector oil inlet adapters in the
high-pressure oil rail.

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348 FUEL SYSTEM

Fuel Injector Assemblies

Figure 545 Rail end plug assembly

8. If necessary, remove rail end plug or attenuator. Figure 547 Removing the injector clamp and
See (TSI-05-12-28 New High-pressure Oil Rails, injector
page465).

1. Use the fuel injector remover tool (#40 Torx®)

(Table 48) to extract the injector clamp and
injector.

Figure 546 ICP sensor assembly

9. Remove ICP sensor assembly and discard O-ring.

Figure 548 Removing the fuel injector assembly

CAUTION: To prevent engine damage, do not clean

fuel injectors with parts solvents or chemicals.
CAUTION: To prevent engine damage, put
hydraulically actuated fuel injectors in an oil
filled closeable plastic container; this prevents
contamination or oxidation damage.

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 FUEL SYSTEM 349

2. Carefully remove each fuel injector assembly. NOTE: If any nozzle gaskets were missing on any of
Remove and discard two external O-rings and the removed injectors, check the bottom of the injector
the nozzle gasket from each injector; put each sleeves. Remove gaskets and discard.
injector into an oil filled plastic container and
close container.

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350 FUEL SYSTEM

Disassembly
Fuel Filter Header Assembly

Figure 549 Fuel filter header assembly

1. Housing cover assembly 8. Fuel filter housing 16. Self tapping screw (4)
2. M12 port fitting (factory fill) 9. M10 Plug assembly 17. Cartridge check valve
3. O-ring seal 10. Fuel strainer 18. Retainer ring
4. Fuel filter element 11. Bowl O-ring seal 19. Primer pump assembly
5. O-ring seal 12. Fuel bowl (with heater option) 20. Bolt, M8 x 20 (2)
6. Fuel pressure regulator 13. Drain valve 21. Primer pump seal
assembly 14. Fitting assembly, 3/8 tube 22. Water In Fuel (WIF) sensor
7. Plug or EFP sensor (optional) 15. Water drain valve assembly 23. Stand pipe

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 FUEL SYSTEM 351

NOTE: Early fuel filter assemblies may have an • Fuel or air leaks involving the priming pump
M12 port fitting (item 2) in the location of M10 plug assembly.
assembly (item 9). Item 2 is used by the assembly
NOTE: If the fuel filter header assembly is
plants as a fuel fill.
disassembled, use clean diesel fuel to lubricate
• If item 2 is installed on housing cover assembly, it the following parts and during reassembly.
can be used to measure unfiltered fuel pressure.
• Threads of fuel bowl.
• If item 2 is installed in item 9 location, it can be
• O-ring gasket.
used to measure fuel inlet restriction.
• Threads and O-ring on Water In Fuel (WIF)
It is not recommended to disassemble the fuel filter
sensor.
beyond circumstances involving periodic servicing
that include the following: • Threads and O-ring on drain valve.
• Fuel filter element replacement
Tighten items to the special torque (Table 47).
• Fuel strainer
• Sensor replacements (if determined by a DTC)
The fuel filter assembly can and should be
disassembled if any of the following issues have
been observed:
• Contaminated fuel has been introduced to the
engine, resulting in poor performance.

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352 FUEL SYSTEM

Installation 2. Lubricate a new lower O-ring with clean engine oil

and slide it into the recess just below the four fuel
Fuel Injectors
inlet ports.

Figure 550 Injector upper O-ring

Figure 552 Installing injector nozzle gasket
1. Upper O-ring (black)
1. Injector nozzle gasket
2. O-ring recess
2. Gasket location
3. Fuel inlet port

CAUTION: To prevent engine damage, do not nick,

1. Lubricate a new upper O-ring with clean engine
scratch or mar nozzle gasket in any way.
oil and slide it into the recess just above the four
fuel inlet ports. 3. Install new injector nozzle gasket onto end of
nozzle. It can go on either way.

Figure 551 Injector lower O-ring

1. Lower O-ring (yellow)
Figure 553 Install injector assembly
2. Fuel inlet port
3. O-ring recess

4. Align injector assembly slot with hold down clamp

assembly.

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 FUEL SYSTEM 353

High-pressure Oil Rail Assembly

CAUTION: To prevent engine damage, a new backup
ring and injector inlet seal must be installed on all six
injector oil inlet tubes.
CAUTION: To prevent engine damage, when
installing new backup rings, a new backup ring must
match the backup ring removed from the injector oil
inlet tubes.
NOTE: To determine the correct width of the new
backup ring, see Groove Measurement (M) in Oil Inlet
Tube and Required Backup Ring (Table 45).
1. Inspect injector oil inlet adaptors for internal
O-ring extrusion and high-pressure oil leak
Figure 554 Installing the injector clamp paths. Verify that each oil inlet tube is moveable.
Replace any adaptor having an extruded internal
O-ring, high-pressure oil leak path or seized oil
5. Using the fuel injector remover tool (Table 48), inlet tube.
install injector hold down clamp assembly.
Injector will be placed at the correct height.
Tighten bolt to the special torque value (Table
47).

Figure 556 Groove Measurement (M) in injector

oil inlet tube

Figure 555 Injector connector 2. Measure groove in the injector oil inlet tube.

6. Connect each injector harness connector to each

injector.

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354 FUEL SYSTEM

Figure 558 Oil inlet O-ring

Figure 557 Injector oil inlet adapter installed in
high-pressure oil rail
6. Coat new oil inlet O-ring with clean engine oil and
1. Injector oil inlet adaptor
install O-ring in recess in cylinder head.
2. Backup ring
3. Injector oil inlet seal
4. Oil inlet tube
5. Internal O-ring (not serviceable)

Table 45 Groove Measurement (M) in Oil Inlet

Tube and Required Backup Ring
Groove (M) in Oil Inlet Backup Ring
Tube
5.080 mm (0.200 in) Backup ring 1.8 mm
(0.07 in)
4.877 mm (0.192 in) Backup ring 1.6 mm
(0.06 in)
4.420 mm (0.174 in) Backup ring 1.1 mm Figure 559 Rail end plug assembly
(0.04 in)
7. See (TSI-05-12-28 New High-pressure Oil Rails,
3. Install a new backup ring onto injector oil inlet
page 465). If rail end plugs or attenuators were
tubes, according to the groove measurements
removed, install new plugs or attenuators and
listed in the table.
tighten to the special torque (Table 47).
4. Install new injector inlet seal onto injector oil inlet
tubes.
WARNING: To prevent personal injury or
5. Coat backup rings and injector oil inlet seals with death, get assistance to remove and install the
clean engine oil. high-pressure oil rail assembly.

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 FUEL SYSTEM 355

Figure 560 Installing the high-pressure oil rail

assembly

8. Lift high-pressure oil rail assembly up and place

onto engine. Align injector oil supply nozzles with
oil inlet adapters.

12 8 4 1 5 9

11 7 3 2 6 10

H08090

Figure 561 High-pressure oil rail bolt torque sequence (typical)

9. Install and hand tighten 12 bolts (M8 x 90) to (Table 47) and in the circular pattern, beginning
secure the high-pressure oil rail to the cylinder from the center.
head. Tighten bolts to the special torque value

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356 FUEL SYSTEM

High-pressure Oil Pump and IPR Valve Assembly 2. Install the IPR valve into the high-pressure pump
assembly finger tight. Use the IPR removal /
IPR Valve Assembly
installation tool (Table 48) and a torque wrench
to tighten IPR valve to the special torque value
(Table 47).

High-pressure Oil Pump

NOTE: A high-pressure pump inlet filter service kit
is available. See (TSI-09-12-02 High-pressure Pump
Assembly Inlet Filter Service Kit, page483).
1. Use petroleum jelly to hold a new O-ring gasket
into the recessed groove, located on the backside
of the front cover.

Figure 562 IPR valve assembly 2. Position high-pressure oil pump making sure gear
meshes with upper idler gear.
1. O-ring seal #015 (green)
2. Back-up ring seal
3. O-ring seal #016 (green)
4. O-ring
5. IPR valve assembly

1. Install new O-rings onto IPR valve assembly.

Figure 564 Installing the high-pressure pump

assembly

Figure 563 Installing the IPR valve

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 FUEL SYSTEM 357

high-pressure hose assembly. Tighten swivel nut

1 by hand.
2. Install a new O-ring seal onto the high-pressure
fitting (M18) at the cylinder head before installing
the high-pressure hose assembly.
3. Orient hose fitting assembly at the cylinder head
at 0°± 7° relative to horizontal. Tighten swivel nut
3
by hand.

2 4. Using a crowfoot, tighten both swivel nuts to the

special torque value (Table 47) making sure hose
is not under any excess tension.

High-pressure Hose Assembly with 70 and 90

Degree Elbows – Generation 2
H11052

Figure 565 IPR orientation

1. Fitting assembly, M18
2. Bolt, M8 x 100 (2)
3. Bolt, M8 x 30 (2)

3. Install two bolts (M8 x 100) behind pump and

two bolts (M8 x 30) outside, securing the
high-pressure pump to the front cover. Tighten
bolts to the special torque value (Table 47).
Figure 567 High-pressure oil elbow (typical)
High-pressure Hose Assembly – Generation 1 1. O-ring seal (#14) (2)
2. Back-up ring
3. Elbow jam nut
4. Elbow

1. Rotate both elbow jam nuts all the way to the base
of the elbows.
2. Install new O-rings and back-up ring on the 70 and
90 degree elbows.
3. Lubricate new O-rings with clean engine oil.
CAUTION: To prevent engine damage, make all
adjustments to the high-pressure oil elbows within 15
minutes of applying Loctite®.
Figure 566 Installation of high-pressure hose 4. Apply two beads of Loctite® 246 Threadlocker
assembly (Table 48) to the threads of both high-pressure oil
elbows.
1. Install a new O-ring seal onto the high-pressure
pump assembly before installing the

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358 FUEL SYSTEM

Figure 568 Good position and alignment of new Figure 569 Bad alignment of high-pressure oil
high-pressure oil hose (typical) hose (hose twisted)
1. High-pressure oil hose
2. High-pressure oil hose nut (2)
3. Elbow jam nut
4. 70 degree elbow
5. Swivel nut (2)
6. 90 degree elbow

5. Install 70 degree elbow into high-pressure oil port

on intake side of the cylinder head. Run fitting all
the way in finger tight and then back fitting off (less
than one full turn) to orient fitting toward the front
of the engine.
6. Install 90 degree elbow into high-pressure oil
pump. Run fitting all the way in finger tight and
then back fitting off (less than one full turn) to
orient fitting. Figure 570 Good alignment of high-pressure oil
7. Connect the high-pressure oil hose to the 70 and hose (hose not twisted)
90 degree elbows and finger tighten swivel nuts.
CAUTION: To prevent engine damage, the
high-pressure oil hose must be positioned and
aligned in a smooth arc, not twisted, under excess
tension or touching engine components.
8. Position and align the high-pressure oil hose, so
the hose is not under excess tension or twisted.
Tighten each swivel nut on the high-pressure
hose, using one wrench to hold the hose nut,
while using another wrench to tighten the swivel
nut to special torque value (Table 47).
9. Position and align the high-pressure oil hose, so
the hose is not under excess tension and the hose
bends in a smooth arc. Use one wrench to hold

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 FUEL SYSTEM 359

each elbow, while using another wrench to tighten 2. Install a new O-ring seal onto the fuel valve
the elbow jam nut to special torque value (Table assembly (air bleed and pressure test port) and
47). install into port located towards the front of the
intake manifold. Tighten to the special torque
10. Install the conduit cover onto the high-pressure
value (Table 47).
hose.

Fuel Filter Header Assembly and Intake Manifold

Figure 573 Installing the fuel filter outlet gasket

3. Coat the fuel filter outlet gasket with petroleum

Figure 571 Installing the fuel rail plug assembly jelly and set into recess located on backside of fuel
(2) filter header. The petroleum jelly will help it stay
in position while the filter header is being oriented
into position.
1. Install a new O-ring seal onto the plug assembly
(M12) and install into each end of intake manifold.
Tighten plug to the special torque value (Table 47).

Figure 574 Installing fuel filter header

Figure 572 Installing the fuel valve assembly 4. Install the fuel filter header and three mounting
(air bleed and pressure test port) bolts (M8 x 100) to the intake manifold.

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360 FUEL SYSTEM

assembly and torque to the special torque value

(Table 47).

Figure 575 Fuel filter mounting bolts

5. Tighten mounting bolts to the special torque value

Figure 577 Installing the fuel filter
(Table 47).
1. Housing cover
2. O-ring
3. Fuel filter housing
4. Fuel filter element

8. Install a new fuel filter element into the fuel filter

housing.
9. Place a new O-ring gasket onto housing cover.
10. Install a new fuel filter onto housing cover.
11. Lubricate housing cover threads and O-ring
gasket with diesel fuel.
12. Thread fuel filter and housing cover in as an
assembly. Torque to the special value (Table 47).
Figure 576 Installing the fuel strainer

Low-pressure Fuel Supply Pump and Tubing

6. If removed, install the fuel strainer into the filter 1. Apply clean engine oil to a new seal and place into
header with the open end of strainer facing the low-pressure fuel pump recess.
bowl.
7. Coat fuel bowl threads and a new O-ring with
clean fuel. Thread fuel bowl into fuel filter header

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 FUEL SYSTEM 361

CAUTION: To prevent engine damage, new 3/8 tube

sleeves should be installed to prevent leakage.
3. Install a new 3/8 tube sleeve on each end of both
transfer tubes (inlet and outlet).

Figure 578 Installing the low-pressure fuel

supply pump
1. Low-pressure fuel supply pump
2. Seal

Figure 580 Connecting the transfer pump outlet

2. Install the low-pressure fuel supply pump and tube assembly
three mounting bolts onto the high-pressure oil
pump. Tighten mounting bolts to the special
torque value (Table 47). 4. Connect transfer pump outlet tube assembly and
tighten all fittings.

Figure 579 Position of tube sleeve on fuel line

ends
Figure 581 Connecting fuel lines
1. Fuel line
2. Coupling nut
3. Tube sleeve 3/8
5. Connect transfer pump inlet tube assembly and
tighten all fittings to the special torque (Table 47).
NOTE: Tube sleeves on fuel lines of engines that used
Low Sulfur Diesel (LSD) fuel could leak after changing
to Ultra Low Sulfur Diesel (ULSD) fuel.

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362 FUEL SYSTEM

Priming Fuel System after Out of Fuel

Figure 582 Fuel filter components and fuel valve assembly

1. Water drain valve 4. Drain valve (fuel) 6. Fuel valve assembly (air bleed
2. Fuel filter cover 5. Fuel primer pump assembly and pressure test port)
3. Fuel filter header

4. To aid in filling the fuel filter header and bleed the

WARNING: To prevent personal injury, fuel rail, do the following:
possible death or damage to the engine or vehicle,
make sure the transmission is in neutral, parking • Bleed the fuel rail by pressing down on the center
brake is set and wheels are blocked before doing stem of the fuel valve assembly and pump the fuel
diagnostic or service procedures on engine or primer pump until fuel starts coming out of the fuel
vehicle. valve assembly.

CAUTION: Do not add fuel to the fuel filter header; • Once the air has bled out of the fuel rail, release
this can add contaminates to the fuel. the center stem of the fuel valve assembly and
push the fuel primer pump a couple of more times.
If the engine runs out of fuel, do the following:
• Push the fuel primer pump in one more time and
1. Set parking brake and place transmission control turn the knob clockwise to lock in place.
lever to NEUTRAL or PARK.
5. See specific starting procedures in the DT 466,
2. Unlock the fuel primer pump assembly by turning DT 570, and HT 570 Engine Operation and
the knob counterclockwise. Maintenance Manual.
3. Fill the fuel filter header with fuel by pumping the
fuel primer pump.

WARNING: To prevent personal injury or

death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).

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 FUEL SYSTEM 363

Specifications

Table 46 Fuel System Specifications

Fuel heater switching points On: 2 °C (36 °F)
Off: 24 °C (75 °F)
Fuel pressure regulator assembly opening pressure 448 - 517 kPa (65-75 psi)
Fuel strainer 150 micron
High-pressure oil manifold, range 5 - 28 MPa (725 - 4,075 psi)

Special Torque

Table 47 Fuel System Special Torques

Bolt, M8 x 20 29 N·m (21 lbf·ft)
Drain valve 0.5 -1 N·m (5 -10 lbf·in)
Elbow jam nut 88 N·m (65 lbf·in)
End plug assembly (AWA) or attenuator 204 N·m (150 lbf·ft)
Fitting assembly, 3/8 tube 27 N·m (20 lbf·ft)
Fuel bowl 39 N·m (29 lbf·ft)
Fuel drain plug 24 N·m (18 lbf·ft)
Fuel fitting 27 N·m (20 lbf·ft)
Fuel filter header mounting bolts, M8 x 100 27 N·m (20 lbf·ft)
Fuel filter housing cover 25 N·m (18 lbf·ft)
Fuel pressure regulator 1 - 1.7 N·m (10 -15 lbf·in)
Fuel valve assembly (air bleed and pressure test port) 15 N·m (132 lbf·in)
High-pressure oil hose fitting, M18 (at head) 54 N·m (40 lbf·ft)
High-pressure oil hose (swivel nuts) 46 N·m (34 lbf·ft)
High-pressure oil manifold bolts, M8 x 90 27 N·m (20 lbf·ft)
High-pressure oil pump assembly bolts 30 N·m (22 lbf·ft)
High-pressure oil pump assembly (gear) 231-279 N·m (170 - 205 lbf·ft)
Injector hold down clamp assembly 41 N·m (30 lbf·ft)
IPR valve assembly 50 N·m (37 lbf·ft)
Low-pressure fuel pump bolts, M6 x 16 15 - 18 N·m (132 - 160 lbf·in)
Low-pressure fuel pump tube coupling nuts 18 N·m (155 lbf·in)
Plug assembly, M12 (intake manifold fuel rail) 24 N·m (18 lbf·ft)
Post 8 N·m (72 lbf·in)
Self tapping screw 5 N·m (41 lbf·in)
Water In Fuel (WIF) sensor 1.7 N·m (15 lbf·in)

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364 FUEL SYSTEM

Special Service Tools

Table 48 Fuel System Special Service Tools

Cap kit, injectors ZTSE4660
Fuel injector remover tool (#40 Torx®) ZTSE4524
IPR removal / installation tool ZTSE4666
Loctite® 246 Threadlocker Obtain locally

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 FLYWHEEL AND FLYWHEEL HOUSING 365

Table of Contents

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .367
.

Flywheel and Flexplate Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .369 .

Manual Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .369
.
Automatic Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .372 .

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .375
.
Flywheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .375 .
Flexplate (Automatic Transmissions). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .376 .
Allison 2000 Series Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .376 .
MD-3000 and HD-4000 Series Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .376 .
Crankshaft Timing Disk and Rear Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .376 .

Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .378
.
Flywheel Housing Face Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .378 .
Flywheel Housing Bore Concentricity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .378 .
Crankshaft Pilot Concentricity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .378 .
Removing Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .379 .

Flywheel Reconditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .379 .

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .379
.
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .379.
Flywheel Resurfacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .379 .
Ring Gear Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .380 .

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .380
.
Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .380 .
Rear Oil Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .381 .
Crankshaft Timing Disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .382 .
Flywheel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .383 .
Checking Flywheel Surface Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .384 .
Flexplate (Automatic Transmissions). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .384 .
Allison 2000 Series Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .384 .
MD-3000 and HD-4000 Series World Transmissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .385 .

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .386
.

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .387

.

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .387

.

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Follow all warnings, cautions, and notes.
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366 FLYWHEEL AND FLYWHEEL HOUSING

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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
 FLYWHEEL AND FLYWHEEL HOUSING 367

Description • Flywheel housing SAE #2 houses a flywheel or

flexplate with a 138 tooth ring gear.
The flywheel housing assembly is bolted to the
crankcase and supports the starter motor, rear engine Starter location will work only with a 138 tooth ring
support brackets, and crankshaft position sensor. All gear.
transmission applications are designed to be mated Standard SAE #2 side mount locations.
to one of four flywheel housing assemblies. Although
all are similar in design there are some subtle • Flywheel housing (Bus) SAE #2 houses a flywheel
changes to accommodate a variety of transmission or flexplate with a 138 tooth ring gear.
applications. The following lists breaks down the Starter location will work only with a 138 tooth ring
various configurations: gear.
• Flywheel housing SAE #1 houses a flywheel or High side mounts for bus.
flexplate with a 138 tooth ring gear.
The following illustrations will expand upon the
Starter location will work only with a 138 tooth ring various flywheel and flexplate applications used with
gear. the DT466 and 570 engines.
Standard SAE #2 side mount locations.
• Flywheel housing SAE #1A houses a flywheel or
flexplate with a 148 tooth ring gear.
Starter location will work only with a 148 tooth ring
gear.
Standard SAE #2 side mount locations.

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Follow all warnings, cautions, and notes.
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368 FLYWHEEL AND FLYWHEEL HOUSING

Figure 583 Flywheel housing and related parts

1. Bolt, M12 x 40 (8) 4. Crankshaft Position sensor 7. Cover plate
2. Rear engine mounting bracket (CKP) 8. Bolt, M6 x 16 (2)
(2) 5. Bolt, M6 x 16 9. Hollow dowel (2)
3. Flywheel housing 6. Flywheel housing seal

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 FLYWHEEL AND FLYWHEEL HOUSING 369

Flywheel and Flexplate

Applications
Manual Transmissions

2
1

H06033

Figure 584 14 inch flywheel - for multiple plate clutch applications, 800 lbf·ft and below
1. Crankshaft timing disk 2. Flywheel assembly 3. Bolt, M12 x 40 (12)

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Follow all warnings, cautions, and notes.
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370 FLYWHEEL AND FLYWHEEL HOUSING

2
1

H06034

Figure 585 15.5 inch flywheel - for multiple plate clutch applications, 800 lbf·ft and above
1. Crankshaft timing disk 2. Flywheel assembly 3. Bolt, M12 x 40 (12)

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Follow all warnings, cautions, and notes.
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 FLYWHEEL AND FLYWHEEL HOUSING 371

3
H06035

Figure 586 Pot type flywheel – for multiple plate clutch applications, 800 lbf·ft and above
1. Flywheel assembly 2. Bolt, M12 x 40 (12) 3. Crankshaft timing disk

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Follow all warnings, cautions, and notes.
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372 FLYWHEEL AND FLYWHEEL HOUSING

Automatic Transmissions

5
2

4
H06036

Figure 587 Application for Allison World Transmissions - MD-3060, MD-3560

1. Flexplate assembly 3. Bolt, M12 x 45 (12)
2. Reinforcement ring (Allison 4. Crankshaft timing disk
transmissions only) 5. Flexplate adapter

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 FLYWHEEL AND FLYWHEEL HOUSING 373

4
5

H06037
Figure 588 Application for Allison World Transmission - HD-4000
1. Flexplate adapter 3. Flexplate assembly 5. Bolt, M12 x 45 (12)
2. Crankshaft timing disk 4. Reinforcement ring

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374 FLYWHEEL AND FLYWHEEL HOUSING

2
1
3

H06038

Figure 589 Application for Allison transmissions - 2000 through 2400 Series
1. Crankshaft timing disk 4. Bolt, M12 x 43 (12) 8. Transmission case
2. Flexplate assembly 5. Reinforcement ring 9. Torque converter assembly
3. Plate assembly, Allison AT 6. Adapter hub, AT
transmissions 7. Hex flange nut, M10 x 1.5

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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
 FLYWHEEL AND FLYWHEEL HOUSING 375

Removal
Flywheel Assembly 1 1

GOVERNMENT REGULATION: Engine

fluids (oil, fuel, and coolant) may be a hazard
to human health and the environment.
2
Handle all fluids and other contaminated
2
materials (e.g. filters, rags) in accordance
with applicable regulations. Recycle
or dispose of engine fluids, filters, and
other contaminated materials according to H06039

applicable regulations. Figure 590 Loosening engine mounting bolts

(148–tooth ring gear only)
1. Rear engine mounting brackets (2)
WARNING: To prevent personal injury or
2. Mounting bolts, M12 x 40 (8)
death, read all safety instructions in the "Safety
Information" section of this manual.
1. There are two types of flywheels for manual
WARNING: To prevent personal injury or transmissions: 138–tooth ring gear and
death, shift transmission to park or neutral, set 148–tooth ring gear. For flywheels with 148–tooth
parking brake, and block wheels before doing ring gears, first loosen the two lowest, rear most
diagnostic or service procedures. mounting bolts for the engine mounts on each
side of the flywheel housing (SAE #1A). This will
provide enough clearance for removal of the ring
WARNING: To prevent personal injury or
gear.
death, disconnect ground (-) cable from battery
before doing service or diagnostic procedures.

WARNING: To prevent personal injury or

death, use a suitable lifting device to support
the transmission assembly during removal and
installation.

WARNING: To prevent personal injury or

death, support engine (if in chassis) before
removing any engine mounting bracket or
flywheel housing bolts.

WARNING: To prevent personal injury or

death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).
Figure 591 Removing flywheel mounting bolts

2. Remove the two flywheel mounting bolts at the 3

o’clock and 9 o’clock positions.
3. Install two guide pins (made locally) in place of the
two flywheel mounting bolts.

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376 FLYWHEEL AND FLYWHEEL HOUSING

4. Remove the remaining ten flywheel mounting 6. Remove guide pins.

bolts.
5. Slide the flywheel out of the flywheel housing and
MD-3000 and HD-4000 Series Transmissions
off the guide pins.
6. Remove guide pins.

Flexplate (Automatic Transmissions)

NOTE: The flexplate assembly is available as a
service part. Typically, there will be no need to
disassemble the flexplate assembly.
Allison 2000 Series Transmissions

Figure 593 Removing flexplate (MD-3000 and

HD-4000 Series Transmissions)
1. Flexplate assembly
2. Guide pins
3. Flexplate assembly bolts (2)
4. Adapter hub
5. Reinforcement ring
6. Mounting bolt holes
Figure 592 Removing flexplate (Allison 2000
Series Transmission)
NOTE: Do not remove the two small flexplate
1. Guide pins assembly bolts.
2. Reinforcement ring
1. Remove the two flexplate mounting bolts at the 3
3. Flexplate assembly
o’clock and 9 o’clock positions.
4. Paint marking index
5. Adapter hub 2. Install two guide pins (made locally) in place of the
two flexplate mounting bolts.
3. Remove the remaining ten flexplate mounting
1. Paint mark the exposed face of the reinforcement
bolts.
ring and flexplate for installation later on.
4. Slide the flexplate assembly off the guide pins.
2. Remove the two flexplate mounting bolts at the 3
and 9 o’clock positions. 5. Remove the guide pins.
3. Install two guide pins (made locally) in place of the
two flexplate mounting bolts.
Crankshaft Timing Disk and Rear Oil Seal
4. Remove the remaining ten flexplate mounting
CAUTION: To prevent engine damage, if only
bolts.
replacing the timing disk, do not use bolts to remove
5. Slide the reinforcement ring, flexplate and adapter timing disk from crankshaft. Damage to the rear oil
hub off guide pins. seal could occur resulting in a leak.

EGES-265-2
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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
 FLYWHEEL AND FLYWHEEL HOUSING 377

NOTE: Use appropriate size drill bit for pulling screw.

2. Drill two holes of appropriate diameter for slide
hammer use into the rear oil seal at approximately
the 3 and 9 o’clock positions.

Figure 594 Removing the crankshaft timing disk

1. Use an H-bar puller to remove the crankshaft

timing disk from the end of the crankshaft (Table
52).
Figure 596 Removing the rear oil seal

3. Use a slide hammer (Table 52) to alternately

pull on each side of the rear oil seal using the
two previously drilled holes. Discard oil seal
assembly.

Figure 595 Drilling holes in the rear oil seal

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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
378 FLYWHEEL AND FLYWHEEL HOUSING

Inspection Flywheel Housing Bore Concentricity

Flywheel Housing Face Runout

Figure 598 Flywheel housing bore concentricity

1. Attach a dial indicator to the crankshaft. Place

the tip of the dial indicator against the flywheel
housing bore.
2. Zero the dial indicator.
3. Slowly rotate the crankshaft. Record the total
indicator variation and compare the result to the
flywheel housing bore concentricity specification.

Crankshaft Pilot Concentricity

Figure 597 Flywheel housing face runout

1. Attach a dial indicator to the crankshaft. Place

the tip of the dial indicator against the face of the
flywheel housing.
2. Zero the dial indicator.
3. Measure the runout at each 90 degree interval
(four locations) around the face of the flywheel
housing.
4. Record the total variation of the four
measurements and compare the result to
the flywheel housing face runout specification.
Figure 599 Crankshaft pilot concentricity

1. Attach a dial indicator to the flywheel housing.

Place the tip of the dial indicator against the
crankshaft pilot.
2. Zero the dial indicator.

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© 2009 Navistar, Inc.
 FLYWHEEL AND FLYWHEEL HOUSING 379

3. Slowly rotate the crankshaft. Record the total Inspection

indicator variation and compare the result to the
1. Inspect the flywheel for cracks, heat checks, and
crankshaft pilot concentricity specification.
extensive scoring which would make it unfit for
further service. Replace or resurface as required.
Removing Flywheel Housing 2. Inspect ring gear for worn, chipped, or cracked
teeth. If teeth are damaged, replace ring gear.
WARNING: To prevent serious personal
injury, possible death, or damage to the engine
Flywheel Resurfacing
or vehicle, do not remove any engine mounting
hardware until the engine is properly supported.
WARNING: To prevent serious personal
injury, possible death, or damage to the engine or
vehicle, carefully examine the 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. Any cracks or heat checks in the flywheel
could cause it to separate, creating the possibility
of injury to the operator or bystanders. If there
are any questions, do not use the flywheel.
CAUTION: Flexplates used with automatic
transmissions cannot be resurfaced. If damaged,
Figure 600 Removing flywheel housing replace flexplate.
mounting bolts
Flywheels used with manual transmissions may be
resurfaced to correct minor wear and scoring.
1. Remove the eight mounting bolts that secure the When resurfacing the flywheel, see dimension “A”
flywheel housing to the crankcase. on figure below, to determine if the flywheel was
2. Use an assistant to help remove the flywheel previously refaced or if it has adequate stock for
housing from the engine. refacing.

3. Inspect for cracks.

Flywheel Reconditioning

Cleaning
Clean the flywheel with a non-caustic solvent and dry
with filtered compressed air.

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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
380 FLYWHEEL AND FLYWHEEL HOUSING

NOTE: Do not heat ring gear to a temperature

higher than 278 °C (500 °F). Heating beyond this
temperature will adversely affect the ring gear
hardness.

Installation
Flywheel Housing
NOTE: Make sure the camshaft seal (page 266) is
installed in the crankcase.
NOTE: Verify that the two hollow dowels and the
flywheel housing seal are in place before installing
the flywheel housing (Figure 583).

Figure 601 Flywheel reconditioning

1. Dimension “A”: New flywheel: 38 + 0.025 mm
(1.500 in + 0.010 in). Minimum permissible after
resurfacing: 36 mm (1.430 in).
2. Clutch disc mounting face
3. Crankshaft flange mounting face

NOTE: If the dimensions depicted in the figure above

cannot be maintained, the flywheel must be replaced.

Ring Gear Replacement

Figure 602 Torquing flywheel housing mounting
1. Remove any damaged ring gear from the flywheel bolts
as follows:
A. Heat ring gear with a torch to expand
gear. 1. Use an assistant to help lift the flywheel housing
into position.
B. Once heated, knock the ring gear off
flywheel. Do not hit the flywheel when 2. Install all eight flywheel housing mounting bolts
removing gear. (M12 x 50) finger tight. Then tighten the bolts to
the special torque value (Table 51).

WARNING: To prevent serious personal 3. Install rear engine mounting brackets and bolts
injury or possible death, wear heat resistant (M12 x 40). Tighten bracket bolts to the special
gloves when handling heated components. torque value (Table 51).

2. Install a new ring gear as follows: NOTE: On engines with a 148–tooth ring gear, leave
the lowest, rear most mounting bracket bolt loose (2
A. Heat the new ring gear evenly until the or 3 threads) on each side of the flywheel housing
gear expands enough to slip onto the (SAE #1A). This will provide enough clearance for
flywheel. installation of the flywheel and ring gear assembly.
B. Make sure the ring gear is seated
properly against the flywheel shoulder.

EGES-265-2
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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
 FLYWHEEL AND FLYWHEEL HOUSING 381

Rear Oil Seal

Figure 603 Applying sealant to the crankshaft

and seal assembly
Figure 605 Applying sealant to the seal
assembly
1. Apply a 360° bead of Loctite® hydraulic sealant
to the crankshaft where the rear oil seal assembly
3. Apply a 360° bead of Loctite® hydraulic sealant to
will be positioned.
the outside diameter of the rear oil seal assembly.

Figure 604 Installing the rear oil seal installer

Figure 606 Placing oil seal onto rear oil seal
base
installer base

2. Install base component of oil seal installer onto

4. Orient steel face of oil seal outward (towards
crankshaft and tighten bolts (2).
transmission) and start seal onto oil seal installer
base.

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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
382 FLYWHEEL AND FLYWHEEL HOUSING

Figure 607 Installing rear oil seal installer onto Figure 609 Crankshaft timing disk alignment
base dowel

5. Place oil seal installer up to steel face of seal and

gently push by hand into flywheel housing as far 1 2
as possible.

7.6 mm
(0.300 in)

Figure 608 Installing the rear oil seal

H07032
6. Put washer and forcing nut onto shaft and tighten
until rear oil seal bottoms out in flywheel housing. Figure 610 Crankshaft timing disk alignment
The seal will be placed at the correct location dowel details
(depth). 1. Crankshaft timing disk
2. Crankshaft
3. Alignment dowel (convex end)
Crankshaft Timing Disk
NOTE: Alignment dowel pin convex end must
protrude out of crankshaft (Figure 583).

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© 2009 Navistar, Inc.
 FLYWHEEL AND FLYWHEEL HOUSING 383

1. Install two guide pins in the flywheel mounting bolt

holes at the 3 o’clock and 9 o’clock positions.
2. Install the flywheel onto the guide pins.
3. Install ten flywheel mounting bolts finger tight.
4. Remove the guide pins and install the remaining
two flywheel mounting bolts finger tight.

Figure 611 Installing the crankshaft timing disk

NOTE: Crankshaft timing disk can be installed with

either side out.
1. Align index notch of the crankshaft timing disk with
alignment dowel. Use a rubber mallet to tap the Figure 613 Torquing the flywheel mounting
crankshaft timing disk onto the crankshaft. Tap bolts
evenly around the crankshaft timing disk to ensure
a flush fit against the end of the crankshaft.
5. Tighten the flywheel mounting bolts to the special
torque value (Table 51).
Flywheel Assembly
6. Tighten two remaining rear engine mounting
bracket bolts on manual transmission applications
with 148 tooth ring gears to the special torque
value (Table 51).

Figure 612 Installing guide pins

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384 FLYWHEEL AND FLYWHEEL HOUSING

Checking Flywheel Surface Runout

Figure 615 Installing guide pins and adapter hub

1. Adapter hub
2. Guide pins

1. Install two guide pins in the flexplate mounting bolt

holes at the 3 o’clock and 9 o’clock positions.
Figure 614 Checking flywheel surface runout 2. Install the adapter hub on the guide pins.

1. Attach a dial indicator to the face of the flywheel

housing. Place the tip of the dial indicator against
the face of the flywheel.
2. Zero the dial indicator.
3. Slowly rotate the flywheel. Record the total
indicator variation and compare the result to the
flywheel surface runout specification.

Flexplate (Automatic Transmissions)

Allison 2000 Series Transmissions
CAUTION: To prevent engine damage, if the vehicle
is being reconfigured with an Allison 2000 Series
transmission, make sure that the correct flywheel Figure 616 Installing the flexplate
housing is installed on the engine. Otherwise, there 1. Flexplate assembly
will be interference between the flexplate studs and
the flywheel housing that will only be evident after the
transmission has been installed. NOTE: When installed correctly, the ring gear on
the flexplate is offset (not centered) toward the
transmission.
3. Install the flexplate assembly on the guide pins.

EGES-265-2
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© 2009 Navistar, Inc.
 FLYWHEEL AND FLYWHEEL HOUSING 385

CAUTION: To prevent engine damage, make sure MD-3000 and HD-4000 Series World
the reinforcement ring is installed with the paint Transmissions
mark or XMSN SIDE facing outward (towards the
transmission), otherwise, premature flexplate failure
may occur.

Figure 618 Installing the flexplate assembly

1. Flexplate assembly
2. End of crankshaft
Figure 617 Installing reinforcement ring with
paint mark
1. Install two guide pins in the flexplate mounting bolt
4. Install the reinforcement ring on the guide pins holes at the 3 o’clock and 9 o’clock positions.
(made locally) with paint mark facing outward. NOTE: The flexplate assembly is available as a
5. Install ten flexplate mounting bolts finger tight. completely assembled service part.

6. Remove the guide pins and install the remaining 2. Install the flexplate assembly on the guide pins.
two flexplate mounting bolts finger tight. NOTE: This following step applies to MD
7. Tighten the flexplate mounting bolts to the special transmissions only.
torque value (Table 51). 3. Install reinforcement ring with part number or logo
facing outward (towards the transmission).
4. Install ten flexplate mounting bolts finger tight.
5. Remove the guide pins and install the remaining
two flexplate mounting bolts finger tight.
6. Tighten the flexplate mounting bolts to the special
torque value (Table 51).
NOTE: Flywheel and ring gear are part of the torque
converter assembly.
NOTE: Make sure that the paint mark, part number
or XMSN SIDE on the flexplate is facing outward
(towards the transmission).

EGES-265-2
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386 FLYWHEEL AND FLYWHEEL HOUSING

Specifications

Table 49 Flywheel and Flywheel Housing Specifications

Flywheel housing:
Flywheel housing bore concentricity SAE # 1 = 0.30 mm (0.012 in)
SAE # 2 = 0.28 mm (0.011 in)

Flywheel housing face runout SAE # 1 = 0.30 mm (0.012 in)

SAE # 2 = 0.28 mm (0.011 in)
Crankshaft pilot:
Crankshaft pilot concentricity 0.13 mm (0.005 in)
Flywheel:
Flat flywheel surface runout at clutch mounting holes. 0.20 mm (0.008 in)
Pot flywheel surface runout 0.20 mm (0.008 in)
Pot flywheel clutch mounting surface runout 0.30 mm (0.012 in)

WARNING: To prevent serious personal

injury, possible death, or damage to the engine
or vehicle, do not machine beyond minimum
dimensions specified for flywheel resurfacing.

WARNING: To prevent serious personal

injury, possible death, or damage to the engine or
vehicle, carefully examine the 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. Any cracks or heat checks in the flywheel
could cause it to separate, creating the possibility
of injury to the operator or bystanders. If there
are any questions, do not use the flywheel.

Table 50 Flywheel Resurfacing Specifications

Flat flywheel minimum thickness after resurfacing 36.32 mm (1.430 in)
Pot flywheel minimum thickness after resurfacing 39.37 mm (1.550 in)
Requires measurement from crankshaft mounting surface of flywheel to clutch surface of flywheel.

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 FLYWHEEL AND FLYWHEEL HOUSING 387

Special Torque

Table 51 Flywheel and Flywheel Housing Special Torques

Engine mounting bracket bolts 108 N·m (80 lbf·ft)
Flexplate mounting bolts 136 N·m (100 lbf·ft)
Flywheel housing mounting bolts 108 N·m (80 lbf·ft)
Flywheel mounting bolts 136 N·m (100 lbf·ft)
Rear engine mounting bracket bolts 108 N·m (80 lbf·ft)

Special Service Tools

Table 52 Flywheel and Flywheel Housing Special Service Tools

Crankshaft timing disk puller (H-bar) Obtain locally
Dial indicator with magnetic base Obtain locally
Guide pins Obtain locally
Rear seal installer ZTSE4637
Slide hammer puller set ZTSE1879

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© 2009 Navistar, Inc.
388 FLYWHEEL AND FLYWHEEL HOUSING

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© 2009 Navistar, Inc.
 DIAMOND LOGIC® ENGINE BRAKE 389

Table of Contents

Brake Specific High-pressure Oil Rail Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .391

.

Periodic Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .392

.
Engine Brake Actuator Lash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .392 .
Brake Lash Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .392 .

Reconditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .394
.
Diagnostic Tests Procedures and Service Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .394 .
Reconditioning Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .394 .
Brake Shutoff Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .395 .
BCP Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .396 .
ICP Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .396 .
M12 Plug assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .397 .
Rail End Plug Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .397 .
Oil Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .397 .
Brake Actuator Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .397 .

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .399
.
Valve Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .399 .
Electrical Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .399 .
High-pressure Oil Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 .

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
.
High-pressure Oil Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401 .
Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .403 .

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .405
.

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .405

.

Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .405

.

EGES-265-2
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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
390 DIAMOND LOGIC® ENGINE BRAKE

EGES-265-2
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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
 DIAMOND LOGIC® ENGINE BRAKE 391

Brake Specific High-pressure Oil

Rail Assembly

Figure 619 Brake specific high-pressure oil rail assembly

1. Brake Control Pressure (BCP) 5. M8 x 90 bolt (12) 10. Injector oil inlet seal (6)
sensor 6. M12 plug 11. High-pressure oil rail (brake)
2. Brake Shut-off Valve (BSV) 7. Rail end plug assembly or 12. Oil inlet O-ring
assembly attenuator (2) 13. Brake actuator piston (6)
3. M10 plug (2) 8. Injector oil inlet adaptor 14. Oil pressure relief valve
4. Injection Control Pressure (ICP) assembly (6) 15. Brake actuator piston locknut (6)
sensor 9. Back-up ring (6)

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© 2009 Navistar, Inc.
392 DIAMOND LOGIC® ENGINE BRAKE

Periodic Service NOTE: If the valve cover is removed for any reason,
check six brake piston locknuts. If loose, reset during
brake lash adjustment.

GOVERNMENT REGULATION: Engine Engine Brake Actuator Lash

fluids (oil, fuel, and coolant) may be a hazard During the procedure to adjust brake lash, the
to human health and the environment. crankshaft is rotated two times:
Handle all fluids and other contaminated
materials (e.g. filters, rags) in accordance • Three actuators are adjusted when piston 1 is at
with applicable regulations. Recycle Top Dead Center (TDC) compression.
or dispose of engine fluids, filters, and • Three actuators are adjusted when piston 6 is at
other contaminated materials according to Top Dead Center (TDC) compression.
applicable regulations.
Corresponding intake and exhaust valve lash can be
adjusted before and after rotating the crankshaft. See
(Adjusting Valve Lash, page150) in the “Cylinder Head
WARNING: To prevent personal injury or and Valve Train” section of this manual.
death, read all safety instructions in the "Safety
Information" section of this manual.
Brake Lash Adjustment
WARNING: To prevent personal injury or
1. Remove valve cover. See (Valve Cover, page120)
death, shift transmission to park or neutral, set
in the “Cylinder Head and Valve Train” section of
parking brake, and block wheels before doing
this manual.
diagnostic or service procedures.
2. Turn the crankshaft in the direction of engine
rotation to remove gear lash. Position piston 1 at
WARNING: To prevent personal injury or
TDC compression by observing cylinder 6 rocker
death, wear safety glasses with side shields.
arms in overlap as the vibration damper timing
Limit compressed air pressure to 207 kPa (30 psi).
mark approaches the TDC mark on the front
cover. Cylinder 6 exhaust valve will be closing
WARNING: To prevent personal injury or (coming up) and the intake valve will be starting
death, disconnect the main battery negative to open (going down).
terminal before disconnecting or connecting
3. If piston 1 is at TDC compression, see Chart 3
electrical components.
(page392) and do steps 4 and 5 for cylinders 1, 3,
and 5.
WARNING: To prevent personal injury or
death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing
and rags contaminated with engine fluids.

EGES-265-2
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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
 DIAMOND LOGIC® ENGINE BRAKE 393

Chart 3
Brake and valve lash adjustments (inches) with piston 1 at TDC compression (Chart 3)
Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6
intake exhaust intake exhaust intake exhaust intake exhaust intake exhaust intake exhaust
1 2 3 4 5 6 7 8 9 10 11 12

0.019 0.019 0.019 0.019 0.019 0.019

Brake 0.019 Brake 0.019 Brake 0.019

Brake and valve lash adjustments with piston 1 at TDC compression

Chart 4
Brake and valve lash adjustments (inches) with piston 6 at TDC compression (Chart 4)
Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6
intake exhaust intake exhaust intake exhaust intake exhaust intake exhaust intake exhaust
1 2 3 4 5 6 7 8 9 10 11 12

0.019 0.019 0.019 0.019 0.019 0.019

Brake 0.019 Brake 0.019 Brake 0.019

Brake and valve lash adjustments with piston 6 at TDC compression

Figure 620 Brake lash adjustment

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394 DIAMOND LOGIC® ENGINE BRAKE

Reconditioning
Diagnostic Tests Procedures and Service Parts
See Engine Diagnostic Manual for diagnostic test
procedures. The following service parts are available,
if required after diagnostic testing.
• BCP sensor
• Brake actuator piston assembly
• Brake shutoff valve assembly
• High-pressure oil rail bolt, M8 x 90 (12)
• ICP sensor
• Oil inlet O-ring
• Oil pressure relief valve
• Plug assembly, M12
• Rail end plug assembly (2)
Figure 621 Measure between valve bridge and
brake actuator The following reconditioning procedures are provided
to replace specific components determined faulty
during diagnostic tests. A new Brake Shutoff Valve,
4. Measure brake lash when engine is cold. Put BCP sensor, or ICP Sensor can be installed without
0.048 mm (0.019 in) feeler gauge (long) (Table removing the high-pressure oil rail, The High-pressure
56) between the pivot foot and valve bridge, a oil rail must be removed to install new brake actuator
light drag on the feeler gauge should be felt. If pistons.
adjustment is required, loosen locknut and turn
actuator adjustment screw.
Reconditioning Procedures
5. Once brake lash is set, tighten the locknut to
Special Torque (Table 55) and remove the feeler NOTE: Remove valve cover. See (Valve Cover, page
gauge. Recheck for light drag on feeler gauge. If 120) in the “Cylinder Head and Valve Train” section of
drag is too tight or loose, repeat steps 4 and 5. this manual.
Corresponding valve lash can be adjusted before NOTE: If the valve cover is removed for any reason,
rotating crankshaft. check six brake piston locknuts. If loose, reset during
brake lash adjustment.
6. Turn crankshaft 360° in the direction of engine
rotation to remove gear lash from gear train and
realign the timing mark on the damper pulley with
the TDC mark on the front cover.
7. If piston 6 is at TDC compression, see Chart 2
(page393) and do steps 4 and 5 for cylinders 2, 4,
and 6.

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© 2009 Navistar, Inc.
 DIAMOND LOGIC® ENGINE BRAKE 395

Brake Shutoff Valve

Figure 624 Brake shutoff valve

Figure 622 Disconnecting brake shutoff valve
3. Remove shutoff valve.

1. Unclip and disconnect brake shutoff valve 4. Install new O-ring on new brake shutoff valve, and
electrical connector from the high-pressure oil lubricate O-ring with clean engine oil.
rail and valve cover gasket. 5. Install new brake shutoff valve.
6. Move valve in and out against spring tension to
check for any binding.
7. Place solenoid over the brake shutoff valve.
8. Install Tinnerman nut and tighten to Special
Torque (Table 55).

Figure 623 Brake shutoff valve assembly

1. Brake shutoff valve
2. Solenoid
3. Tinnerman nut

2. Remove Tinnerman nut and solenoid. Figure 625 Connect brake shutoff valve

9. Connect brake shutoff valve electrical connector

to valve cover gasket pass-through connector and
clip harness to high-pressure oil rail.

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© 2009 Navistar, Inc.
396 DIAMOND LOGIC® ENGINE BRAKE

BCP Sensor 5. Connect the BCP sensor electrical connector to

the valve cover gasket pass-through connector
(front) and clip harness to high-pressure oil rail.

ICP Sensor

Figure 626 Disconnecting BCP sensor

1. Unclip and disconnect Brake Control Pressure

(BCP) sensor electrical connector from the Figure 628 Disconnecting ICP sensor
high-pressure oil rail and valve cover gasket
(front).
1. Unclip and disconnect the Injection Control
Pressure (ICP) sensor electrical connector from
the high-pressure oil rail and valve cover gasket
(rear).

Figure 627 BCP sensor

2. Remove BCP sensor.

3. Install new O-ring on new BCP sensor, and
lubricate O-ring with clean engine oil. Figure 629 ICP sensor

4. Install new BCP sensor and tighten to the Special

Torque (Table 55). 2. Remove ICP sensor.
3. Install new O-ring on new ICP sensor, and
lubricate O-ring with clean engine oil.

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© 2009 Navistar, Inc.
 DIAMOND LOGIC® ENGINE BRAKE 397

4. Install new ICP sensor and tighten to the Special 1. If necessary, remove rail end plug or attenuator.
Torque (Table 55). See (TSI-05-12-28 New High-pressure Oil Rails,
page465).
5. Connect ICP sensor electrical connector to valve
cover gasket pass-through connector (rear) and 2. Install new O-ring on new rail end plug or
clip harness to high-pressure oil rail. attenuator, and lubricate O-ring with clean engine
oil.

M12 Plug assembly 3. Install new rail end plug or attenuator and tighten
to the special torque (Table 55).

Oil Pressure Relief Valve

Figure 630 M12 Plug assembly,

Figure 632 Oil pressure relief valve

1. Remove M12 plug assembly,
2. Install new O-ring on new M12 plug, and lubricate
O-ring with clean engine oil. 1. Remove oil pressure relief valve.

3. Install new M12 plug and tighten to the Special 2. Install new O-ring on new oil pressure relief valve,
Torque (Table 55). and lubricate O-ring with clean engine oil.
3. Install new oil pressure relief valve and tighten to
the Special Torque (Table 55).
Rail End Plug Assembly

Brake Actuator Piston Assembly

1. Inspect all brake actuator pistons and valve
bridge contact surfaces. Look for pitting and
material transfer deformation. Replace pitted or
deformed parts if necessary. Polished surfaces
are acceptable.

Figure 631 Rail end plug assembly

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© 2009 Navistar, Inc.
398 DIAMOND LOGIC® ENGINE BRAKE

3. Use screwdriver to remove brake actuator piston

assembly from the high-pressure oil rail.

Figure 633 Brake actuator lash locknut

2. Remove brake actuator lash locknut.

Figure 635 Brake actuator piston assembly

4. Install new brake actuator piston assembly.

5. Final lash adjustments will be made after the
high-pressure oil rail is installed on cylinder head.
NOTE: Install valve cover after completing final brake
lash adjustments. See Valve Cover (Valve Cover,
page 152) in the “Cylinder Head and Valve Train”
section of this manual.

Figure 634 Removing brake actuator piston

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© 2009 Navistar, Inc.
 DIAMOND LOGIC® ENGINE BRAKE 399

Removal the high-pressure oil rail and valve cover gasket

(rear).
Valve Cover
1. Remove valve cover. See (Valve Cover, page120)
in the “Cylinder Head and Valve Train” section of
this manual.

Electrical Connectors

Figure 638 Brake shutoff valve assembly

electrical connector

3. Unclip and disconnect Brake Shutoff Valve (BSV)

electrical connector from the high-pressure oil rail
and valve cover gasket.
Figure 636 Injector electrical connector

1. Unclip and disconnect each injector electrical

connector from the high-pressure oil rail and
valve cover gasket and place aside.

Figure 639 BCP sensor electrical connector

4. Unclip and disconnect Brake Control Pressure

(BCP) sensor electrical connector from the
Figure 637 ICP sensor electrical connector high-pressure oil rail and valve cover gasket
(front).
2. Unclip and disconnect the Injection Control NOTE: The ICP and BCP sensors are identical and
Pressure (ICP) sensor electrical connector from share the same part number.

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© 2009 Navistar, Inc.
400 DIAMOND LOGIC® ENGINE BRAKE

5. Loosen all high-pressure oil rail bolts (M8 x 90) in 3. Remove oil inlet O-ring from recess in cylinder
a circular pattern beginning from either end. head and discard O-ring.

High-pressure Oil Rail

WARNING: To prevent personal injury or

possible death, get assistance to remove or
install the high-pressure oil rail.

Figure 642 Injector oil inlet adapter installed in

high-pressure oil rail
Figure 640 Removing the high-pressure oil rail
1. Injector oil inlet adaptor
2. Backup ring
3. Injector oil inlet seal
1. Remove all bolts and lift high-pressure oil rail
4. Oil inlet tube
up just enough to drain as much oil out of
5. Internal O-ring (not serviceable)
high-pressure oil rail before lifting it away from
cylinder head.
2. Clean outside of high-pressure oil rail using NOTE: It is not necessary to remove an injector oil
appropriate solvent. inlet adaptor to install a new backup ring and injector
inlet seal.
4. Remove and discard backup ring and injector
inlet seal from injector oil inlet adapters in the
high-pressure oil rail.

Figure 641 Oil inlet O-ring

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© 2009 Navistar, Inc.
 DIAMOND LOGIC® ENGINE BRAKE 401

Installation
High-pressure Oil Rail
1. Back off all valve lash adjustments. This must
be done to eliminate the possibility of additional
forces on the high-pressure oil rail when mounting
bolts are torqued.
CAUTION: To prevent engine damage, a new backup
ring and injector inlet seal must be installed on all six
injector oil inlet tubes.
CAUTION: To prevent engine damage, when
installing new backup rings, a new backup ring must
match the backup ring removed from the injector oil
inlet tubes.
2. Inspect injector oil inlet adaptors for internal Figure 644 Injector oil inlet adapter installed in
O-ring extrusion and high-pressure oil leak high-pressure oil rail
paths. Verify that each oil inlet tube is moveable. 1. Injector oil inlet adaptor
Replace any adaptor having an extruded internal 2. Backup ring
O-ring, high-pressure oil leak path or seized oil 3. Injector oil inlet seal
inlet tube. 4. Oil inlet tube
5. Internal O-ring (not serviceable)

Table 53 Groove Measurement (M) in Oil Inlet

Tube and Required Backup Ring
Groove (M) in Oil Inlet Backup Ring
Tube
5.080 mm (0.200 in) Backup ring 1.8 mm
(0.07 in)
4.877 mm (0.192 in) Backup ring 1.6 mm
(0.06 in)
4.420 mm (0.174 in) Backup ring 1.1 mm
(0.04 in)

Figure 643 Groove Measurement (M) in injector 4. Install a new backup ring onto injector oil inlet
oil inlet tube tubes, according to the groove measurements
listed in the table.
5. Install new injector inlet seal onto injector oil inlet
3. Measure groove in the injector oil inlet tube. tubes.
6. Coat backup rings and injector oil inlet seals with
clean engine oil.

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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
402 DIAMOND LOGIC® ENGINE BRAKE

WARNING: To prevent personal injury or

possible death, have an assistant help remove
or install the high-pressure oil rail when working
within the chassis.

Figure 645 Oil inlet O-ring

Figure 646 High-pressure oil rail

7. Coat new oil inlet O-ring with clean engine oil and
install O-ring in recess in cylinder head. 1. Lift high-pressure oil rail up and place on engine.
Align injector oil inlet adaptors with injector inlets.

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© 2009 Navistar, Inc.
 DIAMOND LOGIC® ENGINE BRAKE 403

12 8 4 1 5 9

11 7 3 2 6 10

H08090

Figure 647 Torque sequence for high-pressure oil rail bolts

2. Install and hand tighten all high-pressure oil rail 1. Connect each valve cover gasket pass-through
bolts (M8 x 90). Torque bolts to the special torque connector to its respective injector and clip
value (Table 55) in a circular pattern, beginning harness on the high-pressure oil rail.
from the center.
NOTE: Air trapped in the engine brake rail will be
purged automatically during the cranking and start up
phase.
Electrical Connections

Figure 649 ICP sensor electrical connector

2. Connect ICP sensor electrical connector to valve

cover gasket pass-through connector (rear) and
clip harness to high-pressure oil rail.
Figure 648 Injector electrical connector

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© 2009 Navistar, Inc.
404 DIAMOND LOGIC® ENGINE BRAKE

Figure 650 Brake shutoff valve assembly

Figure 651 BCP sensor electrical connector
electrical connector

4. Connect the BCP sensor electrical connector to

3. Connect brake shutoff valve electrical connector
the valve cover gasket pass-through connector
to valve cover gasket pass-through connector and
(front) and clip harness to high-pressure oil rail.
clip harness to high-pressure oil rail.
5. Adjust brake actuator lash. See Brake Lash
Adjustment (Steps 2-6) in Periodic Service in this
“Diamond Logic® Engine Brake” section (page
392).
6. Install valve cover. See Valve Cover (Valve Cover,
page152) in the “Cylinder Head and Valve Train”
section of this manual.

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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
 DIAMOND LOGIC® ENGINE BRAKE 405

Specifications
Table 54 Engine Brake Specifications
Brake actuator lash (cold) 0.48 mm (0.019 in)
Engine exhaust valve lash (cold) See (Adjusting Valve Lash,
page150)

Special Torque
Table 55 Engine Brake Special Torques
Brake Control Pressure (BCP) sensor 20-30 N·m (15-22 lbf·ft)
Brake piston adjustment locknut 27 N·m (20 lbf·ft)
Brake shutoff solenoid Tinnermann nut 7 - 11 N·m (5 - 8 lbf·lb)
Brake shutoff valve 24-30 N·m (18-22 lbf·ft)
High-pressure oil rail bolts (M8 x 90) 27 N·m (20 lbf·ft)
Plug assembly, M10 12 N·m (108 lbf·in)
Plug assembly, M12 12 N·m (108 lbf·in)
Injection Control Pressure (ICP) sensor 20-30 N·m (15-22 lbf·ft)
Oil pressure relief valve 41-48 N·m (30-35 lbf·ft)
Rail End Plug Assembly or attenuator 204 N·m (150 lbf·ft)

Special Tools
Table 56 Engine Brake Special Service Tools
Feeler gauge (long) Obtain locally

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© 2009 Navistar, Inc.
406 DIAMOND LOGIC® ENGINE BRAKE

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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
 AIR COMPRESSOR, POWER STEERING PUMP, AND POWER 407
TAKE-OFF

Table of Contents

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .409
.
Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .409 .
Power Steering Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .409 .
Power Take-off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .409 .

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .409
.
Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .410 .
Power Steering Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .411 .

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .411
.
Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .411 .
Power Steering Pump with Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .412 .
Power Steering Pump without Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .414 .
Special Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .415 .

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© 2009 Navistar, Inc.
408 AIR COMPRESSOR, POWER STEERING PUMP, AND POWER
TAKE-OFF

EGES-265-2
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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
 AIR COMPRESSOR, POWER STEERING PUMP, AND POWER 409
TAKE-OFF

Description POWER TAKE-OFF

The air compressor and power steering pump A front cover mounted Power Take-off (PTO)
assemblies are optional on International® DT 466, devise can only be used in conjunction with an
DT 570 and HT 570 Diesel Engines. They can air compressor. See (1171813R1 Front Cover PTO
be configured individually or together depending Adaptation Kit, page487) .
on vehicle application requirements. A front cover
mounted Power Take-off (PTO) devise can be used
in conjunction with the air compressor.
Removal
AIR COMPRESSOR

Air for braking is supplied by an air compressor

mounted on the lower left side of the engine. It is GOVERNMENT REGULATION: Engine
gear driven from the lower idler gear located within fluids (oil, fuel, and coolant) may be a hazard
the front engine cover. to human health and the environment.
Handle all fluids and other contaminated
• Lubrication of the compressor is provided by materials (e.g. filters, rags) in accordance
a hose connected at the engine oil pressure with applicable regulations. Recycle
sensor port with oil draining back to the crankcase or dispose of engine fluids, filters, and
through an elbow at the bottom of the compressor. other contaminated materials according to
• Filtered air is furnished through an air hose applicable regulations.
connected to the air cleaner assembly, and
compressed into a supply tank. When the air
supply tank is full, compressed air is simply WARNING: To prevent personal injury or
vented to the atmosphere. death, read all safety instructions in the "Safety
• Coolant to the compressor is supplied and Information" section of this manual.
returned through two hoses to ports located
on the left side of the engine crankcase. WARNING: To prevent personal injury or
death, shift transmission to park or neutral, set
parking brake, and block wheels before doing
POWER STEERING PUMP diagnostic or service procedures.

The power steering pump assembly is mounted in one

of two following configurations: WARNING: To prevent personal injury or
death, wear safety glasses with side shields.
A. Without an air compressor, the power Limit compressed air pressure to 207 kPa (30 psi).
steering pump is mounted onto rear half
of the front cover and is driven by the lower
idler gear that would normally drive the air WARNING: To prevent personal injury or
compressor. death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash
B. With an air compressor, the power steering with soap and water. Wash or discard clothing
pump is mounted to the air compressor. and rags contaminated with engine fluids.
The compressor is driven by the lower idler
gear and power is transferred through the NOTE: Air compressor and power steering pump may
compressor crankshaft to drive the power be removed as an assembly depending on servicing
steering pump. circumstances.

NOTE: For component service procedures other than

removal and installation refer to the International
Service Information Solutions - ISIS® and then
select manufacturer from suppliers tab.

EGES-265-2
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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
410 AIR COMPRESSOR, POWER STEERING PUMP, AND POWER
TAKE-OFF

Air Compressor

WARNING: To prevent serious personal

injury, possible death, or damage to the engine
or vehicle, do the following before removing
the air compressor because of its heavy weight
and possibly high temperature. Wait until the
air compressor cools down. Also, it is advised
to have two people remove the air compressor
and power steering pump combination from the
engine, especially in chassis.

2
3
o 1 2

43.5 o
3
1
2
1

o
10

4
10 9 2 1 8 7 6 5
H16004

Figure 652 Air compressor mounting and connections

1. Hose clamps (6) 5. Support bracket bolts (to 8. Drain hose elbow
2. Elbow assembly, M18 (3) crankcase), M12 x 25 (2) 9. Elbow assembly, M10 (oil
3. Connector assembly, M18 (2) 6. Air compressor support bracket supply)
4. Support bracket bolts (to assembly 10. Air compressor mounting bolts,
compressor), M10 x 25 (2) 7. Fitting (NPTF), 3/8 x 1/2 M12 x 80 (2)

EGES-265-2
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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
 AIR COMPRESSOR, POWER STEERING PUMP, AND POWER 411
TAKE-OFF

1. Place a coolant drain pan beneath air compressor Installation

bracket.
Air Compressor
2. Loosen the coolant outlet hose clamp (from
crankcase).
WARNING: To prevent serious personal
3. Loosen the coolant inlet hose clamp (to injury, possible death, or damage to the engine
crankcase). or vehicle, do not attempt to install the air
compressor alone. It is advised to have two
4. Remove hose ends from both crankcase fittings.
people install the air compressor onto the engine.
Cap and plug open fittings and hose ends to keep
clean. 1. On work bench, loosely install air compressor
support bracket assembly (Figure 652) to the air
5. Disconnect oil supply line at air compressor. Cap
compressor with two bolts (M10 x 25). Thread
line and fitting.
finger tight but do not tighten.
6. Disconnect oil drain hose elbow and clamps.
2. Apply a small amount of assembly grease to the
7. Remove two bolts (M12 x 80) and nuts (M12) O-ring and install into groove on front cover.
securing compressor to front cover.
3. Install the air compressor and support bracket
8. Support weight of air compressor and remove two assembly onto front cover with two bolts (M12 x
air compressor support bracket bolts (M12 x 25). 80) and nuts. Tighten, but do not torque.
Lift air compressor and bracket assembly from
4. Loosely install two bolts (M12 x 25) through air
engine.
compressor bracket into crankcase.
9. Place air compressor and bracket onto work
5. Torque all air compressor bolts in the following
bench.
order:
10. Remove and discard air compressor gasket.
CAUTION: To prevent engine damage, do not
11. Remove remaining two bracket bolts attached to over torque the air compressor mounting bolts.
air compressor (M10 x 25) (Figure 652). Over torquing bolts will result in a fractured front
cover.
a. Torque two compressor to front cover bolts
Power Steering Pump
(M12 x 80) to the special torque value (Table
1. Disconnect the high-pressure hose at power 57).
steering pump.
b. Torque two compressor to bracket assembly
2. Disconnect the low-pressure hose at power bolts (M12 x 25) to the special torque value
steering pump. (Table 57).
3. Cap oil lines to eliminate contamination. c. Torque two bracket assembly to crankcase
bolts (M12 x 10) to the special torque value
4. Depending on application, do one of the following:
(Table 57).
• For applications with power steering pump
6. Uncap coolant hoses and install onto elbow
attached to the rear of air compressor,
assembly (M18) and connector assembly (M18)
remove two bolts (M10 x 35).
fittings with hose clamps.
• For applications with power steering pump
NOTE: If these fittings were removed from the
attached to rear of the front cover, remove two
crankcase or air compressor for any reason, they
bolts (M12 x 90 and nuts).
will require standard torque values (General Torque
5. Remove gasket and discard. Guidelines, page445) and need to be oriented to the
correct angle (Figure 652) upon installation.

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412 AIR COMPRESSOR, POWER STEERING PUMP, AND POWER
TAKE-OFF

7. Remove caps and install oil supply hose to elbow

assembly (M10) (Figure 652). Tighten oil supply
line fitting.
8. Install oil drain hose elbow and clamps.

Power Steering Pump with Air Compressor

1 2 3
H16019

Figure 653 Power steering pump with air compressor

1. Power steering pump gasket 2. Hex flange bolt, M10 x 35 3. Power steering pump assembly

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 AIR COMPRESSOR, POWER STEERING PUMP, AND POWER 413
TAKE-OFF

1. Apply a small amount of assembly grease to 3. Install low-pressure hose.

the O-ring and install into groove on backside of
4. Install high-pressure hose.
compressor.
2. Install two power steering pump mounting bolts
(M10 x 35) and tighten to the special torque value
(Table 57).

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414 AIR COMPRESSOR, POWER STEERING PUMP, AND POWER
TAKE-OFF

Power Steering Pump without Air Compressor

NOTE: The following steps are only for applications
that are not equipped with an air compressor.

8
7

5 4 3 2 H16020

Figure 654 Power steering pump without air compressor

1. Plug assembly, M18 (standard 3. Power steering pump assembly 7. Power steering pump gear nut
torque) (General Torque 4. Nut, M12 (2) and shaft key (supplied with
Guidelines, page445) 5. O-ring gasket pump)
2. Cap 6. Bolt, M12 x 90 (2) 8. Drive gear (supplied with pump)

1. Apply a small amount of assembly grease to the 3. Install power steering low-pressure hose.
O-ring and install into groove on front cover.
4. Install power steering high-pressure hose.
2. Install two power steering pump mounting
bolts (M10 x 90) and nuts (M10) and tighten
to the standard torque value (General Torque
Guidelines, page445).

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 AIR COMPRESSOR, POWER STEERING PUMP, AND POWER 415
TAKE-OFF

Special Torques

Table 57 TF 550 and TF 750 Air Compressor and Power Steering Pump Special Torques
Air compressor gear nut 150 N·m (110 lbf·ft)
Air compressor mounting bolts (through front cover), M12 x 80 83 N·m (61 lbf·ft)
Bracket bolt to air compressor, M10 x 25 67 N·m (49 lbf·ft)
Bracket bolt to crankcase, M12 x 25 115 N·m (85 lbf·ft)
Elbow assembly, M10 15-16 N·m (132-141lbf·in)
Elbow fitting assembly, M18 48 N·m (35 lbf·ft)
Hose connector assembly, M18 48 N·m (35 lbf·ft)
Power steering mounting bolts, M10 x 35 57 N·m (42 lbf·ft)
Power steering pump drive nut 90 N·m (66 lbf·ft)

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416 AIR COMPRESSOR, POWER STEERING PUMP, AND POWER
TAKE-OFF

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 ABBREVIATIONS AND ACRONYMS 417

Table of Contents

Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .419

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418 ABBREVIATIONS AND ACRONYMS

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 ABBREVIATIONS AND ACRONYMS 419

Abbreviations and Acronyms ESC – Electronic System Controller

ESN – Engine Serial Number
ABS – Antilock Brake System
EST – Electronic Service Tool
AC – Alternating Current
EURO – Eurpoean
ACCEL – Accelerate
EVRT™ – Electronic Variable Response
amp – Ampere
Turbocharger
AMS – Air Management System
EWPS – Engine Warning Protection System
API – American Petroleum Institute
APS – Accelerator Position Sensor F – Fahrenheit
ATA – American Trucking Association ft – Feet
AWA – Acoustic Wave Attenuator FMI – Failure Mode Indicator
BAP – Barometric Absolute Pressure gal – Gallon
BCP – Brake Control Pressure gph – Gallons Per Hour
BDC – Bottom Dead Center GVW – Gross Vehicle Weight
bhp – Brake horsepower
H2O – Water
C – Celsius Hg – Mercury
CAC – Charge Air Cooler hp – Horsepower
CAN – Controller Area Network HT – High Torque
CAN 1 – Controller Area Network (public)
IAT – Intake Air Temperature
CAN 2 – Controller Area Network (private)
ICP – Injector Control Pressure
CAP – Cold Ambient Protection
IDM – Injector Drive Module
cc – Cubic centimeter
IGN – Ignition
CDPF – Catalyzed Diesel Particulate Filter
in – Inch
cfs – Cubic feet per second
in Hg – Inches of mercury
CKP – Crankshaft Position
in H2O – Inches of water
CKPO – Crankshaft Position Output
INJ – Injector drive
cm – Centimeter
IPR – Injection Pressure Regulator
CMP – Camshaft Position
ISIS® – International® Service Information Solutions
CMPO – Camshaft Position Output
IST – Idle Shutdown Timer
CPU – Central Processing Unit
IVS – Idle Validation Switch
CTC – Coolant Temperature Compensation
kg – Kilogram
DC – Direct Current
km – Kilometer
DDS – Driveline Disengagement Switch
KOEO – Key-On Engine-Off
DLC – Data Link Control
KOER – Key-On Engine-Running
DMM – Digital Multimeter
kPa – Kilopascal
DT – Diesel Turbocharged
DTC – Diagnostic Trouble Code L – Liter
lb – Pound
ECL – Engine Coolant Level
lbf – Pounds of force
EBP – Exhaust Back Pressure
lbf•ft – Pounds of force per foot
ECI – Engine Crank Inhibit
lbf•in – Pounds of force per inch
ECM – Electronic Control Module
ECT – Engine Coolant Temperature m – Meter
EFAN – Engine Fan m/s – Meters per second
EFRC – Engine Family Rating Code MAP – Manifold Absolute Pressure
EGR – Exhaust Gas Recirculating MAT – Manifold Air Temperature
EGRP – Exhaust Gas Recirculating Position mm – Millimeter
EOP – Engine Oil Pressure mph – Miles per hour
EOT – Engine Oil Temperature MY – Model Year
EPA – Environmental Protection Agency
N – Newton
EPR – Engine Pressure Regulator

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420 ABBREVIATIONS AND ACRONYMS

NEG – Negative SCCS – Speed Control Command Switches

NETS – Navistar Electronics Technical Support SID – Subsystem Identifier
N•m – Newton meter SO2 – Sulfur Dioxide
NO – Nitrogen Oxide SYNC – Synchronization
NOX – Nitrogen Oxides
TACH – Tachometer output signal
NSBU – Netural Start Backup Switch
TCAPE – Truck Computer Analysis of Performance
OCC – Output Circuit Check and Economy
OL – Over Limit TDC – Top Dead Center
PID – Parameter Identifier UVC – Under Valve Cover
P/N – Part Number
V – Volt
POS – Positive
VBAT – Battery Voltage
POSE – Positive On Shaft Excluder
VIGN – Ignition Voltage
PROM – Programmable Read Only Memory
VREF – Reference Voltage
psi – Pounds per square inch
VREF A – Reference Voltage (engine)
pt – Pint
VREF B – Reference Voltage (chassis)
PTO – Power Take Off
VGT – Variable Geometry Turbocharger
RAM – Random Access Memory VIN – Vehicle Identification Number
rev – Revolution VOP – Valve Opening Pressure
rpm – Revolutions per minute VSS – Vehicle Speed Sensor
ROM – Read Only Memory
WIF – Water In Fuel
RSE – Radiator Shutter Enable
WTEC – World Transmission Electronically Controlled
SAE – Society of Automotive Engineers automatic transmissions (Allison)

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 TERMINOLOGY 421

Table of Contents

Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .423
.

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422 TERMINOLOGY

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 TERMINOLOGY 423

Terminology Barometric Absolute Pressure (BAP) sensor – A

variable capacitance sensor which, when supplied
Accelerator Position Sensor (APS) – A
with a 5 volt reference signal from the ECM, produces
potentiometer sensor that indicates the position of
a linear analog voltage signal indicating atmospheric
the accelerator pedal.
pressure.
Accessory work – The work per cycle required
Boost pressure – 1. The pressure of the charge air
to drive engine accessories (normally, only those
leaving the turbocharger.
essential to engine operation).
2. Inlet manifold pressure that is greater than
Actuator – A device that performs work in response
atmospheric pressure. Obtained by turbocharging.
to an input signal.
Bottom Dead Center (BDC) – The lowest position of
Aeration – The entrainment of gas (air or combustion
the piston during the stroke.
gas) in the coolant, lubricant, or fuel.
Brake Control Pressure (BCP) sensor – The
After cooler (Charge Air Cooler) – A heat exchanger
BCP sensor is a variable capacitance sensor that
mounted in the charge air path between the
senses the oil pressure in the brake gallery of the
turbocharger and engine intake manifold. The
high-pressure oil rail.
after cooler reduces the charge air temperature by
transferring heat from the charge air to a cooling Brake Horsepower (bhp) – The power output from
medium (usually air). an engine, not the indicated horsepower. The power
output of an engine, sometimes called flywheel
Air Management System (AMS) – The AMS controls
horsepower is less than the indicated horsepower by
and directs air through the intake and exhaust which
the amount of friction horsepower consumed in the
affects engine performance and controls emissions.
engine.
Alternating Current (AC) – An electric current that
Brake Horsepower (bhp) net – Net brake
reverses its direction at regularly recurring intervals.
horsepower is measured with all engine components.
Ambient temperature – The environmental air The power of an engine when configured as a fully
temperature in which a unit is operating. In general, equipped engine. (SAE J1349 JUN90)
the temperature is measured in the shade (no solar
Calibration – The data values used by the strategy
radiation) and represents the air temperature for other
to solve equations and make decisions. Calibration
engine cooling performance measurement purposes.
values are stored in ROM and put into the processor
Air entering the radiator may or may not be the same
during programming to allow the engine to operate
ambient due to possible heating from other sources
within certain parameters.
or recirculation. (SAE J1004 SEP81)
Camshaft Position (CMP) sensor – The CMP
Ampere (amp) – The standard unit for measuring the
sensor is a magnetic pickup sensor which indicates
strength of an electrical current. The flow rate of a
engine position. Speed is indicated by the number
charge in a conductor or conducting medium of one
of vanes counted per revolution of the camshaft.
coulomb per second. (SAE J1213 NOV82)
Camshaft position is indicated by a single position
Analog – A continuously variable voltage. peg that indicates Cylinder Number 1.
Analog to digital converter (A/D) – A circuit in the Catalyst – A substance that produces a chemical
ECM processing section that converts an analog reaction without undergoing a chemical change itself.
signal (DC or AC) to a usable digital signal for the
Catalytic converter – An antipollution device in the
microprocessor.
exhaust system that contains a catalyst for chemically
American Trucking Association (ATA) Data link – converting some pollutants in the exhaust gases
A serial data link specified by the American Trucking (carbon monoxide, unburned hydrocarbons, and
Association and the SAE. oxides of nitrogen) into harmless compounds.
Acoustic Wave Attenuator – A component of the Cavitation – A dynamic condition in a fluid system that
high-pressure oil rail designed to reduce hydraulic forms gas-filled bubbles (cavities) in the fluid.
fluctuations resulting in a decrease of acoustic energy.

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424 TERMINOLOGY

Cetane number – 1. The auto ignition quality of diesel Crankcase – The housing that encloses the
fuel. crankshaft, connecting rods, and allied parts.
2. A rating applied to diesel fuel similar to octane Crankcase breather – A vent for the crankcase to
rating for gasoline. release excess interior air pressure.
3. A measure of how readily diesel fuel starts to burn Crankcase pressure – The force of air inside the
(autoignites) at high compression temperature. crankcase against the crankcase housing.
Diesel fuel with a high cetane number autoignites Crankshaft (CKP) sensor – The CKP sensor is a
shortly after injection into the combustion chamber. magnetic pickup sensor that indicates crankshaft
Therefore, it has a short ignition delay time. Diesel speed and position.
fuel with a low cetane number resists autoignition.
Current – The flow of electrons passing through a
Therefore, it has a longer ignition delay time.
conductor. Measured in amperes.
Charge air – Dense, pressurized, heated air
Damper – A device that reduces the amplitude of
discharged from the turbocharger.
torsional vibration. (SAE J1479 JAN85)
Charge Air Cooler (CAC) – See After cooler.
Deaeration – The removal or purging of gases (air or
Closed crankcase – Crankcase ventilation system combustion gas) entrapped in coolant or lubricating
that recycles crankcase gases through a breather, oil.
then back to the clean air intake.
Deaeration tank – A separate tank in the cooling
Closed loop operation – A system that uses a sensor system used for one or more of the following functions:
to provide feedback to the ECM. The ECM uses the
• Deaeration
sensor to continuously monitor variables and it make
adjustments to match engine requirements. • Coolant reservoir (fluid expansion and after boil)
Cloud point – The point when wax crystals occur in • Coolant retention
fuel, making fuel cloudy or hazy. Usually below –12°C
• Filling
(10°F).
• Fluid level indication (visible)
Cold cranking ampere rating (battery rating) – The
sustained constant current (in amperes) needed to Diagnostic Trouble Code (DTC) – Formerly called
produce a minimum terminal voltage under a load of a Fault Code or Flash Code. A DTC is a three digit
7.2 volts per battery after 30 seconds. numeric code used for troubleshooting.
Continuous Monitor Test – An ECM function that Diamond Logic™ Engine Brake – The Diamond
continuously monitors the inputs and outputs to logic™ Engine Brake is a compression release
ensure that readings are within set limits. braking system that uses a high-pressure oil rail
components together with the VGT for additional
Controller Area Network (CAN) – This is a J1939
braking. The operator controls the engine brake for
high speed communication link. CAN 1 is a public
different operating conditions.
drive train data link between the vehicle modules and
ECM. CAN 2 is a private link between the ECM and Diamond Logic™ Exhaust Brake – The Diamond
IDM. Logic™ Exhaust Brake is an exhaust brake system
that uses only the VGT to restrict exhaust flow for
Coolant – A fluid used to transport heat from one point
additional braking. The operator controls the exhaust
to another.
brake for different operating conditions.
Coolant level switch – A switch used to indicate
Digital Multimeter (DMM) – An electronic meter that
coolant level.
uses a digital display to indicate a measured value.
Cooling system capacity (volume) – The amount Preferred for use on microprocessor systems because
of coolant that completely fills a cooling system to its it has a very high internal impedance and will not load
designated cold level mark. (SAE J1004 SEP81) down the circuit being measured.

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 TERMINOLOGY 425

Direct Current (DC) – An electric current flowing in Engine Control Module (ECM) power relay – An
one direction only and substantially constant in value. ECM controlled relay that supplies power to the ECM.
Disable – A computer decision that deactivates a Engine Coolant Temperature (ECT) sensor –
system and prevents operation of the system. A thermistor sensor that senses engine coolant
temperature.
Displacement – The stroke of the piston multiplied by
the area of the cylinder bore multiplied by the number Engine Fuel Pressure (EFP) sensor – A variable
of cylinders in the engine. capacitance sensor that senses fuel pressure.
Driveline Disengagement Switch (DDS) – A switch Engine Family Rating Code (EFRC) – A readable
that indicates when the driveline is disengaged from code in the calibration list of the EST that identifies
the engine. engine horsepower and emission calibrations.
Driver (high side) – A transistor in an electronic Engine lamp – An instrument panel lamp that comes
module that controls the power to an actuator circuit. on when DTCs are set. DTCs can be read as flash
codes (red and amber instrument panel lamps).
Driver (low side) – A transistor in an electronic
module that controls the ground to an actuator circuit. Engine OFF tests – Tests that are done with the
ignition key ON and the engine OFF.
Drivetrain data link (CAN 1) J1939 – The primary
communication link for the ECM, ESC, and instrument Engine RUNNING tests – Tests done with the engine
cluster. running.
Duty cycle – A control signal that has a controlled Engine Oil Pressure (EOP) sensor – A variable
on/off time measurement from 0 to 100%. Normally capacitance sensor that senses engine oil pressure.
used to control solenoids.
Engine Oil Temperature (EOT) sensor – A
Elastomer – An elastic, rubber like substance such thermistor sensor that senses engine oil temperature.
as natural or synthetic rubber material. (SAE J111
Exhaust brake – A brake device using engine
MAR85)
exhaust back pressure as a retarding medium.
Electronic Control Module (ECM) – The Electronic
Exhaust Gas Recirculation (EGR) – The Exhaust
Control Module is an electronic microprocessor that
Gas Recirculation is a system that recycles a
monitors and controls engine performance, exhaust
controlled portion of exhaust gas back into the
emissions, and vehicle system performance (cruise
combustion chamber to reduce Nitrogen Oxide
control, transmission control, starter engagement,
exhaust emissions.
etc.). The ECM provides diagnostic information for
engine and vehicle systems and can be programmed Exhaust Gas Recirculation (EGR) drive module –
at different levels for engine protection, warning, and The EGR drive module controls the position of the
shutdown. EGR valve.
Electronic Service Tool (EST) – A computer Exhaust Gas Recirculation (EGR) cooler – The
diagnostic and programming tool for the ECM and exhaust gas is cooled in the EGR cooler and flows
ESC. The hardware is typically a laptop computer or through the EGR control valve to the EGR mixer duct.
notebook computer. The diagnostic and programming
Exhaust Gas Recirculation (EGR) valve – The EGR
software includes International Master Diagnostics,
valve, when open, will mix exhaust gas with filtered
ISIS on-line documentation, and NETS for factory
intake air which flows into the intake manifold. The
programming.
EGR valve, when closed, only allows filtered air to flow
Electronic System Controller (ESC) – An electronic into the intake manifold.
module that provides multiple analog and switched
Exhaust manifold – Exhaust gases flow through the
input interfaces to monitor vehicle functions through
exhaust manifold to the turbocharger exhaust inlet and
solid state switches, relay driver outputs, and serial
are directed to the EGR cooler or out the exhaust
data communication.
system.

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426 TERMINOLOGY

EVRT® electronic controlled turbocharger – Hall effect – The development of a transverse electric
International’s version of a Variable Geometry potential gradient in a current-carrying conductor or
Turbocharger (VGT). semiconductor when a magnetic field is applied.
EZ-Tech® inerface cable – The EZ-Tech® inerface Hall effect sensor – Generates a digital on or off
cable connects to the EST to communicate with the signal that indicates speed or position.
Electronic Controlled Module (ECM).
High speed digital inputs – Inputs to the ECM from
Fault detection and management – An alternate a sensor that generates varying frequencies (engine
control strategy that reduces adverse effects that can speed and vehicle speed sensors).
be caused by a system failure. If a sensor fails, the
Horsepower (hp) – Horsepower is the unit of work
ECM substitutes a good sensor signal or assumed
done in a given period of time, equal to 33,000 pounds
sensor value in its place. A lit amber or red instrument
multiplied by one foot per minute. 1 hp = 33,000 lb x
panel lamp signals that the vehicle needs service.
1 ft /1 min.
Filter restriction – A blockage, usually from
Hydrocarbons – Unburned or partially burned fuel
contaminants, that prevents the flow of fluid through
molecules.
a filter.
Idle speed – Low idle is the minimum engine speed.
Flash code – See Diagnostic Trouble Code (DTC).
High idle is the maximum governed engine speed with
Fuel inlet restriction – A blockage, usually from no load.
contaminants, that prevents the flow of fluid through
Idle Validation Switch (IVS) – An On/Off switch
the fuel inlet line.
that senses when the accelerator pedal is in the
Fuel pressure – The force that the fuel exerts on the idle position. There is also a cold idle advance that
fuel system as it is pumped through the fuel system. increases low idle speed for a short period to aid in
engine warm-up in cold temperatures.
Fuel strainer – A prefilter in the fuel system that keeps
larger contaminants from entering the fuel system. Injector Drive Module (IDM) power relay – An IDM
controlled relay that supplies power to the IDM.
Fully equipped engine – A fully equipped engine
is an engine equipped with only those accessories Indicated horsepower – The theoretical power
necessary to perform its intended service. A fully transmitted to the pistons by gas in the cylinders.
equipped engine does not include components
Injection Control Pressure (ICP) – High lube
that are used to power auxiliary systems. If these
oil pressure generated by a high-pressure
components are integral with the engine or for any
pump/pressure regulator used to hydraulically
reason are included on the test engine, the power
actuate the fuel injectors and the optional Diamond
absorbed may be determined and add to the net
Logic™ engine brake.
brake power. (SAE J1995 JUN90)
Injection Pressure Regulator (IPR) – A Pulse Width
Fusible link (fuse link) – A fusible link is a special
Modulated (PWM) regulator valve, controlled by the
section of low tension cable designed to open the
ECM, that regulates injection control pressure.
circuit when subjected to an extreme current overload.
(SAE J1156 APR86) Injection Control Pressure (ICP) sensor – A
variable capacitance sensor that senses injection
Gradeability – The maximum percent grade which
control pressure.
the vehicle can transverse for a specified time at a
specified speed. The gradeability limit is the grade Intake Air Temperature (IAT) sensor – A thermistor
upon which the vehicle can just move forward. (SAE sensor that senses intake air temperature.
J227a)
Intake manifold – A plenum through which the air
Gross brake horsepower – The power of a complete mixture flows from the charged air cooler piping to the
basic engine, with air cleaner, without fan, and intake passages of the cylinder head.
alternator and air compressor not charging.
International NGV Tool Utilized for Next
Generation Electronics (INTUNE) – The

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 TERMINOLOGY 427

diagnostics software for chassis related components volt will maintain a current of one ampere. (SAE J1213
and systems. NOV82)
Low speed digital inputs – Switched sensor inputs On demand test – A self test that the technician
that generate an on/off (high/low) signal to the ECM. initiates using the EST. It is run from a program in the
The input to the ECM from the sensor could be from processor.
a high input source switch (usually 5 or 12 volts) or
Output Circuit Check (OCC) – An On demand test
from a grounding switch that grounds the signal from
done during an Engine OFF self test to check the
a current limiting resistor in the ECM that creates a low
continuity of selected actuators.
signal (0 volts).
Output State Check (OSC) – An On demand test
Lubricity – Lubricity is the ability of a substance
that forces the processor to activate actuators (High
to reduce friction between solid surfaces in relative
or Low) for additional diagnostics.
motion under loaded conditions.
pH – A measure of the acidity or alkalinity of a solution.
Lug (engine) – A condition when the engine is
operating at or below maximum torque speed. Particulate matter – Particulate matter includes
mostly burned particles of fuel and engine oil.
Manifold Absolute Pressure (MAP) – Intake
manifold pressure (boost pressure). Piezometer – An instrument for measuring fluid
pressure.
Manifold Absolute Pressure (MAP) sensor –
A variable capacitance sensor that senses intake Positive On Shaft Excluder (POSE) – It is a separate
manifold pressure. piece from the rest of the front or rear seal used to
keep out dust / debris.
Manometer – A double-leg liquid-column gauge, or a
single inclined gauge, used to measure the difference Potentiometer – A potentiometer is a variable voltage
between two fluid pressures. Typically, a manometer divider that senses the position of a mechanical
records in inches of water. component. A reference voltage is applied to one
end of the potentiometer. Mechanical rotary or linear
Master Diagnostics (MD) – The diagnostics software
motion moves the wiper along the resistance material,
for engine related components and systems to use on
changing voltage at each point along the resistive
the electronic service tool or personal computer.
material. Voltage is proportional to the amount of
Manifold Air Temperature (MAT) – Intake manifold mechanical movement.
air temperature
Power – Power is a measure of the rate at which work
Manifold Air Temperature (MAT) sensor – A is done. Compare with Torque.
thermistor style sensor housed in the intake manifold
Power Take Off (PTO) – Accessory output, usually
used to indicate air temperature after passing through
from the transmission, used to power a hydraulic
the charge air cooler.
pump for a special auxiliary feature (garbage packing,
Microprocessor – An integrated circuit in a lift equipment, etc.).
microcomputer that controls information flow.
Pulse Width Modulation (PWM) – The time that an
Nitrogen Oxides (NOx) – Nitrogen oxides form by actuator, such as an injector, remains energized.
a reaction between nitrogen and oxygen at high
Random Access Memory (RAM) – Computer
temperatures and pressures in the combustion
memory that stores information. Information can
chamber.
be written to and read from RAM. Input information
Normally closed – Refers to a switch that remains (current engine speed or temperature) can be stored
closed when no control force is acting on it. in RAM to be compared to values stored in Read Only
Memory (ROM). All memory in RAM is lost when the
Normally open – Refers to a switch that remains open
ignition switch is turned off.
when no control force is acting on it.
Rated gross horsepower – Engine gross
Ohm (Ω) – The unit of resistance. One ohm is the
horsepower at rated speed as declared by the
value of resistance through which a potential of one
manufacturer. (SAE J1995 JUN90)

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428 TERMINOLOGY

Rated horsepower – Maximum brake horsepower Switch sensors – Switch sensors indicate position.
output of an engine as certified by the engine They operate open or closed, allowing or preventing
manufacturer. The power of an engine when the flow of current. A switch sensor can be a voltage
configured as a basic engine. (SAE J1995 JUN90) input switch or a grounding switch. A voltage input
switch supplies the ECM with a voltage when it is
Rated net horsepower – Engine net horsepower at
closed. A grounding switch grounds the circuit closed,
rated speed as declared by the manufacturer. (SAE
causing a zero voltage signal. Grounding switches
J1349 JUN90)
are usually installed in series with a current limiting
Rated speed – The speed, as determined by the resistor.
manufacturer, at which the engine is rated. (SAE
System restriction (air) – The static pressure
J1995 JUN90)
differential that occurs at a given air flow from air
Rated torque – Maximum torque produced by an entrance through air exit in a system. Usually
engine as certified by the manufacturer. measured in inches (millimeters) of water. (SAE
J1004 SEP81)
Read Only Memory (ROM) – Computer memory
that stores permanent information for calibration Tachometer output signal – Engine speed signal for
tables and operating strategies. Permanently stored remote tachometers.
information in ROM cannot be changed or lost
Thermistor – A thermistor sensor changes its
by turning the engine off or when ECM power is
electrical resistance to temperature. Resistance in the
interrupted.
thermistor decreases as temperature increases, and
Reference voltage (VREF) – A 5 volt reference increases as temperature decreases. Thermistors
supplied by the ECM to operate the engine and works with a resistor that limits current in the ECM
chassis sensors. to form a voltage signal matched with a temperature
value.
Reserve capacity – Time in minutes that a fully
charged battery can be discharged to 10.5 volts at 25 Thrust load – A thrust load pushes or reacts through
amperes. a bearing in a direction parallel to the shaft.
Signal ground – The common ground wire from the Top Dead Center (TDC) – The highest position of the
ECM for the sensors. piston during the stroke.
Speed Control Command Switches (SCCS) – A set Top Dead Center (compression) – Top Dead Center
of switches used for cruise control, Power Take Off (compression) is when the piston is at the highest
(PTO), and remote hand throttle system. position and both intake and exhaust valves are
closed.
Steady state condition – An engine operating
at a constant speed and load and at stabilized Torque – Torque is a measure of force producing
temperatures and pressures. (SAE J215 JAN80) torsion and rotation around an axis. Torque is the
product of the force, usually measured in pounds, and
Strategy – A plan or set of operating instructions
radius perpendicular to the axis of the force extending
that the microprocessor follows for a desired goal.
to the point where the force is applied or where it
Strategy is the computer program itself, including
originates, usually measured in feet.
all equations and decision making logic. Strategy is
always stored in ROM and cannot be changed during Truck Computer Analysis of Performance and
calibration. Economy (TCAPE) – Truck Computer Analysis of
Performance and Economy is a computer program
Stroke – Stroke is the movement of the piston from
that simulates the performance and fuel economy of
Top Dead Center (TDC) to Bottom Dead Center
trucks.
(BDC).
Turbocharger – A turbine driven compressor
Substrate – Material that supports the wash coating
mounted to the exhaust manifold. The turbocharger
or catalytic materials.
increases the pressure, temperature and density of
Sulfur dioxide (SO2) – Sulfur dioxide is caused by intake air to charge air.
oxidation of sulfur contained in fuel.

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 TERMINOLOGY 429

Valve cover gasket – A valve cover gasket that Vehicle Speed Sensor (VSS) – A magnetic pickup
contains the pass through electronic wiring harness sensor mounted in the tail shaft housing of the
connectors for the ICP and BCP sensors, the brake transmission, used to calculate ground speed.
shutoff valve, and six fuel injectors.
Viscosity – The internal resistance to the flow of any
Variable capacitance sensor – A variable fluid.
capacitance sensor is a sensor that measures
Viscous fan – A fan drive that is activated when a
pressure. The pressure measured is applied to a
thermostat, sensing high air temperature, forces fluid
ceramic material. The pressure forces the ceramic
through a special coupling. The fluid activates the fan.
material closer to a thin metal disk. This action
changes the capacitance of the sensor. Volt (v) – A unit of electromotive force that will move
a current of one ampere through a resistance of one
Variable Geometry Turbocharger (VGT) – The
Ohm.
VGT is a turbocharger with actuated vanes inside
the turbine housing. The vanes modify flow Voltage – Electrical potential expressed in volts.
characteristics of exhaust gases through the turbine
Voltage drop – Reduction in applied voltage from the
housing for boast pressure control at various engine
current flowing through a circuit or portion of the circuit
speeds and load conditions.
current multiplied by resistance.
(VGT) control module – The VGT control module
Voltage ignition – Voltage supplied by the ignition
is an electronic microprocessor that converts a pulse
switch when the key is ON.
width modulated signal from the ECM to control a DC
motor that controls the VGT vane position. Water In Fuel (WIF) switch – The WIF switch detects
water in the fuel.
Vehicle Electronic System Programming System –
The computer system used to program electronically Water supply housing (Freon bracket) – The water
controlled vehicles. supply housing (Freon Bracket) is a coolant supply
housing with a deaeration port and a connection for
Vehicle Retarder Enable/Engage – Output from the
cab heat.
ECM to a vehicle retarder.

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430 TERMINOLOGY

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 APPENDIX A – SPECIFICATIONS 431

Table of Contents

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433
.

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432 APPENDIX A – SPECIFICATIONS

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 APPENDIX A – SPECIFICATIONS 433

Specifications
NOTE: The following sections of the manual do not
require any specifications for service work:
• Mounting Engine on Stand
• Engine Electrical
• Air Compressor and Power Steering Pump

Table 58 VGT Specifications

Turbine shaft axial end play 0.05 - 0.13 mm (0.002-0.005
in)
Turbine shaft radial movement 0.52 - 0.74 mm (0.020-0.029
in)
VGT axial linkage shaft Must strike open and closed
stops in actuator, 90° rotation

Table 59 Exhaust Manifold Specifications

Allowable warpage (max.) 0.10 mm (0.004 in) overall
Flange thickness (min.) 21.59 mm (0.850 in)

Table 60 Valve Specifications

Camshaft lobe lift Intake: 6.68 mm (0.263 in)
Exhaust: 6.91 mm (0.272 in)
Valve face angle Intake: 59.75- 60.00°
Exhaust: 44.75-45.00°
Valve face margin (min.) Intake: 1.32 mm (0.052 in)
Exhaust: 1.16 mm (0.046 in)
Valve face-to-valve stem runout (max.) 0.038 mm (0.0015 in)
Valve lash (cold), intake and exhaust 0.48 mm (0.019 in)
Valve stem diameter (new condition) Intake: 7.928 ± 0.0089 mm (0.3121 ± 0.00035
in)
Exhaust: 7.908 ± 0.0089 mm (0.3113 ± 0.00035
in)
Valve stem-to-valve guide clearance (max.) Intake: 0.10 mm (0.004 in)
Exhaust: 0.11 mm (0.005 in)

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434 APPENDIX A – SPECIFICATIONS

Table 61 Valve Spring Specifications

Intake and Exhaust Valve Springs
Free length 52.35 mm (2.061 in)
Solid height (max.) 27.43 mm (1.080 in)
Valve closed test length @ 410.1 ± 24.5 N (92.2 ± 5.5 40 mm (1.575 in)
lbf) test load

Valve closed test length @ 764.2 ± 48.9 N (171.8 ± 29.3 mm (1.155 in)
11.0 lbf) test load

Table 62 Cylinder Head Specifications

Cylinder head gasket surface flatness 0.10 mm (0.004 in.) per 229 mm (9.0 in)
Cylinder head thickness New: 160.48 mm (6.318 in)
Minimum: 159.97 mm (6.298 in)
Exhaust valve seat insert counterbore diameter Standard: 37.503 ± 0.003 mm (1.477 ± 0.001 in)
Oversize: 0.05 mm (0.002 in) 37.55 ± 0.03 mm
(1.478 ± 0.001 in)
Exhaust valve seat outside diameter Standard: 37.56 mm (1.479 in)
Oversize: 0.05 mm (0.002 in) 37.61 mm (1.481 in)
Intake valve seat insert counterbore diameter Standard: 33.50 ± 0.03 mm (1.319 ± 0.001 in)
Oversize: 0.05 mm (0.002 in) 35.55± 0.03 mm
(1.321 ± 0.001 in)
Intake valve seat outside diameter Standard: 40.20 mm (1.583 in)
Oversize: 0.05 mm (0.002 in) 40.25 mm (1.585 in)
Push rod runout (maximum) 0.508 mm (0.020 in)
Valve guide bore diameter 14.308 ± 0.017 mm (0.5633 ± 0.0007 in)
Valve guide bore out-of-round (max.) 0.005 mm (0.0002 in)
Valve guide bore taper (max.) 0.013 mm (0.0005 in)
Valve guide height from cylinder head spring pocket
16.53 ± 0.13 mm (0.651 ± 0.005 in)
(intake)
Valve guide insert inside diameter (installed) 7.98 - 8.00 mm (0.314 - 0.315 in)
Valve guide insert interference fit dimension 0.043 mm (0.0017 in)
Valve guide insert outside diameter 14.351 ± 0.010 mm (0.5650 ± 0.0004 in)
Valve guide length (overall) 65.71 mm (2.587 in)
Valve recession Intake: 1.02 mm (0.040 in)
Exhaust: 1.40 mm (0.055 in)
Valve seat angles Intake: 59.75 - 60°
Exhaust: 44.75 - 45°

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Table 62 Cylinder Head Specifications (cont.)

Valve seat runout (max.) 0.05 mm (0.002 in)
Valve seat width 1.91 - 2.16 mm (0.075 - 0.085 in)

Table 63 Front Cover, Vibration Damper, Gerotor Oil Pump, Front Engine Mount, and Gear Train
Specifications
Camshaft gear end play 0.33 mm (0.013 in)
Camshaft gear-to-upper idler gear backlash 0.46 mm (0.018 in)
High-pressure pump end play 0.45 - 1.22 mm
(0.018-0.48 in)
Lower idler gear-to-air compressor gear backlash 0.508 mm (0.020 in)
Lower idler gear-to-crankshaft gear backlash 0.36 mm (0.014 in)
Oil pump end clearance 0.05 - 0.13 mm
(0.002-0.005 in)
Oil pump side clearance 0.36 - 0.48 mm
(0.014-0.019 in)
Upper idler gear-to-high-pressure oil pump gear backlash 0.48 mm (0.019 in)
Upper idler gear-to-lower idler gear backlash 0.48 mm (0.019 in)
Vibration damper face runout (max.) 1.52 mm (0.060 in)

Fan Drive Configurations Diameters and Ratios

Engine fan drive Fan CL to Crankshaft CL, Pulley Diameter Drive Ratio
configuration mm (in) OBD, mm (in)
466 high-mount, (Horton 508 (20) 242.8 (9.56) 0.894 : 1
DriveMaster)
570 high-mount, (Horton 508 (20) 242.8 (9.56) 1.08 : 1
DriveMaster)
570 high-mount, (Horton 508 (20) 219.4 (8.636) 1.2 : 1
DriveMaster)
570 high-mount, (Horton 465 (18.3) 201.2 (7.92) 1.3 : 1
DriveMaster)
570 high-mount, (Horton 465 (18.3) 201.2 (7.92) 1.3 : 1
DriveMaster)
466 high-mount, (Horton 465 (18.3) 219.4 (8.636) 1.2 : 1
DriveMaster)
466 high-mount, (Horton 465 (18.3) 219.4 (8.636) 0.99 : 1
DriveMaster)
466 mid-mount, (Horton 411 (16.2) 201.2 (7.92) 1.08 : 1
DriveMaster)
466 high-mount, (spin-on) 465 (18.3) 201.2 (7.92) 1.08 : 1

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436 APPENDIX A – SPECIFICATIONS

Table 63 Front Cover, Vibration Damper, Gerotor Oil Pump, Front Engine Mount, and Gear Train
Specifications (cont.)
570 high-mount, (spin-on) 465 (18.3) 201.2 (7.92) 1.3 : 1
466 mid-mount, (spin-on) 411 (16.2) 201.2 (7.92) 1.08 : 1
466 low-mount, (spin-on) 310 (12.2) 201.2 (7.92) 1.08 : 1
466 low-mount, Horton 310 (12.2) 201.2 (7.92) 1.08 : 1
DriveMaster)
570 low-mount, (spin-on) 310 (12.2) 201.2 (7.92) 1.3 : 1
570 low-mount, (Horton 310 (12.2) 201.2 (7.92) 1.3 : 1
DriveMaster)
466 low-mount, (bolt-on) 310 (12.2) 201.2 (7.92) 1.08 : 1
570 low-mount, (bolt-on) 310 (12.2) 201.2 (7.92) 1.3 : 1
NOTE: The high-mount and mid-mount fan drives share the same part number, however the fan drive is
inverted depending upon application.

Table 64 Oil Fill Specifications

Dry engine (after rebuild and new filter) 34 L (36 quarts US)
Wet engine (after oil drain and filter change) 28 L (30 quarts US)

Table 65 Connecting Rod Specifications

Bend (max.) 0.06 mm (0.003 in)
Center-to-center distance between connecting rod bearing bore and 219.4 - 219.5 mm (8.638 - 8.642 in)
piston pin bushing bore
Connecting rod bearing bore inside diameter 85.130 - 85.156 mm (3.3516 -
3.3526 in)
Connecting rod bearing inside diameter (installed) 80.05 - 80.10 mm (3.1518 - 3.1536
in)
Connecting rod bearing bore out-of-round (max.) 0.02 mm (0.00078 in)
Connecting rod bearing bore taper (max.) 0.02 mm (0.00078 in)
Connecting rod bearing running clearance 0.030 - 0.107 mm (0.0012 - 0.0042
in)
Connecting rod side clearance on crankshaft 0.13 - 0.48 mm (0.005 - 0.019 in)
Piston pin bushing inside diameter 46.393 - 46.401 mm (1.8265 -
1.8268 in)
Twist (max.) 0.05 mm (0.002 in)

Table 66 Piston Specifications

466 piston configuration
Piston material Aluminum alloy

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Table 66 Piston Specifications (cont.)

Piston rings
225 bhp and below Top ring - keystone cross section
Intermediate - rectangular cross
section
230 bhp and above Top ring - keystone cross section
Intermediate - keystone cross
section
570 piston configuration
Piston crown Steel crown, two-piece articulated
Piston skirt Aluminum alloy
Piston rings
All 570 series engines Top ring – keystone cross section
Intermediate – rectangular cross
section
466 and 570 piston specifications
Running clearance between piston and cylinder sleeve 466 piston: 0.076 - 0.128 mm
(0.0030 - 0.0050 in)
570 piston: 0.063 - 0.115 mm
(0.0025 - 0.0045 in)
Skirt diameter 466 piston: 116.44 - 116.49 mm
(4.584 - 4.586 in)
570 piston: 116.48 - 116.51 mm
(4.586 - 4.587 in)
Top compression ring groove width, 466 measure over 0.122 gauge 115.90 - 115.68 mm (4.563 -
pins 4.554 in)
Top compression ring groove width, 570 measure over 0.126 gauge 116.74 - 116.50 mm (4.596 -
pins 4.587 in)
Intermediate compression ring groove width (keystone shaped ring) 115.92 - 115.73 mm (4.564 -
measure over 0.110 gauge pins 4.556 in)
Intermediate compression ring groove width (rectangular shaped 3.05 - 3.03 mm (0.120 - 0.119 in)
ring), 466
Intermediate compression ring groove width (rectangular shaped 3.05 - 3.03 mm (0.120 - 0.119 in)
ring), 570
0.076 - 0.026 mm (0.0030 -
Oil control ring, side clearance, 466
0.0010 in)
0.080 - 0.030 mm (0.0031 -
Oil control ring, side clearance, 570
0.0012 in)

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438 APPENDIX A – SPECIFICATIONS

Table 67 Piston Ring Specifications

Intermediate compression ring end gap 1.65 - 1.90 mm (0.065 - 0.075 in)
Oil control ring end gap 0.35 - 0.66 mm (0.014 - 0.026 in)
Top compression ring end gap 0.35 - 0.66 mm (0.014 - 0.026 in)

Table 68 Piston Pin Specifications

Clearance in piston 466 piston: 0.0165 - 0.0292 mm (0.00065 -
0.00115 in)
0.035 - 0.048 mm (0.0014 - 0.0019 in)
570 skirt (vertical plane): 0.0165 - 0.0292 mm
(0.00065 - 0.00115 in)
570 skirt (horizontal plane): 0.0280 - 0.0574 mm
(0.00114 - 0.00226 in)
570 crown: 0.038 - 0.053 mm (0.0015 - 0.0021 in)
Diameter 46.352 - 46.357 mm (1.8249 - 1.8251 in)
Length 96.57 - 96.82 mm (3.802 - 3.812 in)

Table 69 Cylinder Sleeve Specifications

Allowable variation of counterbore depth between four points (max.) 0.03 mm (0.001 in)
Counterbore depth before adding shims (max.) 10.49 mm (0.413 in)
Counterbore depth (including shims- if any) 8.84 - 8.89 mm (0.348 - 0.350
in)
Cylinder sleeve protrusion 0.05 - 0.13 mm (0.002 - 0.005
in)
Cylinder sleeve taper, at top of ring travel (max.) 0.10 mm (0.004 in)
Flange thickness 8.94 - 8.96 mm (0.352 - 0.353
in)
Inside diameter 114.50 - 116.60 mm (4.590 -
4.591 in)

Table 70 Crankshaft Specifications

Type Steel forged, induction hardened, grindable
Main Bearing journal diameter
Standard size 107.95 ± 0.015 mm (4.250 ± 0.0006 in)
0.254 mm (0.010 in) undersized 107.70 ± 0.015 mm (4.240 ± 0.0006 in)
0.508 mm (0.020 in) undersized 107.44 ± 0.0152 mm (4.230 ± 0.0006 in)
0.762 mm (0.030 in) undersized 107.19 ± 0.0152 mm (4.220 ± 0.0006 in)
Damper mounting area runout (maximum) 0.03 mm (0.001 in)

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Table 70 Crankshaft Specifications (cont.)

Flywheel mounting surface runout (maximum) 0.05 mm (0.002 in)
Main bearing journal maximum out-of-round 0.05 mm (0.002 in)
Main bearing journal taper (maximum per inch) 0.071 mm (0.0028 in)
Main bearing thrust face runout (TIR maximum) 0.03 mm (0.001 in)
Main bearing width (except rear thrust) 34.19 ± 0.13 mm (1.346 ± 0.005 in)
Number of main bearings 7
Rear oil seal journal runout (maximum) 0.08 mm (0.003 in)
Thrust taken by No. 7 rear upper main bearing
Thrust bearing journal length 34.404 ± 0.038 mm (1.3545 ± 0.0015 in)
Connecting rod journal diameter
Standard Size 80.0 ± 0.0152 mm (3.1500 ± 0.0006 in)
0.0254 mm (0.010 in) undersized 79.7 ± 0.0152 mm (3.1400 ± 0.0006 in)
0.508 mm (0.020 in) undersized 79.5 ± 0.0152 mm (3.1300 ± 0.0006 in)
0.762 mm (0.030 in) undersized 79.2 ± 0.0152 mm (3.1200 ± 0.0006 in)
Center line of main bearing bore to head deck 368.3 ± 0.05 mm (14.50 ± 0.002 in)
Connecting rod bearing to crankshaft running 0.030 - 0.107 mm (0.0012 - 0.0042 in)
clearance
Connecting rod bearing width 40.01 mm (1.575 in)
Connecting rod journal maximum out-of-round 0.0064 mm (0.00025 in)
Connecting rod journal taper (maximum per inch) 0.0069 mm (0.00027 in)
Crankshaft end play 0.15-0.31 mm (0.006 - 0.012 in)
Crankshaft end play maximum wear limit 0.51 mm (0.020 in)
Crankshaft flange outside diameter 155.58 mm (6.125 in)
Crankshaft gear backlash 0.08-0.41 mm (0.003 - 0.016 in)
Main bearing to crankshaft running clearance 0.046 - 0.127 mm (0.0018 - 0.0050 in)
Connecting rod to crankshaft side clearance 0.30 ± 0.11 mm (0.012 ± 0.005 in)
Standard size to 0.51 mm (0.020 in) undersized 34.404 ± 0.03 mm (1.3545 ± 0.010 in)

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440 APPENDIX A – SPECIFICATIONS

Table 71 Crankcase Specifications

Cap attachment 2 bolts per cap
Coolant heater rating 1250 W, 120 V
Counterbore dimension in crankcase 8.865 ± 0.025 at 132 mm (0.349 ± 0.001
at 5.189 in)
Crankcase deck flatness 0.08 mm (0.003 in)
Cylinder sleeve counterbore maximum allowable depth 9.25 mm (0.364 in)
Main bearing type Precision replaceable
Material Steel-backed copper, lead, tin
Maximum allowable variation of counterbore depth (between 0.025 mm (0.001 in)
four points)
Piston cooling tube dia. (spray hole) DT 466 1.91 - 2.06 mm (0.075 - 0.081 in)
Piston cooling tube dia. (spray hole) DT 570, HT 570 2.26 - 2.41 mm (0.089 - 0.095 in)
Roller tappet outside diameter 28.435 - 28.448 mm (1.1195 -1.1200 in)
Sleeve protrusion above crankcase 0.05 - 0.13 mm (0.002 - 0.005 in)
Tappet bore diameter 28.51 - 28.55 mm (1.123 - 1.124 in)
Thrust taken by No. 7 rear upper main bearing
Camshaft
Bushing I.D. (installed) 58.03 - 58.12 mm (2.285 - 2.288 in)
Cam lobe lift, exhaust 6.91 mm (0.272 in)
Cam lobe lift, intake 6.68 mm (0.263 in)
Camshaft end play 0.18 - 0.33 mm (0.007 - 0.013 in)
Camshaft journal diameter 57.95 - 58.98 mm (2.282 - 2.283 in)
Camshaft radial clearance 0.05- 0.17 mm (0.002 - 0.007 in)
Maximum permissible cam lobe wear 0.25 mm (0.010 in)
Service bushings furnished to size Yes
Thrust plate thickness (new) 6.96 - 7.01 mm (0.274 - 0.276 in)
Camshaft Bushing Bore Diameter in Crankcase
Front 65.51 - 63.55 mm (2.501 - 2.502 in)
Intermediate front 63.01 - 63.04 mm (2.481 - 2.482 in)
Intermediate rear 63.01 - 63.04 mm (2.481 - 2.482 in)
Rear 65.51 - 63.55 mm (2.501 - 2.502 in)

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 APPENDIX A – SPECIFICATIONS 441

Table 72 Oil System Module and Secondary Filter Specifications

Cooler heat exchanger, DT 466 23 plates
Cooler heat exchanger, HT 570 33 plates
Cooler heat exchanger, all engines with front drive axle 33 plates
Oil pressure regulating valve, opening pressure 380 kPa (55 psi) @ 38° C (100° F)
Oil filter bypass valve, opening pressure 345 kPa (50 psi)
Oil thermal valve, opening temperature 111° C (232° F)

Table 73 Fuel System Specifications

Fuel heater switching points On: 2 °C (36 °F)
Off: 24 °C (75 °F)
Fuel pressure regulator assembly opening pressure 448 - 517 kPa (65-75 psi)
Fuel strainer 150 micron
High-pressure oil manifold, range 5 - 28 MPa (725 - 4,075 psi)

Table 74 Flywheel Resurfacing Specifications

Flat flywheel minimum thickness after resurfacing 36.32 mm (1.430 in)
Pot flywheel minimum thickness after resurfacing 39.37 mm (1.550 in)
Requires measurement from crankshaft mounting surface of flywheel to clutch surface of flywheel.

Table 75 Engine Brake Specifications

Brake actuator lash (cold) 0.48 mm (0.019 in)
Engine exhaust valve lash (cold) Refer to (Adjusting Valve
Lash, page150)

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© 2009 Navistar, Inc.
442 APPENDIX A – SPECIFICATIONS

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 APPENDIX B – TORQUES 443

Table of Contents

General Torque Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .445

.

Using a Torque Wrench Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .447

.

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .448

.

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444 APPENDIX B – TORQUES

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Follow all warnings, cautions, and notes.
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 APPENDIX B – TORQUES 445

General Torque Guidelines

CAUTION: To prevent engine damage, do not
substitute fasteners. Original equipment standard
hardware is defined as Class 10.9 metric or Grade 8
standard coarse thread bolts (Rockwell "C" 33-39),
all phosphate coated.
CAUTION: To prevent engine damage, do not use this
standard torque chart with other International brand
engines or engines made by other manufacturers.
The standard torque chart provides the tightening
values for general purpose applications using original
equipment standard hardware as listed in the Parts
Catalog for the application involved.

Table 76 Standard Torque Values – Class 10.9 Metric Flange Head Bolts and Studs
1
Thread Diameter (mm) Thread Pitch (mm) Torque
6 1 13 N·m (115 lbf·in)
8 1.25 31 N·m (23 lbf·ft)
10 1.5 62 N·m (45 lbf·ft)
12 1.75 107 N·m (79 lbf·ft)
14 2 172 N·m (127 lbf·ft)
15 2 216 N·m (159 lbf·ft)
16 2 266 N·m (196 lbf·ft)
18 2.5 368 N·m (272 lbf·ft)
20 2.5 520 N·m (384 lbf·ft)
1
Values listed are 80% of proof load.

Figure 655 Classification and Identification – Metric and Special Use Fasteners

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446 APPENDIX B – TORQUES

Many conditions affect torque and the results of Threads that are dry, excessively rough, battered or
torque applications. The major purpose in tightening a filled with dirt require considerable effort just to rotate.
fastener to a specified torque is to obtain tension in the Then when the clamping load is developed or the bolt
fastener (i.e., bolt, nut, etc.), which in turn develops tension is applied, the torque reading mounts rapidly
a clamping load which exceeds any possible loading (due to thread friction) to the specified torque value.
imposed on parts due to engine rpm or vibration. However, the desired bolt tension and maximum
clamping effect is not achieved. This condition can
Phosphate coated fasteners do not require oil
lead to failure of the fastener to maintain component
lubrication during assembly and torque application.
integrity. The proper bolt tension and clamping effect
Reused fasteners, even if originally phosphate
can never be attained if the fastener is dry. The
coated, do require a light film of engine oil lubrication
fastener threads must have a film of clean lubricant
to threads and under head area for proper torque
(engine oil) to be considered lubricated.
application.

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 APPENDIX B – TORQUES 447

Using a Torque Wrench Extension • LE – Length of extension

Occasionally the need will arise to use an extension, • LW – Length of torque wrench
crowfoot, or other type of adapter with your torque
• TE – Torque applied at fastener
wrench to torque a bolt or line fitting. Sometimes an
extension or adapter is necessary to reach a bolt in a • TW – Torque applied at end of torque wrench
hard to reach location. Adding adapters or extensions
• TS – Torque wrench setting
will alter the actual clamping force at the fastener. By
using the following formula you can determine what
the torque wrench setting should be to achieve the TS = TE (LW / (LW + LE)
known standard or special torque value.
Example:
A component has a known torque value of 88 N·m (65
lbf·ft) and an extension is required to reach it. What
will the torque wrench setting have to be in order to
compensate for the additional extension?

• Torque wrench = 12 inches

• Extension = 6 inches
TS = 65 lbf·ft (12 in / (12 in + 6 in)
Figure 656 Torque wrench extension TS = 65 lbf·ft (12 in / 18 in)
TS = 65 lbf·ft (0.666)
• F – Force applied by service technician TS = 43.3 lbf·ft or 58.9 N·m
• L – Length through which force is applied to
fastener

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448 APPENDIX B – TORQUES

Special Torque

Table 77 Engine Mounting Special Torques

Oil pan drain plug (M25) 68 N·m (50 lbf·ft)

Table 78 VGT Special Torques

VGT Spiralock® nuts (M10) 71 N·m (52 lbf·ft)

Table 79 Intake Manifold, Inlet and EGR Mixer, and Exhaust Manifold Special Torques
Exhaust manifold mounting torque and sequence. See “Exhaust manifold torque
sequence” (page 85).
Fuel assembly valve 15 N·m (132 lbf·in)
Intake manifold mounting bolts 40 N·m (30 lbf·ft)
Intake plug assembly 25 N·m (18 lbf·ft)

Table 80 EGR Cooler Special Torques

Constant tension EGR hose clamps (if equipped) 3.4 N·m (30 lbf·in)
EGR cooler mounting bracket lower bolt, M12 x 120 116 N·m (85 lbf·ft)
EGR cooler mounting bracket 116 N·m (85 lbf·ft)
EGR cooler supply tube retaining bolt 15-22 N·m (11.3-6.2
lbf·ft)

Table 81 Cylinder Head and Valve Train Special Torques

BCP sensor 20-30 N·m (15-22 lbf·ft)
Cylinder head mounting bolts torque and sequence
Fuel injector mounting bolt 41 N·m (30 lbf·ft)
High-pressure oil hose fitting 46 N·m (34 lbf·ft)
ICP sensor 20-30 N·m (15-22 lbf·ft)
Rocker arm bolts torque and sequence (Installing Rocker Arms, page148)
Valve adjustment locknut 27 N·m (20 lbf·ft)

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 APPENDIX B – TORQUES 449

Table 82 Front Cover, Vibration Damper, Gerotor Oil Pump, Front Engine Mount, and Gear Train
Special Torques
Automatic belt tensioner assembly 50 N·m (37 lbf·ft)
Damper retaining plate bolts 163 N·m (120 lbf·ft)
Retorque all bolts until no
movement
End cover adapter (PTO equipped engines only) 52 N·m (38 lbf·ft)
Fan drive, high-mount, Horton DriveMaster (20, 18.3 in.) 26 N·m (19 lbf·ft)
Fan drive, mid-mount, Horton DriveMaster (16.2 in.) 26 N·m (19 lbf·ft)
Fan drive, low-mount, Horton DriveMaster (12.2 in.) 26 N·m (19 lbf·ft)
Fan spacer retaining bolt, M10 x 20 (bolt-on drive only) 52 N·m (38 lbf·ft)
Front cover mounting bolts (rear half) 26 N·m (19 lbf·ft)
Front engine mounting bracket bolts (4) 386 N·m (284 lbf·ft)
Horton DriveMaster bearing retainer nut 177 N·m (130 lbf·ft)
Lower idler gear mounting bolt 639 N·m (470 lbf·ft)
Oil pump and rotor housing M8 bolts 25 N·m (18 lbf·ft)
Upper idler gear mounting bolt 326 N·m (240 lbf·ft)
Viscous or rubber vibration damper mounting bolts 54 N·m (40 lbf·ft)
Water outlet tube assembly at cylinder head 33 N·m (24 lbf·ft)
Water outlet tube assembly at front cover 33 N·m (24 lbf·ft)
Wear plate (water pump) 7 N·m (60 lbf·in)

Table 83 Oil Pan and Oil Suction Tube Special Torques

Oil pan drain plug 68 N·m (50 lbf·ft)
Oil heating element assembly (optional) 68 N·m (50 lbf·ft)
Oil pan heater plug 68 N·m (50 lbf·ft)
Oil pan mounting bolts 32 N·m (24 lbf·ft)
Oil suction tube bracket, M10 x 25 63 N·m (46 lbf·ft)
Oil suction tube, M8 x 35 27 N·m (20 lbf·ft)

Table 84 Power Cylinder Special Torque

Connecting rod bolts (verify connecting rod type) See Torque Procedures for
Connecting Rod with M12
Bolts (page241) or M11 Bolts
(page241).
Piston cooling tube bolts, M6 x 12 13 N·m (115 lbf·in)
Piston cooling tube bolts, M6 x 16 13 N·m (115 lbf·in)

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450 APPENDIX B – TORQUES

Table 85 Crankcase, Crankshaft and Camshaft Special Torques

Camshaft thrust plate bolts 26 N·m (19 lbf·ft)
Crankcase ladder, M12 x 35 122 N·m (90 lbf·ft)
Coolant heater bolt 4.5-5.1 N·m (40-45 lbf·in)
Crankcase ladder, M10 x 25 63 N·m (46 lbf·ft)
Crankshaft main bearing cap bolt torque and sequence (Torque Procedure for
Torque-to-Yield Main Bearing
Bolts, page271)

Table 86 Oil System Module and Secondary Filter Special Torques

Coolant drain plug, M18 24 N·m (18 lbf·ft)
Lube adapter bolts 29 N·m (21 lbf·ft)
Oil system module mounting bolts 26 N·m (19 lbf·ft)
Oil pressure regulator valve 68 N·m (50 lbf·ft)
Oil thermal valve assembly 29 N·m (21 lbf·ft)
Cooler heat exchanger mounting bolts, M8 29 N·m (21 lbf·ft)
Oil cooler drain tube bracket bolt 26 N·m (19 lbf·ft)
Oil supply tube fitting (turbocharger) 24-26 N·m (17-19
lbf·ft)
Plug assembly, M12 5 N·m (46 lbf·in)
Secondary filter mounting bolts 26 N·m (19 lbf·ft)
Secondary filter stud assembly 20 N·m (15 lbf·ft)

Table 87 Engine Electrical Special Torques

ECM / IDM mounting bolts (2), M8 x 45 20 N·m (15 lbf·ft)
ECM / IDM mounting stud bolts (2), M8 x 45/19 20 N·m (15 lbf·ft)
Engine coolant temperature (ECT) sensor 15-20 N·m (11-15 lbf·ft)
Engine oil pressure (EOP) sensor 9-14 N·m (79-124 lbf·in)
Engine oil temperature (EOT) sensor 15-20 N·m (11-15 lbf·ft)
Injection control pressure (ICP) sensor and Brake Control (BCP) sensor 20-30 N·m (15-22 lbf·ft)
Intake Manifold Air Pressure (MAP) sensor 10-20 N·m (88-176 lbf·in)
Intake Manifold Air Temperature (MAT) sensor 10-20 N·m (88-176 lbf·in)

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 APPENDIX B – TORQUES 451

Table 88 Fuel System Special Torques

Bolt, M8 x 20 29 N·m (21 lbf·ft)
Drain valve 0.5 - 1 N·m (5-10 lbf·in)
Elbow jam nut 88 N·m (65 lbf·ft)
End plug assembly (AWA) or attenuator 204 N·m (150 lbf·ft)
Fitting assembly, 3/8 tube 27 N·m (20 lbf·ft)
Fuel bowl 39 N·m (29 lbf·ft)
Fuel drain plug 24 N·m (18 lbf·ft)
Fuel fitting 27 N·m (20 lbf·ft)
Fuel filter header mounting bolts, M8 x 100 27 N·m (20 lbf·ft)
Fuel filter housing cover 25 N·m (18 lbf·ft)
Fuel pressure regulator 1-1.7 N·m (10-15 lbf·in)
Fuel valve assembly (air bleed and pressure test port) 15 N·m (132 lbf·in)
High-pressure oil hose fitting, M18 (at head) 54 N·m (40 lbf·ft)
High-pressure oil hose (swivel nuts) 46 N·m (34 lbf·ft)
High-pressure oil manifold bolts, M8 x 90 27 N·m (20 lbf·ft)
High-pressure oil pump assembly bolts 30 N·m (22 lbf·ft)
High-pressure oil pump assembly (gear) 231-279 N·m (170-205 lbf·ft)
Injector hold down clamp assembly 41 N·m (30 lbf·ft)
IPR valve assembly 50 N·m (37 lbf·ft)
Low-pressure fuel supply pump bolts, M6 x 16 15-18 N·m (132-160 lbf·in)
Low-pressure fuel pump tube coupling nuts 18 N·m (155 lbf·in)
Plug assembly, M12 (intake manifold fuel rail) 24 N·m (18 lbf·ft)
Post 8 N·m (72 lbf·in)
Self tapping screw 5 N·m (41 lbf·in)
Water In Fuel (WIF) sensor 1.7 N·m (15 lbf·in)

Table 89 Flywheel and Flywheel Housing Special Torques

Engine mounting bracket bolts 108 N·m (80 lbf·ft)
Flexplate mounting bolts 136 N·m (100 lbf·ft)
Flywheel housing mounting bolts 108 N·m (80 lbf·ft)
Flywheel mounting bolts 136 N·m (100 lbf·ft)
Rear engine mounting bracket bolts 108 N·m (80 lbf·ft)

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452 APPENDIX B – TORQUES

Table 90 Engine Brake Special Torques

Brake Control Pressure (BCP) sensor 20-30 N·m (15-22 lbf·ft)
Brake piston adjustment locknut 27 N·m (20 lbf·ft)
Brake shutoff solenoid Tinnermann nut 7-11 N·m (5-8 lbf·lb)
Brake shutoff valve 24-30 N·m (18-22 lbf·ft)
High-pressure oil rail bolts (M8 x 90) 27 N·m (20 lbf·ft)
Plug assembly, M10 12 N·m (108 lbf·in)
Plug assembly, M12 12 N·m (108 lbf·in)
Injection Control Pressure (ICP) sensor 20-30 N·m (15-22 lbf·ft)
Oil pressure relief valve 41-48 N·m (30-35 lbf·ft)
Rail End Plug Assembly or attenuator 204 N·m (150 lbf·ft)

Table 91 TF 550 and TF 750 Air Compressor and Power Steering Pump Special Torques
Air compressor gear nut 150 N·m (110 lbf·ft)
Air compressor mounting bolts (through front cover), M12 x 80 83 N·m (61 lbf·ft)
Bracket bolt to air compressor, M10 x 25 67 N·m (49 lbf·ft)
Bracket bolt to crankcase, M12 x 25 115 N·m (85 lbf·ft)
Elbow assembly, M10 15-16 N·m (132-141 lbf·in)
Elbow fitting assembly, M18 48 N·m (35 lbf·ft)
Hose connector assembly, M18 48 N·m (35 lbf·ft)
Power steering mounting bolts, M10 x 35 57 N·m (42 lbf·ft)
Power steering pump drive nut 90 N·m (66 lbf·ft)

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 APPENDIX C – SPECIAL SERVICE TOOLS 453

Table of Contents

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .455
.

Photos of Essential Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .459

.

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454 APPENDIX C – SPECIAL SERVICE TOOLS

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© 2009 Navistar, Inc.
 APPENDIX C – SPECIAL SERVICE TOOLS 455

Description
Special service tools for the DT 466, DT 570 and
HT 570 series engines can be ordered from the SPX
Corporation, 1-800-520-2584.
NOTE: The following sections of the manual do not
require any special tools for service work:
• Intake, Inlet, and Exhaust Manifolds
• Oil Pan and Oil Suction Tube
• Engine Electrical
• Air Compressor and Power Steering Pump

Table 92 Special Tools

Engine mounting plate ZTSE4649
Engine stand OTC1750A

Table 93 EGR System Special Service Tools

EGR cooler pressure test plates ZTSE4636

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456 APPENDIX C – SPECIAL SERVICE TOOLS

Table 94 Cylinder Head Special Service Tools

Cylinder head test plate ZTSE4289A
Dye penetrant kit Obtain locally
Feeler gauge Obtain locally
Head bolt thread gauge ZTSE4667
Injector sleeve brush set (set of 2) ZTSE4304
Injector sleeve installer ZTSE4642
Injector sleeve remover ZTSE4643
Pressure regulator Obtain locally
Slide hammer puller set ZTSE1879
Small hole gauge set Obtain locally
Straightedge Obtain locally
Thermostat opening pressure adapter ZTSE4647
Valve guide deburring tool ZTSE4393
Valve guide installer ZTSE1943
Valve guide remover ZTSE4377
Valve seat extractor kit (universal) ZTSE1951C
Valve seat grinder ZTSE1631A
Valve seat grinding stones 45° (exhaust) Obtain locally
Valve seat grinding stones 60° (intake) Obtain locally
Valve seat installer ZTSE4641
Valve seat remover (collet) ZTSE4640
Valve spring compressor ZTSE1846
Valve spring compressor jaws ZTSE4652
Water supply housing pressure adapter ZTSE4648

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 APPENDIX C – SPECIAL SERVICE TOOLS 457

Table 95 Front Cover, Vibration Damper, Gerotor Oil Pump, Front Engine Mounts, and Gear Train
Special Service Tools
Dial indicator set Obtain locally
Feeler gauge Obtain locally
Front seal and wear sleeve installer ZTSE3004B
H-bar Obtain locally
Hot plate Obtain locally
Loctite® 569 Hydraulic Sealant Obtain locally
Lower Idler Gear Socket ZTSE4383
Slide hammer puller set ZTSE1879
Straightedge Obtain locally
Thermo-melt crayon, 100 °C (212 °F) Obtain locally
16 mm 12 point impact socket Obtain locally

Table 96 Oil Pan and Oil Suction Tube

Wacker T – 442 RTV sealant Obtain locally

Table 97 Piston, Piston Ring, and Connecting Rod Special Service Tools
Counterbore cutting head ZTSE25144A
Cylinder bore gauge Obtain locally
Cylinder sleeve counterbore tool kit ZTSE2514
Cylinder sleeve holding adapters (set of 3) ZTSE4672
Cylinder sleeve puller ZTSE2536
Dial indicator set Obtain locally
EGR water coolant supply plate ZTSE4648
Piston ring compressor tool ZTSE4396
Piston ring expander Obtain locally
Piston ring gauge pins (set of 3) ZTSE4653
Telescoping gauge set Obtain locally

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458 APPENDIX C – SPECIAL SERVICE TOOLS

Table 98 Crankcase, Crankshaft and Camshaft Special Service Tools

Cam gear puller ZTSE4411
Camshaft bushing puller ZTSE2893B
Hot plate Obtain locally
Nylon brush ZTSE4389
Tap, cylinder head bolt holes ZTSE4671
Tap set ZTSE4386
Stiff nylon brush ZTSE4392

Table 99 Oil System Module and Secondary Filter Special Tools

Air Pressure Regulator Obtain locally
Oil CoolerTest Plate ZTSE4654
Oil Filter Wrench ZTSE1879
Slide Hammer Puller Set Obtain locally

Table 100 Fuel System Special Service Tools

Cap kit, injectors ZTSE4660
Fuel injector rack cups ZTSE4645
Fuel injector remover tool (#40 Torx®) ZTSE4524
IPR removal / installation tool ZTSE4666
Loctite® 246 Threadlocker Obtain locally

Table 101 Flywheel and Flywheel Housing Special Service Tools

Crankshaft timing disk puller (H-bar) Obtain locally
Dial indicator with magnetic base Obtain locally
Guide pins Obtain locally
Rear seal installer ZTSE4637
Slide hammer puller set ZTSE1879

Table 102 Engine Brake Special Service Tools

Feeler gauge (long) Obtain locally

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 APPENDIX C – SPECIAL SERVICE TOOLS 459

Photos of Essential Tools

Figure 660 Valve seat installer, ZTSE4641

Figure 657 EGR cooler pressure test plates,

ZTSE4636

Figure 661 Injector sleeve installer, ZTSE4642

Figure 658 Rear seal installer, ZTSE4637

Figure 662 Injector sleeve remover, ZTSE4643

Figure 659 Valve seat remover (collet),

ZTSE4640

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460 APPENDIX C – SPECIAL SERVICE TOOLS

Figure 665 Water supply housing pressure

adapter-cylinder head, ZTSE4648

Figure 663 Injector rack – ZTSE4299B, Injector

rack cups – ZTSE4645

Figure 666 Engine mounting plate, ZTSE4649

Figure 664 Thermostat opening pressure

adapter– cylinder head, ZTSE4647

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 APPENDIX C – SPECIAL SERVICE TOOLS 461

Figure 667 Valve spring compressor jaws,

ZTSE4652

Figure 669 Oil cooler test plate, ZTSE4654

Figure 670 Head bolt and main bolt thread

gauge, ZTSE4667

Figure 668 Piston gauge pins (set of three),

ZTSE4653

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462 APPENDIX C – SPECIAL SERVICE TOOLS

Figure 671 Head bolt bottoming tap, ZTSE4671

Figure 673 Cap kit– Injector, ZTSE4660

Figure 674 IPR valve removal and installation

tool, ZTSE4666

Figure 672 Sleeve protrusion hold down clamps,

ZTSE4672

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 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) 463
BULLETINS

Table of Contents

TSI-05-12-28 New High-pressure Oil Rails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .465

.

TSI-05-12-35 New 1500 Watt Single Grid Intake Air Heater Production Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .466
.

TSI-06-12-15 Sensor O-ring Kit for CMP or CKP Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .468

.

TSI-06-12-14 Update Valve Train Components – Push Rod and Tappet Compatibility. . . . . . . . . . . . . . . . . . . . .469
.

TSI-06-12-21 Update Valve Train Components – Adjuster Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .474

.

TSI-06-12-27 New Piston and Piston Ring Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .475

.

TSI-07-12-12 EGR Coolant Return Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .477

.

TSI-08-12-20 Rubber Vibration Damper Replacement Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .480

.

TSI-09-12-02 High-pressure Pump Assembly Inlet Filter Service Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .483

.

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© 2009 Navistar, Inc.
464 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI)
BULLETINS

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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) 465
BULLETINS

TSI-05-12-28 New High-pressure Oil Rails

EGES-265-2
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Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
466 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.
 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) 467
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.
468 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.
 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) 469
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.
470 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.
 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) 471
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.
472 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.
 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) 473
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.
474 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.
 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) 475
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.
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.
 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) 477
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.
478 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.
 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) 479
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.
480 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.
 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) 481
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.
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.
 APPENDIX D – TECHNICAL SERVICE INFORMATION (TSI) 483
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.
484 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.
 APPENDIX E – INSTRUCTION SHEETS 485

Table of Contents

1171813R1 Front Cover PTO Adaptation Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .487

.

1171836R1 Air Compressor Bracket Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .489

.

1171846R1 Aluminum Air Inlet Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .492

.

1171848R1 300 Watt Oil Pan Heater Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .495

.

1171855R1 Turbo Actuator Service Kit (SRA). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .497

.

1171908R1 Turbocharger VGT Linkage Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .499

.

1171913R1 Turbine Vane Assembly Cleaning Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .503

.

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.
486 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.
 APPENDIX E – INSTRUCTION SHEETS 487

1171813R1 Front Cover PTO Adaptation

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.
488 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.
 APPENDIX E – INSTRUCTION SHEETS 489

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.
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.
 APPENDIX E – INSTRUCTION SHEETS 491

EGES-265-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
492 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.
 APPENDIX E – INSTRUCTION SHEETS 493

EGES-265-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
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.
 APPENDIX E – INSTRUCTION SHEETS 495

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.
496 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.
 APPENDIX E – INSTRUCTION SHEETS 497

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.
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.
 APPENDIX E – INSTRUCTION SHEETS 499

1171908R1 Turbocharger VGT Linkage

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.
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.
 APPENDIX E – INSTRUCTION SHEETS 501

EGES-265-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
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.
 APPENDIX E – INSTRUCTION SHEETS 503

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.
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.
 APPENDIX E – INSTRUCTION SHEETS 505

EGES-265-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
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.
 APPENDIX E – INSTRUCTION SHEETS 507

EGES-265-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
508 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.
 APPENDIX E – INSTRUCTION SHEETS 509

EGES-265-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
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.
 APPENDIX E – INSTRUCTION SHEETS 511

EGES-265-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
512 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.
 APPENDIX E – INSTRUCTION SHEETS 513

EGES-265-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2009 Navistar, Inc.
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.
Printed in the United States of America