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Table of Contents
- 3. Table of Contents
- 5. Foreword
- 6. Service Diagnosis
- 7. Safety Information
- 9. Engine Systems
- 11. Engine Identification
- 12. Engine Emission Label
- 13. Engine Description
- 16. Engine Component Locations
- 22. Engine Systems
- 23. Air Management System
- 24. Charge Air Cooler (CAC)
- 25. Variable Geometry Turbocharger (VGT)
- 27. Exhaust Gas Recirculation (EGR) System
- 28. Exhaust System
- 29. Fuel Management System
- 30. Injection Control Pressure (ICP) System ...
- 33. Fuel Injectors
- 37. Fuel Supply System
- 38. Fuel Flow Schematic
- 41. Engine Lubrication System
- 44. Cooling System
- 47. Electronic Control System
- 49. Injection Drive Module (IDM)
- 51. Engine and Vehicle Sensors
- 57. Diamond Logic® Engine Brake System
- 58. Engine Brake Control
- 60. Operation of Diamond Logic® Engine Brake...
- 63. Mounting Engine on Engine Stand
- 65. Engine Preparation
- 66. Component Removal
- 67. Oil Filter
- 68. Engine
- 69. Special Torque
- 71. EVRT® Electronically Controlled Turbocha...
- 73. Description
- 75. Removal
- 76. Cleaning
- 77. Inspection
- 79. Specifications
- 81. Intake, Inlet, and Exhaust Manifolds
- 84. Removal
- 85. Inlet and EGR Mixer Duct
- 86. Aluminum Air Inlet Adapter and Inlet Air...
- 87. Cleaning and Inspection
- 88. Installation
- 90. Intake Manifold
- 91. Inlet and EGR Mixer Duct
- 93. Specifications
- 95. EGR Cooler and Tubing
- 97. Description
- 98. EGR System Components (Beginning Model Y...
- 102. Cleaning EGR System Components
- 103. Installation EGR System Components
- 107. Modification 1 - Deeper O-ring Location i...
- 112. Modification 2 - EGR Coolant Return Tube ...
- 114. Modification 3 - Round EGR Cooler and EGR...
- 115. Installation
- 116. EGR Coolant Return Kits (Conversion from...
- 118. Special Torque
- 119. Cylinder Head and Valve Train
- 121. Description
- 124. Removal
- 125. Removing Rocker Arm Assembly
- 126. Measuring Camshaft Lift
- 127. Removing Rocker Arms
- 128. Roller Tappets
- 129. Cleaning
- 130. Rocker Arms
- 131. Cylinder Head Warpage
- 132. Cylinder Head Cracking
- 133. Pressure Check Cylinder Head
- 134. Reconditioning
- 135. Replacing Valve Guides
- 136. Inspecting Valves
- 137. Valve Stem Tip
- 138. Checking Valve Face-to-Valve Seat Contac...
- 139. Resurfacing Valve Seats
- 140. Replacing Valve Seats
- 142. Installation
- 143. Inspecting Valve Springs
- 144. Inspecting Valve Rotators
- 145. Inspecting Valve Spring Retainer Keys
- 146. Installing Valves
- 148. Installation
- 150. Torque-to-Yield Procedure for Cylinder H...
- 152. Valve Train Components
- 153. Installing the Rocker Arm Assembly
- 154. Valve Lash for Intake and Exhaust Valves
- 156. High-pressure Oil Rail Assembly
- 158. Specifications
- 159. Special Torque
- 160. Special Service Tools
- 161. Front Cover and Related Components
- 163. Description
- 166. Checking Gear Train Timing without Remov...
- 167. DT 570 and HT 570 Engines Only
- 168. Removal
- 169. Flat Idler Pulley and Automatic Belt Ten...
- 170. Fan Drive Hub
- 171. Water Pump Assembly
- 172. Vibration Damper, Damper Hub, and Wear S...
- 173. Gerotor Assembly Oil Pump and Front Oil ...
- 175. Front Engine Mount
- 176. Front Cover (Front Half)
- 177. Generation 2 (Mounting Bolts)
- 178. Idler Gears
- 180. Front Cover (Rear Half)
- 181. Inspection
- 182. Checking Camshaft Gear Backlash
- 183. Measuring Oil Pump End Clearance
- 184. Installation
- 185. Mounting Bolts (Rear Half)
- 186. Idler Gears
- 188. Front Cover (Front Half)
- 189. Generation 1 (Mounting Bolts)
- 190. Generation 2 (Mounting Bolts)
- 191. Front Engine Mount
- 194. POSE Dust Seal and Wear Sleeve
- 195. Vibration Damper Hub and Damper Retainin...
- 196. Vibration Damper assembly
- 197. Fan Drive
- 199. Horton DriveMaster
- 200. Water Pump Assembly
- 201. Water Supply Housing
- 202. Flat Idler Pulley and Automatic Belt Ten...
- 204. Specifications
- 205. Special Torque
- 206. Special Service Tools
- 207. Oil Pan and Oil Suction Tube
- 210. Removal
- 211. Removing the Oil Suction Tube
- 212. Cleaning and Inspection
- 213. Installing the Oil Pan
- 214. Watt Oil Pan Heater (Optional)
- 215. Specifications
- 217. Power Cylinders
- 219. Description
- 221. Removal
- 222. New Piston Cooling Tubes
- 223. Disassembling Piston and Connecting Rod ...
- 224. Cylinder Sleeve Removal
- 225. Cleaning
- 226. Top and Intermediate Compression Ring Gr...
- 227. Piston-to-Cylinder Sleeve Running Cleara...
- 228. Piston Pins
- 229. Connecting Rod Bearing Bore
- 230. Bearing Running Clearance
- 231. Connecting Rod Side Clearance
- 233. Checking Counterbore Depth
- 236. Reconditioning
- 238. Installation
- 239. Assembling Piston and Connecting Rod Ass...
- 241. Installing Piston and Connecting Rod Ass...
- 245. Torque Procedure for Connecting Rods wit...
- 246. Piston Cooling Tubes
- 253. Crankcase, Crankshaft, and Camshaft
- 257. Removal
- 259. Oil Level Gauge
- 260. Crankcase Ladder (DT 466 series - 225 hp...
- 261. Cam Gear from Camshaft
- 262. Camshaft Disassembly
- 263. Camshaft Bushings
- 264. Coolant Heater (if equipped)
- 265. Cleaning and Inspection
- 266. Crankshaft and Main Bearings
- 267. Checking Camshaft Lobes and Journals
- 270. Camshaft Assembly
- 271. Cam Gear on Camshaft
- 272. Crankshaft Assembly
- 273. Bearing Fitting Procedure
- 274. Main Bearings and Caps
- 275. Torque Procedure for Torque-to-Yield Mai...
- 276. Crankcase Ladder (DT 466 series - 225 hp...
- 278. Oil Level Gauge
- 280. Specifications
- 282. Special Torque
- 283. Oil System Module Assembly and Secondary...
- 287. Removal
- 290. Secondary Filtration Assembly
- 291. Disassembling the Oil System Module
- 293. Disassembling the Secondary Filtration F...
- 294. Cleaning and Inspection
- 296. Internal
- 297. Installation
- 299. Assembling the Secondary Filtration Filt...
- 300. Secondary Filtration Assembly
- 302. Priming the Lubrication System
- 303. Specifications
- 305. Engine Electrical
- 307. Sensor Identification
- 310. Removal
- 316. Injector Wiring Harness
- 317. ECM, IDM, EGR Drive Module, and Intake A...
- 321. Valve Cover Gasket with Pass-Through Con...
- 323. Cleaning and Inspection
- 324. Installation
- 325. ECM, IDM, EGR Drive Module, and Intake A...
- 331. Injector Wiring Harness
- 332. Sensor Wiring Harness
- 339. Fuel System
- 341. Description
- 342. High-pressure Oil System
- 344. Periodic Service
- 345. Fuel Filter
- 346. Removal
- 347. Fuel Filter Header Assembly and Intake M...
- 349. High-pressure Hose Assembly - Generation...
- 350. High-pressure Pump and IPR Valve
- 352. Fuel Injector Assemblies
- 354. Disassembly
- 356. Installation
- 357. High-pressure Oil Rail Assembly
- 360. High-pressure Oil Pump and IPR Valve Ass...
- 361. High-pressure Hose Assembly - Generation...
- 363. Fuel Filter Header Assembly and Intake M...
- 364. Low-pressure Fuel Supply Pump and Tubing
- 366. Priming Fuel System after Out of Fuel
- 367. Specifications
- 368. Special Service Tools
- 369. Flywheel and Flywheel Housing
- 371. Description
- 373. Flywheel and Flexplate Applications
- 376. Automatic Transmissions
- 379. Removal
- 380. Flexplate (Automatic Transmissions)
- 382. Inspection
- 383. Removing Flywheel Housing
- 384. Ring Gear Replacement
- 385. Rear Oil Seal
- 386. Crankshaft Timing Disk
- 387. Flywheel Assembly
- 388. Checking Flywheel Surface Runout
- 389. MD-3000 and HD-4000 Series World Transmi...
- 390. Specifications
- 391. Special Torque
- 393. Diamond Logic® Engine Brake
- 396. Periodic Service
- 398. Reconditioning
- 399. Brake Shutoff Valve
- 400. BCP Sensor
- 401. M12 Plug assembly
- 403. Removal
- 404. High-pressure Oil Rail
- 405. Installation
- 407. Electrical Connections
- 409. Specifications
- 411. Air Compressor, Power Steering Pump, and...
- 413. Description
- 414. Air Compressor
- 415. Power Steering Pump
- 416. Power Steering Pump with Air Compressor
- 418. Power Steering Pump without Air Compress...
- 419. Special Torques
- 421. Abbreviations and Acronyms
- 425. Terminology
- 435. Appendix A - Specifications
- 447. Appendix B - Torques
- 469. TSI-05-12-28 New High-pressure Oil Rails
- 470. TSI-05-12-35 New 1500 Watt Single Grid I...
- 472. TSI-06-12-15 Sensor O-ring Kit for CMP o...
- 473. TSI-06-12-14 Update Valve Train Componen...
- 478. TSI-06-12-21 Update Valve Train Componen...
- 479. TSI-06-12-27 New Piston and Piston Ring ...
- 481. TSI-07-12-12 EGR Coolant Return Kit
- 484. TSI-08-12-20 Rubber Vibration Damper Rep...
- 487. TSI-09-12-02 High-pressure Pump Assembly...
- 491. 1171813R1 Front Cover PTO Adaptation Kit
- 493. 1171836R1 Air Compressor Bracket Kit
- 496. 1171846R1 Aluminum Air Inlet Adapter
- 499. 1171848R1 300 Watt Oil Pan Heater Kit
- 501. 1171855R1 Turbo Actuator Service Kit (SR...
- 503. 1171908R1 Turbocharger VGT Linkage Kit
- 507. 1171913R1 Turbine Vane Assembly Cleaning...
- 512. 1171915R2 Turbocharger Actuator Flange a...
Page 1 of 520
Table of Contents
- 3. Table of Contents
- 5. Foreword
- 6. Service Diagnosis
- 7. Safety Information
- 9. Engine Systems
- 11. Engine Identification
- 12. Engine Emission Label
- 13. Engine Description
- 16. Engine Component Locations
- 22. Engine Systems
- 23. Air Management System
- 24. Charge Air Cooler (CAC)
- 25. Variable Geometry Turbocharger (VGT)
- 27. Exhaust Gas Recirculation (EGR) System
- 28. Exhaust System
- 29. Fuel Management System
- 30. Injection Control Pressure (ICP) System ...
- 33. Fuel Injectors
- 37. Fuel Supply System
- 38. Fuel Flow Schematic
- 41. Engine Lubrication System
- 44. Cooling System
- 47. Electronic Control System
- 49. Injection Drive Module (IDM)
- 51. Engine and Vehicle Sensors
- 57. Diamond Logic® Engine Brake System
- 58. Engine Brake Control
- 60. Operation of Diamond Logic® Engine Brake...
- 63. Mounting Engine on Engine Stand
- 65. Engine Preparation
- 66. Component Removal
- 67. Oil Filter
- 68. Engine
- 69. Special Torque
- 71. EVRT® Electronically Controlled Turbocha...
- 73. Description
- 75. Removal
- 76. Cleaning
- 77. Inspection
- 79. Specifications
- 81. Intake, Inlet, and Exhaust Manifolds
- 84. Removal
- 85. Inlet and EGR Mixer Duct
- 86. Aluminum Air Inlet Adapter and Inlet Air...
- 87. Cleaning and Inspection
- 88. Installation
- 90. Intake Manifold
- 91. Inlet and EGR Mixer Duct
- 93. Specifications
- 95. EGR Cooler and Tubing
- 97. Description
- 98. EGR System Components (Beginning Model Y...
- 102. Cleaning EGR System Components
- 103. Installation EGR System Components
- 107. Modification 1 - Deeper O-ring Location i...
- 112. Modification 2 - EGR Coolant Return Tube ...
- 114. Modification 3 - Round EGR Cooler and EGR...
- 115. Installation
- 116. EGR Coolant Return Kits (Conversion from...
- 118. Special Torque
- 119. Cylinder Head and Valve Train
- 121. Description
- 124. Removal
- 125. Removing Rocker Arm Assembly
- 126. Measuring Camshaft Lift
- 127. Removing Rocker Arms
- 128. Roller Tappets
- 129. Cleaning
- 130. Rocker Arms
- 131. Cylinder Head Warpage
- 132. Cylinder Head Cracking
- 133. Pressure Check Cylinder Head
- 134. Reconditioning
- 135. Replacing Valve Guides
- 136. Inspecting Valves
- 137. Valve Stem Tip
- 138. Checking Valve Face-to-Valve Seat Contac...
- 139. Resurfacing Valve Seats
- 140. Replacing Valve Seats
- 142. Installation
- 143. Inspecting Valve Springs
- 144. Inspecting Valve Rotators
- 145. Inspecting Valve Spring Retainer Keys
- 146. Installing Valves
- 148. Installation
- 150. Torque-to-Yield Procedure for Cylinder H...
- 152. Valve Train Components
- 153. Installing the Rocker Arm Assembly
- 154. Valve Lash for Intake and Exhaust Valves
- 156. High-pressure Oil Rail Assembly
- 158. Specifications
- 159. Special Torque
- 160. Special Service Tools
- 161. Front Cover and Related Components
- 163. Description
- 166. Checking Gear Train Timing without Remov...
- 167. DT 570 and HT 570 Engines Only
- 168. Removal
- 169. Flat Idler Pulley and Automatic Belt Ten...
- 170. Fan Drive Hub
- 171. Water Pump Assembly
- 172. Vibration Damper, Damper Hub, and Wear S...
- 173. Gerotor Assembly Oil Pump and Front Oil ...
- 175. Front Engine Mount
- 176. Front Cover (Front Half)
- 177. Generation 2 (Mounting Bolts)
- 178. Idler Gears
- 180. Front Cover (Rear Half)
- 181. Inspection
- 182. Checking Camshaft Gear Backlash
- 183. Measuring Oil Pump End Clearance
- 184. Installation
- 185. Mounting Bolts (Rear Half)
- 186. Idler Gears
- 188. Front Cover (Front Half)
- 189. Generation 1 (Mounting Bolts)
- 190. Generation 2 (Mounting Bolts)
- 191. Front Engine Mount
- 194. POSE Dust Seal and Wear Sleeve
- 195. Vibration Damper Hub and Damper Retainin...
- 196. Vibration Damper assembly
- 197. Fan Drive
- 199. Horton DriveMaster
- 200. Water Pump Assembly
- 201. Water Supply Housing
- 202. Flat Idler Pulley and Automatic Belt Ten...
- 204. Specifications
- 205. Special Torque
- 206. Special Service Tools
- 207. Oil Pan and Oil Suction Tube
- 210. Removal
- 211. Removing the Oil Suction Tube
- 212. Cleaning and Inspection
- 213. Installing the Oil Pan
- 214. Watt Oil Pan Heater (Optional)
- 215. Specifications
- 217. Power Cylinders
- 219. Description
- 221. Removal
- 222. New Piston Cooling Tubes
- 223. Disassembling Piston and Connecting Rod ...
- 224. Cylinder Sleeve Removal
- 225. Cleaning
- 226. Top and Intermediate Compression Ring Gr...
- 227. Piston-to-Cylinder Sleeve Running Cleara...
- 228. Piston Pins
- 229. Connecting Rod Bearing Bore
- 230. Bearing Running Clearance
- 231. Connecting Rod Side Clearance
- 233. Checking Counterbore Depth
- 236. Reconditioning
- 238. Installation
- 239. Assembling Piston and Connecting Rod Ass...
- 241. Installing Piston and Connecting Rod Ass...
- 245. Torque Procedure for Connecting Rods wit...
- 246. Piston Cooling Tubes
- 253. Crankcase, Crankshaft, and Camshaft
- 257. Removal
- 259. Oil Level Gauge
- 260. Crankcase Ladder (DT 466 series - 225 hp...
- 261. Cam Gear from Camshaft
- 262. Camshaft Disassembly
- 263. Camshaft Bushings
- 264. Coolant Heater (if equipped)
- 265. Cleaning and Inspection
- 266. Crankshaft and Main Bearings
- 267. Checking Camshaft Lobes and Journals
- 270. Camshaft Assembly
- 271. Cam Gear on Camshaft
- 272. Crankshaft Assembly
- 273. Bearing Fitting Procedure
- 274. Main Bearings and Caps
- 275. Torque Procedure for Torque-to-Yield Mai...
- 276. Crankcase Ladder (DT 466 series - 225 hp...
- 278. Oil Level Gauge
- 280. Specifications
- 282. Special Torque
- 283. Oil System Module Assembly and Secondary...
- 287. Removal
- 290. Secondary Filtration Assembly
- 291. Disassembling the Oil System Module
- 293. Disassembling the Secondary Filtration F...
- 294. Cleaning and Inspection
- 296. Internal
- 297. Installation
- 299. Assembling the Secondary Filtration Filt...
- 300. Secondary Filtration Assembly
- 302. Priming the Lubrication System
- 303. Specifications
- 305. Engine Electrical
- 307. Sensor Identification
- 310. Removal
- 316. Injector Wiring Harness
- 317. ECM, IDM, EGR Drive Module, and Intake A...
- 321. Valve Cover Gasket with Pass-Through Con...
- 323. Cleaning and Inspection
- 324. Installation
- 325. ECM, IDM, EGR Drive Module, and Intake A...
- 331. Injector Wiring Harness
- 332. Sensor Wiring Harness
- 339. Fuel System
- 341. Description
- 342. High-pressure Oil System
- 344. Periodic Service
- 345. Fuel Filter
- 346. Removal
- 347. Fuel Filter Header Assembly and Intake M...
- 349. High-pressure Hose Assembly - Generation...
- 350. High-pressure Pump and IPR Valve
- 352. Fuel Injector Assemblies
- 354. Disassembly
- 356. Installation
- 357. High-pressure Oil Rail Assembly
- 360. High-pressure Oil Pump and IPR Valve Ass...
- 361. High-pressure Hose Assembly - Generation...
- 363. Fuel Filter Header Assembly and Intake M...
- 364. Low-pressure Fuel Supply Pump and Tubing
- 366. Priming Fuel System after Out of Fuel
- 367. Specifications
- 368. Special Service Tools
- 369. Flywheel and Flywheel Housing
- 371. Description
- 373. Flywheel and Flexplate Applications
- 376. Automatic Transmissions
- 379. Removal
- 380. Flexplate (Automatic Transmissions)
- 382. Inspection
- 383. Removing Flywheel Housing
- 384. Ring Gear Replacement
- 385. Rear Oil Seal
- 386. Crankshaft Timing Disk
- 387. Flywheel Assembly
- 388. Checking Flywheel Surface Runout
- 389. MD-3000 and HD-4000 Series World Transmi...
- 390. Specifications
- 391. Special Torque
- 393. Diamond Logic® Engine Brake
- 396. Periodic Service
- 398. Reconditioning
- 399. Brake Shutoff Valve
- 400. BCP Sensor
- 401. M12 Plug assembly
- 403. Removal
- 404. High-pressure Oil Rail
- 405. Installation
- 407. Electrical Connections
- 409. Specifications
- 411. Air Compressor, Power Steering Pump, and...
- 413. Description
- 414. Air Compressor
- 415. Power Steering Pump
- 416. Power Steering Pump with Air Compressor
- 418. Power Steering Pump without Air Compress...
- 419. Special Torques
- 421. Abbreviations and Acronyms
- 425. Terminology
- 435. Appendix A - Specifications
- 447. Appendix B - Torques
- 469. TSI-05-12-28 New High-pressure Oil Rails
- 470. TSI-05-12-35 New 1500 Watt Single Grid I...
- 472. TSI-06-12-15 Sensor O-ring Kit for CMP o...
- 473. TSI-06-12-14 Update Valve Train Componen...
- 478. TSI-06-12-21 Update Valve Train Componen...
- 479. TSI-06-12-27 New Piston and Piston Ring ...
- 481. TSI-07-12-12 EGR Coolant Return Kit
- 484. TSI-08-12-20 Rubber Vibration Damper Rep...
- 487. TSI-09-12-02 High-pressure Pump Assembly...
- 491. 1171813R1 Front Cover PTO Adaptation Kit
- 493. 1171836R1 Air Compressor Bracket Kit
- 496. 1171846R1 Aluminum Air Inlet Adapter
- 499. 1171848R1 300 Watt Oil Pan Heater Kit
- 501. 1171855R1 Turbo Actuator Service Kit (SR...
- 503. 1171908R1 Turbocharger VGT Linkage Kit
- 507. 1171913R1 Turbine Vane Assembly Cleaning...
- 512. 1171915R2 Turbocharger Actuator Flange a...
Also for: INTERNATIONAL DT 570, INTERNATIONAL HT 570
File size: 22.42 MB
Created: March 11, 2023
Last updated: April 13, 2023
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