International DT 466, DT 570 and HT 570 Turbo Repair

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1 A NAVISTAR COMPANY International DT 466, DT 570 and HT 570 Turbo Repair Study Guide TMT Study Guide International DT 466, DT 570 and HT 570 Turbo Repair TMT

2 2010 Navistar, Inc Winfield Road, Warrenville, IL All rights reserved. No part of this publication may be duplicated or stored in an information retrieval system without the express written permission of Navistar, Inc.

3 Table of Contents Introduction...3 Module 1: Disassembly...5 Module 2: Assembly...9 Conclusion...15

4 2 International DT 466, DT 570 and HT 570 Turbo Repair

5 Introduction 3 Introduction Welcome to the International DT 466, DT 570 and HT 570 turbocharger actuator flange, pivot shaft, and turbine housing replacement program. Objectives Upon completion of this program you should be able to identify all the parts of the turbocharger assembly and replace the turbine housing. The procedures discussed in this program apply to 2004 through 2006 model-year International DT 466, DT 570, and HT 570 Diesel Engines. Before demonstrating the procedures, let s locate and identify the components to be removed or replaced. They include the Actuator linkage with forks, Actuator shaft, Actuator, Serrated locknuts, Actuator flange, Fork lever bolts, Nord-Lock washer assembly, compressor housing, center section, center section bolts, and turbine housing.

6 4 International DT 466, DT 570 and HT 570 Turbo Repair NOTES

7 Module 1: Disassembly 5 Disassembly Module 1 Remove the turbocharger assembly, and set it on a clean workbench. Refer to the Engine Service Manual EGES on ISIS for turbocharger removal procedures. Remove the bolt and Nord-Lock washer from each linkage fork. Disconnect the forks, and remove the linkage. Remove the four serrated locknuts, and then remove the actuator from the flange. Remove the four center section bolts. Since the kit includes new bolts, the originals should be discarded. Separate the center section from the turbine housing. Set the compressor housing on the workbench with the turbine wheel facing up. Place a protective cap over the turbine wheel.! Caution To prevent engine damage, do not damage the turbine wheel. If the turbine wheel is damaged, a new turbocharger must be installed. Paint a locating mark on the turbine housing to indicate the position of the pivot shaft.

8 6 International DT 466, DT 570 and HT 570 Turbo Repair Apply penetrating oil to the actuator flange bolts and wait approximately five minutes.! Caution Do not use an impact wrench on the flange bolts. To prevent engine damage, do not use an impact wrench to remove the bolts from the actuator flange. If a bolt is broken, a new turbocharger may need to be installed. Note Save the old housing and actuator flange for core return. Instead, use a hand wrench to break the bolts loose. Then apply penetrating oil to the bolts and allow them to soak for another five minutes. Remove the eight bolts from the actuator flange. The kit includes new bolts, however, save two for optional use as alignment studs. Tap the actuator flange with a hammer to separate it from the turbine housing. Do not discard the old housing and flange. The turbine housing must be returned as a core. Let s locate and identify the components under the actuator flange. They are the unison ring, outer ring and six rollers, turbine housing, main pivot block, and pivot shaft. The pivot shaft may have seized to the flange and been removed along with it. If not, pull upward on the shaft to remove it. The shaft can be discarded.

9 Module 1: Disassembly 7 Next, remove the outer ring, six rollers, and the unison ring. Set these parts aside. They will be reused during assembly. There are two parts under the unison ring to be familiar with. They are the vane levers and the Torx screws. Note Retain outer ring, six rollers and unison ring for use during assembly. Clean the outer ring, rollers and unison ring using a non-abrasive cleaning method. Inspect the outer ring, rollers, and unison ring for cracks, dents and other damage. Replace the turbocharger if damage is found.

10 8 International DT 466, DT 570 and HT 570 Turbo Repair NOTES

11 Module 2: Assembly 9 Assembly Put the new Turbine housing, supplied in the kit, on the workbench, and transfer the paint mark from the old housing to the new housing. Center the vane levers in the new housing. Align the main pivot block with the Torx screw that s opposite the exhaust flange. This will ensure proper operation of the turbocharger. Use a small screwdriver or pick to line the levers up with the small pivot blocks on the underside of the unison ring. The unison ring will drop into place when the small pivot blocks line up with the levers. Install the six rollers and outer ring. Then, test the movement of the vane levers to ensure that they move freely. Do not rotate the unison ring too far clockwise, as it could detach from the levers. Install the new pivot shaft on the main pivot block, and align the shaft with the line painted on the housing.! Module 2 Caution To prevent engine damage, do not use an anti-seize compound on the inside surfaces of the turbocharger. Note The unison ring fits multiple ways, but it will only function properly one way. The main pivot block on top of the unison ring must line up with the Torx screw opposite the exhaust flange of turbine housing.! Caution To prevent engine damage, do not rotate the unison ring too far clockwise. The unison ring could detach from the vane levers.

12 10 International DT 466, DT 570 and HT 570 Turbo Repair Note Guide studs are available locally or can be made from the old bolts. It s a good idea, but not required, to install two guide studs into the turbine housing. Make sure the pivot shaft is properly aligned, and set the new flange on the housing. Install six of the new flange bolts finger tight. If used, remove the guide studs, and install the last two bolts finger tight. Tighten all the bolts in a star shaped pattern to 21 lb-ft, or 29 Nm. Set the center section on the bench and remove the protective cap from the turbine wheel. The center section is bean shaped in the area that meets the turbine housing and flange. Align the bean shaped areas and set the center section in the turbine housing. Install the four new bolts.! Caution Adding adapters or extensions to a torque wrench will alter the actual clamping force at the fastener. Therefore, your torque wrench must be adjusted to achieve the required torque. Proper tightening of the four inner bolts will require the use of an adapter. Using adapters that alter the length of the torque wrench will require that the proper torque wrench value be calculated. See Using a Torque Wrench Extension in Appendix B of Service Manual EGES on ISIS for

13 Module 2: Assembly 11 instructions on calculating the new torque value. The center section bolts need to be tightened in two steps. After each torque step, make sure the turbine shaft spins freely. First, using a criss-cross pattern, torque each bolt to, 97 lb-in or 11 Nm. Then, repeating the pattern, torque each bolt to 221 lb-in or 25 Nm. Check the actuator suffix. If the suffix letter is A, B, C, or D, a new actuator must be installed. Install the actuator and four serrated lock nuts and torque them to 123 lb-in or 14 Nm. Note If the actuator is stamped A, B, C, or D, a new actuator must be installed. Position the pivot and actuator forks on their respective shafts. Place a Nord-Lock washer on each fork bolt and thread them into the forks. Finger tighten each bolt. Move the pivot shaft linkage to ensure it moves freely. Anti-seize should be used on the linkage to prevent binding. Adjustments are made by using a screwdriver to square the forks on both

14 12 International DT 466, DT 570 and HT 570 Turbo Repair the actuator and pivot shafts. Next, torque both bolts to 62 lb in or 7 Nm. Place the turbocharger on the workbench with the actuator facing down. Move the fork lever on the actuator shaft until it stops. The actuator linkage should fall, bounce once, and stop. Release the fork lever. The actuator linkage should fall, bounce once, and stop. The fork adjustment may need to be performed again to ensure fluid motion of the actuator linkage. Install the turbocharger assembly on the engine. Refer to the Engine Service Manual EGES on ISIS for proper installation instructions.

15 Module 2: Assembly 13 NOTES

16 14 International DT 466, DT 570 and HT 570 Turbo Repair NOTES

17 Conclusion 15 Conclusion This concludes the International DT 466, DT 570 and HT 570 turbocharger repair program. Thank you for your participation.

18 16 International DT 466, DT 570 and HT 570 Turbo Repair NOTES

IK : High-Pressure Turbocharger Replacement. Study Guide. Course Code: 8472

IK : High-Pressure Turbocharger Replacement. Study Guide. Course Code: 8472 IK1200938: High-Pressure Turbocharger Replacement Study Guide Course Code: 8472 1 IK1200938: High-Pressure Turbocharger Replacement Study Guide 2013 Navistar, Inc. 2701 Navistar Drive, Lisle, IL 60532.