2001 through 2003 - US, Canada

INTERNATIONAL® DT530 & HT530

®
INTERNATIONAL DT530 & HT530
Equipped with International® Diamond Logic® Engine Control Module

Engine Operation and Maintenance Manual

Navistar, Inc.
2701 Navistar Drive, Lisle, IL 60532 USA

September 2012

1171755R5
Revision 5
© 2012 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
 IMPORTANT
The information, specifications, and illustrations contained in this manual are based on data that was current at the time of
publication. Navistar, Inc. reserves the right to make changes and/or improvements at any time without notification, liability,
or without applying those changes or improvements to vehicles previously manufactured and/or sold.

NOTICE
Be advised that this motor vehicle may be equipped with
computer / recording devices. Their function is to allow an
authorized individual to download data or information relating
to the operation or performance of this vehicle.
The stored data or information may be neither downloaded
nor retrieved except by the vehicle’s registered owner, or, in
the alternative, by another individual or entity authorized by
the registered owner, (e.g., International Dealer) who may
need this data or information to properly service or diagnose
this vehicle for repair or following an accident.
Any access to this information without the owner’s consent
may be in violation of law and may subject that person or
entity to criminal penalties.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Battery posts, terminals and related accessories contain
lead and lead compounds, chemicals known to the State
of California to cause cancer and reproductive harm.
Wash hands after handling.
 TABLE OF CONTENTS

INTRODUCTION
To The Operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Publications Ordering Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 1 – GENERAL INFORMATION

Component Location (Front View). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Component Location (Left Side View). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Location (Rear View). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Component Location (Right Side View). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Introduction:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DT530 and HT530 On-Highway Diesel Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine Identification:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DT530 and HT530 Series Diesel Engine Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Explanation Of The Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Turbocharger Identification (Non Wastegate Version). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Turbocharger Identification (Wastegate Version). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

SECTION 2 – ENGINE SYSTEMS

General Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Chassis Mounted Air-to-Air Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

SECTION 3 – WARRANTY INFORMATION

Emission Control Systems Maintenance And Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Federal Emission System Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
California Emission System Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Emission Limited Warranty Coverage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
 TABLE OF CONTENTS

The Emission Limited Warranty Does Not Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

SECTION 4 – INSTRUMENTS AND INDICATORS

Instrument Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Engine Diagnostics Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Water Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Oil Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Oil Temperature Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Change Engine Oil Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Air Cleaner Restriction Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Air Restriction Indicator Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

SECTION 5 – OPERATION
Before Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Engine Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Starting The Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Starting The Engine Above -12°C (10°F) Ambient Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Starting The Engine Below -12°C (10°F) Ambient Temperature With Optional Ether Injector. . . . .35
Emergency Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Hot Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Extended Idling Periods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
CAP Shutoff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Engine Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Automatic Engine Idle Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Shutdown Warning Light Or Audible Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
 TABLE OF CONTENTS

Parking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Road Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Downhill Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Idle Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

SECTION 6 – SPECIFICATIONS AND CAPACITIES

Fuel Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Recommended Fuel For On-Highway Navistar® Diesel Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Fuel For Export only Navistar® Diesel Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Advisory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Diesel Fuel/Gasoline Blends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Hazards Of Fire And Explosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Engine Performance Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
ROTELLA Extended Life Coolant (Red In Color). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Cooling System Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Maintaining Required Inhibitor Concentration (For Extended Life Antifreeze [Red In Color]). . . . . .51
Coolant Testing For Inhibitor Concentration – (For Extended Life [Red] Coolants). . . . . . . . . . . . . . . . .51
Cooling System Requirements – (For Conventional Coolant (Green or purple In Color). . . . . . . . . . .52
Ethylene Glycol Antifreeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Propylene Glycol Antifreeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Maintaining Required Conditioner Concentration (For Conventional Coolant [Green or
purple In Color]). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Coolant Filter/Conditioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Coolant Testing For Conditioner Concentration – (For Conventional [Green or Purple] Coolants). . .54
Cleaning The Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Corrosion Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Radiator Fins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Coolant Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
 TABLE OF CONTENTS

Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Coolant Contamination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Engine Lubrication Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Oil Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Oil Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Oil Change Interval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Identification Symbol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
DT530 and HT530 Series Diesel Engine Crankcase Refill Capacities For Unit Without Front
Drive/Steering Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
DT530 and HT530 Series Diesel Engine Crankcase Refill Capacities For Unit With Front
Drive/Steering Axle and short filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Checking Engine Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

SECTION 7 – MAINTENANCE INSTRUCTIONS

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Maintenance Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Maintenance Operations — 1 through 6 Daily Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
OPERATION 1 – Check Oil Level (Daily). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
OPERATION 2 — Check Coolant Level (Daily). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
OPERATION 3 — Water Separator, Fuel System - If Equipped (Daily). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
OPERATION 4 — Inspect Air-to-Air Cooler (Daily). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
OPERATION 5 — Inspect for External Leakage (Daily). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
OPERATION 6 — Inspect Air Cleaner Restriction Indicator (Daily). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Maintenance Operations – 7 through 10 Inspection Interval: Every 24,100 km (15,000
miles), 550 hours, 6 months or 2100 Gallons of Fuel; Whichever Occurs First. . . . . . . . . . . . . . . . . . . .71
OPERATION 7 — Inspect Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
OPERATION 8 — Change Engine Oil And Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Reset Change Oil Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
OPERATION 9 — Check Coolant SCA Concentration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
 TABLE OF CONTENTS

OPERATION 10 — Inspect Air Intake Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Maintenance Operations – 11 thru 12 Inspection Interval: Every 48,300 Km (30,000 miles),
1,100 hours, 12 months or 4200 Gallons of Fuel; Whichever Occurs First. . . . . . . . . . . . . . . . . . . . . . . . . .76
OPERATION 11 — Measure Air Intake Restriction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Optional Dual Element Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
OPERATION 12 — Change Fuel Filter And Strainer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Bleeding Air From Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Maintenance Operation —13 Replacement Intervals Depend On Type of Coolant Used.
Coolant Types Are Extended Life (Red In Color) and Conventional (Green or Purple In
Color).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Change Coolant Filter (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Maintenance Operation — 14 Inspection Interval: Every 24 Months. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Pressurize Induction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Maintenance Operation — 15 Inspection Interval: Every 193,100 Km (120,000 Miles), 5,000
Hours; Whichever Occurs First. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Inspection Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Maintenance Operation — 16 Inspection Interval: Annually. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Adjust Valve Lash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Maintenance Operations 17 And 18 Inspection Interval: Every 290,000 To 322,000 Km
(180,000 to 200,000 miles), 6,700 To 7,500 Hours; Whichever Occurs First. . . . . . . . . . . . . . . . . . . . . . . . .84
OPERATION 17 — Measure Crankcase Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
OPERATION 18 — Inspect Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Maintenance Operation — 19 Inspection Interval: Annually. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Inspect Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Maintenance Operation — 20 Inspection Interval: Every 322,000 Km (200,000 Miles), 3,800
Hours Or 2 Years; Whichever Occurs First. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Service Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
For School Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Clean Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Maintenance Operation — 21 Inspection Interval: Every 500,000 Km (300,000 Miles),
12,000 Hours Or 5 Years; Whichever Occurs First. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
 TABLE OF CONTENTS

Check Extended Life Coolant Inhibitor Concentration.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

SECTION 8 – SERVICE RECORDS

Emission Maintenance Service Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

SECTION 9 – DAILY MAINTENANCE REPORT

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
 INTRODUCTION
To The Operator
SAFETY TERMINOLOGY
Three terms are used in this manual to stress your safety and
safe operation of the engine: Warning, Caution, and Note.
Warning: Signals conditions, hazards, and unsafe practices that
can cause injury or death.
Caution: Signals conditions and practices that can cause
damage to the engine or vehicle.
Note: A note signals a key point or procedure that must be
followed for correct, efficient engine operation.
Do not operate your vehicle until you are completely familiar
with the contents of this manual. Always keep this manual in
your vehicle for reference. If you sell the vehicle make sure the
manual goes with it.
Safety Precautions
A CAREFUL OPERATOR IS THE BEST INSURANCE
AGAINST AN ACCIDENT.
Wear proper safety equipment as required for the job. These
may include: hard hat, safety shoes, ear protectors, reflective
clothing, safety goggles and heavy gloves.
Always wear safety glasses.
Be sure to wear safe work clothing and shoes. They should be
well fitted and in good repair.
Do not wear rings, wrist watches, jewelry, loose or hanging
apparel that can catch on moving parts causing serious injury.
Quick access to a FIRST AID KIT should be provided at all times.
It is recommended that a FIRE EXTINGUISHER be provided at
an accessible location.
Provide proper ventilation when operating an engine in a closed
area to remove deadly exhaust gases. Breathing of exhaust
fumes may be fatal.
Keep engine exhaust system and exhaust manifolds clear of
combustible material.
Be sure the operator's area is clean, organized and free of
obstructions. Remove or secure all maintenance or personal
items.
Be sure that everything is clear before starting the engine.
Engine should be operated or serviced only by those who are
qualified, responsible and delegated to do so.
CAUTION: To avoid engine damage, do not use starting fluid.
Do not use an open flame as a light source to look for leaks or
for inspection anywhere on the truck.
Page 1
 INTRODUCTION
Safety Precautions (cont.)
Always shift the transmission to neutral or park, stop engine, set
parking brake, block the wheels, and remove start key before
permitting anyone to inspect, clean, lubricate, adjust, or repair
any part of the engine or its attachments unless otherwise
specifically recommended in this manual.
When it is required to make any checks with the engine running,
always use two people; one person must be at the operator's
position while the other does the checking. As an added
precaution, when making checks with the engine running, apply
and lock the parking brake.
Be sure that the gear shift lever is in neutral or park before
starting the engine.
Always be sure that all shields, guards and access covers are in
place when engine is in operation.
Avoid running engines with unprotected air inlets or exhaust
openings. If such running is unavoidable for service reasons,
place protective screens over all openings before servicing
engine.
Do not operate an engine with an unsafe condition. If one is
noticed, tag engine and ignition key, if equipped, so others will
also know.
Do not place head, body, limbs, feet, fingers or hands near a
rotating fan, belt, or power driven part.
Do not adjust the engine when the vehicle is in motion.
Page 2
Electric storage batteries give off highly flammable hydrogen
gases. To prevent possible explosion, never allow lighted
smoking material, an open flame, or electrical sparks near the
battery. Do not lay tools or other conductive materials on the
battery where they may cause short circuits and sparks.
Always disconnect batteries and TAG all controls according to
OSHA requirements before working on electrical system and to
warn that work is in progress. Be sure to connect the battery
cables to proper terminals (+ to +) and (- to -) at both ends. Avoid
shorting battery cables.
Because battery gas is highly flammable, leave battery box open
to improve ventilation when charging batteries. Never charge
batteries in a closed area. Provide proper ventilation to guard
against an accidental explosion from an accumulation of gases
given off in the charging process.
Fluid in electric storage batteries contain sulfuric acid which can
cause severe burns. Avoid all contact of fluid with the eyes, skin,
or clothing. If contact does occur, flush immediately with large
amounts of water. Get prompt medical attention.
Never attempt to check or adjust rotating parts when engine is
running.
Always permit parts that contain hot fluid to cool to a safe
temperature before handling or disconnecting.
Shut off engine and be sure all pressure in system has been
relieved before removing panels, housing covers, and caps.
 INTRODUCTION

Safety Precautions (cont.)

Use extreme caution when removing the coolant fill cap. Loosen
very slowly and avoid pressurized steam that might be in cooling
system. Allow engine to cool before removing cap. Add coolant
only when engine is idling or stopped.
Be extremely careful when dealing with fluids under pressure.
Fluid escaping under pressure from a small hole can almost be
invisible and can have sufficient force to penetrate the skin. Use
a piece of cardboard or wood to search for suspected pressure
leaks. NEVER use hands to inspect for pressure leaks. If injured
by escaping fluid, see a doctor at once. Serious infection or
reaction can result if medical treatment is not given immediately.
Always stop engine when filling fuel tank. Always place hose,
nozzle, or funnel in contact with side of filler opening before
starting and during fuel flow to reduce the chance of static
electricity spark. Keep contact until after fuel flow has stopped.
Do not over fill the fuel tank. Do not smoke or have open flame
in the refueling area and never refuel when the engine is hot or
running.
Never use gasoline, diesel fuel, or other flammable fluid for
cleaning parts unless otherwise specified. Use authorized
commercial, nonflammable, nontoxic solvents.
Handle all parts with extreme care. Keep hands and fingers from
between parts. Wear authorized protective equipment such as
safety glasses, heavy gloves, and safety shoes.
Always use safety stands in conjunction with hydraulic jacks or
hoists. Do not rely on jack or hoist alone to carry the load.
Lift and handle all heavy parts with a lifting device of proper
capacity. Be sure parts are supported by proper slings and
hooks. Use lifting eyes if provided. Watch out for people in the
vicinity.
Never align holes with fingers or hands. Use the proper aligning
tool.
Remove sharp edges and burrs from reworked parts.
Shop or field service platforms and ladders used to maintain or
service engine should be constructed and maintained according
to OSHA requirements.
When using compressed air use safety glasses with side shields
or goggles. Limit the pressure on approved air blow gun to
207 kPa (30 psi) according to OSHA requirements to avoid injury.
Do not use defective portable power tools. Check for frayed
cords prior to using the tool. Be sure all electric tools are
grounded.
Be sure all mechanics tools are in good condition. Do not use
tools that require repair.
CAUTION: To avoid damage to your engine, disconnect engine
and chassis harness connectors at the Engine Control Module
(ECM) before any welding is to be performed on the vehicle.
Damage to the ECM will result if the ECM is not disconnected.

Page 3
 INTRODUCTION

Safety Precautions (cont.)

TECHNICAL SERVICE LITERATURE
WARNING: To avoid personal injury or death, when
performing maintenance and repairs to turbocharged 1171755R5 International® DT530 & HT530 Engine
engines with air inlet piping disconnected, Turbocharger Operation and Maintenance Manual
Screen Cover (Tool number ZTSE4293) should be installed EGES-210-1 DT466, DT466E, DT530, DT530E, and HT530
on the turbocharger air inlet. Order Turbocharger Screen Diesel Engine Service Manual
Cover from your nearest International dealer.
EGED-140 Supplemental Coolant Level Ref. Chart (for
conventional “green” coolant)

Publications Ordering Information EGES-215 DT466/ DT530 Diesel Engine Diagnostic

Manual
Technical Service Literature is revised periodically and mailed EGED-220 DT466/ DT530 Mechanical Diagnostic Form
automatically to “Revision Service” subscribers. If a technical
publication is ordered, the latest revision will be supplied. EGED-225 DT466/ DT530 Electronic Control System
Diagnostic Form
To order technical service literature, contact your International
dealer.

Page 4
 SECTION 1 – GENERAL INFORMATION

Component Location (Front View)

Figure 1 Component Location — Front View

1. Fan Pulley 5. Water Pump Pulley 9. Thermostat
2. Front Cover 6. Auto Belt Tensioner 10. Thermostat Housing
3. Vibration Damper 7. Camshaft Position (CMP) Sensor
4. Front Engine Mounting Bracket 8. Coolant Temperature Sensor

Page 5
 SECTION 1 – GENERAL INFORMATION

Component Location (Left Side View)

Figure 2 Component Location — Left Side View

1. Electronic Control Module (ECM) 7. Lifting Eye 14. High Pressure Oil Pump
2. ECM Connector 8. Hand Primer Pump 15. Oil Temperature Sensor
3. Manifold Absolute Pressure Sensor 9. Flywheel Housing 16. Fuel Supply Pump
(MAP) 10. Oil Pan 17. Grounding Bolt
4. Injection Control Pressure Sensor (ICP) 11. Oil Fill Tube and Oil Level Gauge 18. Quick Disconnect Fuel Inlet
5. High Pressure Oil/Fuel Supply Manifold 12. Fuel Filter 19. Quick Disconnect Fuel Outlet
6. Valve Cover/Intake Manifold 13. Engine Oil Pressure Sensor (EOP) 20. Engine Block Heater (If Equipped)

Page 6
 SECTION 1 – GENERAL INFORMATION

Component Location (Rear View)

Figure 3 Component Location — Rear View

1. Road Draft Tube 3. Flywheel Housing 5. Oil Fill Tube and Oil Level Gauge
2. Turbocharger Assembly 4. Flywheel 6. Lifting Eye (2)

Page 7
 SECTION 1 – GENERAL INFORMATION

Component Location (Right Side View)

Figure 4 Component Location — Right Side View

1. Valve Cover/Intake Manifold 5. Coolant Filter (if equipped) 10. Flywheel Housing
2. Manifold Absolute Pressure Sensor 6. Water Inlet 11. Road Draft Tube
(MAP) 7. Oil Cooler 12. Exhaust Manifold
3. Lifting Eye 8. Oil Pan 13. Turbocharger Assembly
4. Alternator Bracket 9. Oil Filter 14. Thermostat Housing

Page 8
 SECTION 1 – GENERAL INFORMATION

Introduction: When new engine parts are required be sure to specify genuine
INTERNATIONAL® service or ReNewed® parts to ensure the
DT530 AND HT530 ON-HIGHWAY DIESEL ENGINE best results and high quality.

The information in this manual will familiarize you with the
DT530 and HT530 series on-highway diesel engine and
provide sufficient information to enable you to perform services
necessary for efficient operation.
Refer to emission label on engine for compliance information.
Because permissible smoke levels depend on proper engine
operation the engine must be correctly adjusted and maintained.
This manual lists the schedule of maintenance operations
required to ensure optimum emission control and service from
the engine.
Throughout this manual use of the terms “left," “right," “front,"
and “rear" must be understood to avoid confusion when following
instructions. The left and right sides of the engine are described
when facing the flywheel from flywheel end of the engine. The
front of engine is the fan drive pulley end.
Engine Identification:
DT530 AND HT530 SERIES DIESEL ENGINE SERIAL
NUMBER LOCATIONS

As the owner, it is your responsibility to be certain that the We suggest you write the engine model, serial number, and
maintenance operations are performed at specified intervals. turbocharger identification in the following spaces provided, for
In addition to controlling required emission levels, proper quick reference when parts or service are required.
maintenance pays off in improved vehicle performance and
more economical operations.
Remember that maximum life and efficiency of equipment is
ensured if proper precautions are taken to keep dirt and other
foreign particles out of the units. Be sure that oil, coolant, and
fuel are always kept clean and that combustion air is always
filtered. Always follow specified maintenance schedule and
maintenance procedures to reduce problems.

Page 9
 SECTION 1 – GENERAL INFORMATION

Engine Identification: (cont.)

DT530 AND HT530 SERIES DIESEL ENGINE SERIAL
NUMBER LOCATIONS (cont.)

Engine Serial No. Stamped on machined pads located on the crankcase left side or right side depending
on engine model year. The serial number is also located on the emission label, located
on valve cover/intake manifold (Figure 6).
Engine Model Printed on the Emission Label, located on Valve Cover/Intake Manifold (Figure 7)
and (Figure 8)
Turbocharger Serial No. Located on Turbocharger Nameplate (Figure 9) and (Figure 10)
Turbocharger Part No. Located on Turbocharger Nameplate (Figure 9) and (Figure 10)

When in need of parts, always specify the engine model and manufacturer and specifications, are important to assist operator
serial number. The engine serial number is stamped either on a or maintenance personnel as to what equipment is on the
machined pad located on the crankcase left side or a machined engine.
strip located on the right side of the engine depending on the
model year. Model years 1999 through 2002, the serial number
is on the left side. Model year 2003, the serial number is on
the right side. The serial number also appears on the exhaust
emissions label. The engine exhaust emission labels are
located on the top of the valve cover/intake manifold. Engine
emission labels designate the model as well as other pertinent
1
information .
Other nameplates, that should be located, are on the
Turbocharger and Starter. These nameplates, showing
1
Exhaust Emission Label The labels, located on the valve cover/intake manifold of each engine, indicate the model year it is certified to meet governmental emission
standards.

Page 10
 SECTION 1 – GENERAL INFORMATION

Engine Identification: (cont.)

EXPLANATION OF THE SERIAL NUMBER

Figure 5 Explanation of the Engine Serial Number

Page 11
 SECTION 1 – GENERAL INFORMATION

Engine Identification: (cont.)

EXPLANATION OF THE SERIAL NUMBER (cont.)

Figure 6 Engine Serial Number Pad and Exhaust Emission Label Locations for both the DT530 and HT530

Page 12
 SECTION 1 – GENERAL INFORMATION

Engine Identification: (cont.)

EXPLANATION OF THE SERIAL NUMBER (cont.)

Figure 7 Emissions Label Example for the DT530 (See Label on Own Engine For Your Specific Engine Information)
1. Engine Model 3. If applicable, the 310@ 2000 is the peak
2. The 300@ 2000 is the engine rating. power of the engine.

Page 13
 SECTION 1 – GENERAL INFORMATION

Engine Identification: (cont.)

EXPLANATION OF THE SERIAL NUMBER (cont.)

Figure 8 Emissions Label Example for the HT530 (See Label On Own Engine for Your Specific Engine Information)
1. Engine Model 3. If applicable, the 345@ 1800 is the peak
2. The 340@ 2000 is the engine rating. power of the engine.

Page 14
 SECTION 1 – GENERAL INFORMATION

Turbocharger Identification (Non Wastegate

Version)

Figure 9 Turbocharger Identification

1. International® Part Number 5. Oil Cooled Center Housing 9. Compressed Air to Cooler
2. Turbocharger Serial Number 6. Oil Outlet 10. Oil Inlet
3. Turbine Housing 7. Compressor Housing
4. Exhaust Outlet 8. Air Intake

Page 15
 SECTION 1 – GENERAL INFORMATION

Turbocharger Identification (Wastegate Version)

Figure 10 Turbocharger Identification

1. International® Part Number 5. Exhaust Outlet 9. Air Intake
2. Turbocharger Serial Number 6. Oil Cooled Center Housing 10. Compressor Housing
3. Wastegate Actuator 7. Oil Inlet 11. Oil Outlet
4. Turbine Housing 8. Compressed Air to Cooler

Page 16
 SECTION 2 – ENGINE SYSTEMS
General Features
The DT530 and HT530 diesel engine series are inline six
cylinder, four (4) cycle water cooled, turbocharged, overhead
valve, and air-to-air cooled. Both intake and exhaust valve
guides and seats are replaceable. The engine is fueled by
a direct injection fuel system with electronic sensors and
Hydraulically actuated Electronically controlled Unit Injectors
(HEUI). It has a displacement of 8.7 Liter (530 cubic inches).
The firing order is 1-5-3-6-2-4.
The engine is equipped with an Engine Control Module (ECM);
mounted on the left side of the engine (Refer to “Engine
Component Location” in Section 1). The ECM is used for
monitoring and controlling engine and vehicle performance.
CAUTION: To avoid damage to your engine, disconnect engine
and chassis harness connectors at the Engine Control Module
(ECM) before any welding is to be performed on the vehicle.
Damage to the ECM will result if the ECM is not disconnected.
The crankcase has been especially designed to withstand
the loads of diesel engine operation and has cast water and
oil passages. The crankcase also has replaceable wet type
cylinder sleeves. Every main bearing web has angled, drilled
holes which are fitted with jet tubes that direct lube oil, under
pressure, to the underside of each piston to help dissipate heat.
The crankshaft is forged steel with induction hardened journals
and undercut fillets. It is supported on seven precision insert
bearings. The camshaft is supported on four pre-reamed
bushings and is gear driven from the crankshaft via idler gears.
The end thrust of the camshaft is controlled by a thrust flange
located between the front camshaft journal and the cam gear.
The tee-pee style connecting rod is constructed of forged steel.
They are attached to the crankshaft, one (1) per journal. The
pistons are cast aluminum or a steel aluminum combination (two
piece) alloy and are fitted with two compression rings and one
oil ring. The piston pin is a free floating type permitting the pin to
move or float freely in the piston and connecting rod and is held
in place with pin retaining rings.
A gerotor type lube oil pump is mounted to the front cover. The
pump is driven directly by the crankshaft at engine speed. All
models are equipped with an oil cooler. The oil cooler has a
single spin-on type oil filter. If equipped, there is also a single
spin-on type coolant filter on the rear of the front cover. The
fuel system has a single spin-on type fuel filter and pre strainer
assembly attached to the fuel filter header. With the exception of
the air compressor, high pressure pump and turbocharger, there
is no external oil piping.
There are two oil galleys in the crankcase. The unfiltered oil
galley runs down the lower right hand side of the crankcase and
the filtered oil galley runs above it. Unfiltered oil travels from
the oil pump, through the front cover assembly, past the high
pressure oil relief valve and into the unfiltered oil galley. The
high pressure oil relief valve controls unfiltered oil pressure at
552 kPa (80 psi). There are two exit ports in the unfiltered oil
galley. One exits to the front header of the oil cooler and one
exits to the rear header of the oil cooler.
Page 17
 SECTION 2 – ENGINE SYSTEMS
General Features (cont.)
Depending upon the position of the oil thermostat, located in
the rear oil cooler header, unfiltered oil can by-pass the oil
cooler core and go directly to the oil filter or can flow through
the oil cooler core and into the rear header and oil filter. The oil
thermostat opens or closes by sensing the temperature of the
unfiltered oil as it enters the rear header. Once the unfiltered
oil has passed the thermostat, the unfiltered oil goes into the oil
filter.
Clean engine oil flows out of the filter and goes back into the oil
cooler header, then out the header and into the crankcase clean
oil galley. The clean oil enters the crankcase, passes the main oil
pressure regulating valve and is directed through various ports of
the crankcase. The regulator valve controls filtered oil pressure
at 103 kPa (15 psi) minimum at normal operating temperature.
2
Manual specified with latest revision.
Page 18
Chassis Mounted Air-to-Air Cooler
The DT530 and HT530 diesel engine series are equipped with
a chassis mounted air-to-air cooling system. The charge air
cooler is chassis mounted either in front of the radiator or above
the radiator. Air from the turbocharger is pushed through a
network of heat exchanger tubes prior to entering the valve
cover/intake manifold. Outside air flowing over the tubes and
fins cools the charged air. The resulting cooler intake air is
denser than uncooled air, which allows an improved fuel/air ratio
in the cylinders during combustion. This results in improved
emission control and power output.
Detailed descriptions of the following systems can be found in
the EGES-210-1, DT466, DT466E, DT530, DT530E and HT530
2
Diesel Engine Service Manual .
• Fuel System
• Lubrication System
• Cooling System
• Air Induction and Exhaust Systems
 SECTION 3 – WARRANTY INFORMATION
Emission Control Systems Maintenance And
Limited Warranty
FEDERAL EMISSION SYSTEM LIMITED WARRANTY
(California emissions limited warranty is described elsewhere)
Navistar, Inc. warrants that your new vehicle and heavy-duty
diesel engine was designed and built to conform to applicable
U.S. Environmental Protection Agency regulations for a period
of use of:
Five (5) years or 160,000 km (100,000 miles) or 3,000 hours of
operation, whichever occurs first, for medium-heavy duty diesel
class engines. The new model year, class of diesel engine, and
emission application determination for your engine is identified
on the emission control information label affixed to the top of the
valve cover/intake manifold. The warranty period begins on the
date the new vehicle is delivered to the first retail purchaser.
Any emission control system parts which are proven defective
during normal use will be repaired or replaced during the
warranty period. The warranty repairs and service will be
performed by any authorized International dealer at the dealer's
place of business with no charge for parts or labor (including
diagnosis).
As the vehicle owner you are responsible for performing all the
required maintenance listed in your owner's manual. Navistar,
Inc. will not deny an emission warranty claim solely because
you have no record of maintenance; however, a claim may be
denied if failure to perform maintenance resulted in the failure of
a warranted part. Receipts covering regular maintenance should
be retained in the event of questions and these receipts should
be passed on to each subsequent owner of the vehicle.
It is recommended that replacement parts used for maintenance
or repairs be International® Service Parts or International®
ReNEWed® Parts to maintain the quality originally designed
into your emission certified vehicle/engine. The use of
non-International® parts does not invalidate the warranty on
other components unless the use of such parts causes damage
to warranted parts.
Navistar, Inc. wishes to ensure the emission control systems
warranty is being properly administered. If you believe you
have not received the service entitled to under this warranty you
should contact the Manager, Customer Relations. If additional
assistance or information is needed, contact:
Manager, Customer Relations
Navistar, Inc.
2701 Navistar Drive
Lisle, Illinois 60532
(Telephone 1-800-448-7825)
Page 19
 SECTION 3 – WARRANTY INFORMATION
Emission Control Systems Maintenance And
Limited Warranty (cont.)
FEDERAL EMISSION SYSTEM LIMITED WARRANTY (cont.)
Please note the Emission Limited Warranty does not cover:
1. Systems and parts that were not first installed on the new
vehicle or engine as original equipment by Navistar, Inc.
2. Part malfunctions caused by abuse, misuse, improper
adjustment, modification, alteration, tampering,
disconnection, improper or inadequate maintenance, or use
of non-recommended fuels and lubricating oils.
3. Accident caused damage, acts of nature or other events
beyond the control of Navistar, Inc.
4. Replacement of expendable items made in connection with
scheduled maintenance.
5. Parts requiring replacement at inspection or adjustment
maintenance intervals for reasons other than being
defective.
6. Parts which are not International® Service Parts or
ReNEWed® Parts.
7. Loss of time, inconvenience, loss of use of vehicle/engine or
commercial loss.
8. Vehicles with altered or disconnected odometer or
hourmeter where the mileage or hours cannot be
determined.
Page 20
9. Vehicles registered and normally operated outside the
United States.
10. Non-defective parts replaced by other than International
dealers.
CALIFORNIA EMISSION SYSTEM LIMITED WARRANTY
California Emission Control Limited Warranty
California Air Resources Board is pleased to explain the
emission control system warranty on your 2001 through 2003
vehicle. In California, new motor vehicles must be designed,
built and equipped to meet the State's stringent anti-smog
standards. Navistar, Inc. warrants the emission control system
on your vehicle for the time listed below provided there has
been no abuse, neglect or improper maintenance of your
engine. Your emission control system may include parts such
as the fuel injection system or catalytic converter. Also included
may be hoses, belts, connectors and other emission-related
assemblies. Where a warrantable condition exists, Navistar,
Inc. will repair your vehicle at no cost including diagnosis,
parts, and labor; for five (5) years or 160,000 km (100,000
miles) or 3,000 hours of engine operation, whichever occurs
first. If an emission-related part on your vehicle is defective,
the part will be repaired or replaced by Navistar, Inc. This is
 SECTION 3 – WARRANTY INFORMATION

Emission Control Systems Maintenance And

Limited Warranty (cont.)
CALIFORNIA EMISSION SYSTEM LIMITED WARRANTY
(cont.)

your emission system defects warranty. The vehicle owner is
responsible for performance of all required maintenance listed in
the owner's manual. We recommend that you retain all receipts
covering maintenance on your truck, but will not deny warranty
solely for the lack of receipts or for your failure to ensure the
performance of all scheduled maintenance. You are responsible
for presenting your vehicle to an International dealer as soon
as a problem exists. The warranty repairs should be completed
in a reasonable amount of time, not to exceed 30 days. As
the vehicle owner, you should also be aware that Navistar,
Inc. may deny you warranty coverage if your vehicle or a part
has failed due to abuse, neglect, improper maintenance or
unapproved modifications. If you have any questions regarding
your warranty rights and responsibilities, you should contact:
Manager, Customer Relations
Navistar, Inc.
2701 Navistar Drive
Lisle, Illinois 60532
(Telephone 1-800-448-7825) or:
The Air Resources Board
9528 Telstar Avenue
El Monte, California 91731
EMISSION LIMITED WARRANTY COVERAGE
Navistar, Inc. warrants that your new vehicle and heavy-duty
diesel engine, certified for sale and registered in California,
was designed, and built to conform to applicable California Air
Resources Board regulations for the above stated warranty
period. The warranty period begins on the date the new vehicle
is delivered to the first retail purchaser. The engine model year
and emissions application for your engine are identified on the
emission control information label affixed to the top of the valve
cover/intake manifold. This warranty is based on the heavy-duty
engine model year stated on the label, not the model year of the
vehicle. Your maintenance records and receipts covering the
required maintenance should be passed on to each subsequent
owner of the vehicle.

Page 21
 SECTION 3 – WARRANTY INFORMATION

Emission Control Systems Maintenance And

Limited Warranty (cont.)
EMISSION LIMITED WARRANTY COVERAGE (cont.)

Any emission control system parts which are defective during except in the case of an emergency as noted above. If such
normal use will be repaired or replaced during the warranty parts are used the owner should ensure that these parts are
period. The warranty repairs and service will be performed equivalent in design and durability to International® parts.
by any authorized International dealer at the dealer's place of
business with no charge for parts or labor (including diagnosis). NOTE: The use of non-International® parts does not invalidate
In an emergency where an International dealer is not reasonably the warranty on other components unless the use of such parts
available, repairs may be performed at any available service causes damage to warranted parts.
establishment or by the owner using any replacement part. A
Navistar, Inc. wishes to ensure the emission control systems
part not being available within 30 days or a repair not completed
warranty is being properly administered. If you believe you
within 30 days also constitutes an emergency. Navistar, Inc.
have not received the service entitled to under this warranty
will reimburse you for such repairs (including diagnosis), not
you should contact the Manager, Customer Relations. If
to exceed the manufacturer's suggested retail price for all
further questions of warranty rights and responsibilities remain,
warranted parts replaced and labor charges based on the
the above “California Emission Control Warranty" lists other
manufacturer's recommended time allowance for the warranty
contacts that can be made.
repair and the geographically appropriate hourly labor rate.
Replaced parts and paid invoices must be presented to an
International dealership as a condition of reimbursement for
such emergency repairs.
It is recommended that replacement parts used for maintenance
or repairs be International® Service Parts or International
ReNEWed® Parts to maintain the quality originally designed into
your emission certified engine. You may elect to use other than
International® parts and service for maintenance, replacement
or repair without invalidating this warranty. However, the costs of
such parts and services will not be covered under the warranty

Page 22
 SECTION 3 – WARRANTY INFORMATION

Emission Control Systems Maintenance And

Limited Warranty (cont.)
EMISSION LIMITED WARRANTY COVERAGE (cont.)

New vehicle/engines certified for sale and registered in California THE EMISSION LIMITED WARRANTY DOES NOT COVER
have the following items that are covered by the emission
warranty when the items were first installed on the new engine Please note that the Emission Limited Warranty statement does
as original equipment: not cover the following:

1. Fuel injection system 1. Part malfunctions caused by abuse, misuse, improper

adjustment (unless done by an International dealer
2. Air induction system during warranty work), modification, alteration, tampering,
a. Turbocharger system (includes exhaust manifold) disconnection, improper or inadequate maintenance or use
of non-recommended fuels and lubricating oils
b. Intake manifold
2. Accident caused damage, acts of nature or other events
3. Positive crankcase ventilation system (if applicable) beyond the control of Navistar, Inc.
a. PCV valve 3. Replacement of parts beyond their first required
b. Oil fill cap maintenance point

4. Diesel particulate control system (if applicable)
a. Catalytic converter or trap
5. Miscellaneous items used in above systems
a. Hoses, clamps, fittings and tubing
b. Pulleys, belts and idlers
4. Parts which are not International® Service Parts or
ReNEWed® Parts
5. Loss of time, inconvenience, loss of use of vehicle/engine or
commercial loss
6. Vehicles with altered or disconnected odometer or
hourmeter where the mileage or hours cannot be determined

c. Vacuum, temperature and time sensitive valves and 7. Vehicles registered and normally operated outside the
switches United States

Page 23
 SECTION 3 – WARRANTY INFORMATION

Emission Control Systems Maintenance And

Limited Warranty (cont.)
THE EMISSION LIMITED WARRANTY DOES NOT COVER
(cont.)

8. Non-defective parts replaced by other than International

dealers

Page 24
 SECTION 4 – INSTRUMENTS AND INDICATORS
Instrument Panel
WARNING: To avoid 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 the engine or vehicle.
After the engine starts and at frequent intervals while the engine
is operating, all gauges should be observed for proper readings.
This engine operator’s manual describes the gauges in general
terms as gauge type may vary with vehicle application (Figure
11).
Figure 11 Instrument Panel Gauge Cluster
ENGINE DIAGNOSTICS LIGHTS
Most gauges have their own warning lights which signal the
operator when a gauge reading is outside preset limits. The
instrument panel also contains warning and indicator lamps to
monitor conditions not monitored by the gauges.
“AMBER” warning lamps indicate situations that should be
reviewed by the operator.
“RED” warning lamps indicate situations that must be inspected
before operating the vehicle.
An audible alarm is activated when any warning lamp is lit. This
will alert the operator that an active fault exists.
Page 25
 SECTION 4 – INSTRUMENTS AND INDICATORS

WATER TEMPERATURE GAUGE NOTE: Intermittent coolant operating temperatures up to 110°C

(230°F) are permissible. Operation of engine above 110°C
The temperature gauge indicates the temperature of the coolant (230°F) may cause internal damage. Intermittent coolant
in the cooling system. The gauge operates only when the operating temperatures are not to exceed 1 hour out of every
ignition switch is turned to the “ON" position. If the indicator 25 hours of operation.
suddenly rises, the engine should be stopped and the cause of
overheating determined. Normal engine operating temperature
is between 88°C to 100°C (190°F to 212°F) (Figure 12).
The indicator lamp will be activated at engine coolant
temperatures above 110°C (230°F).

Figure 12 Water Temperature Gauge

Page 26
 SECTION 4 – INSTRUMENTS AND INDICATORS

OIL PRESSURE GAUGE

The engine oil pressure gauge indicates operating oil pressure

of the engine (Figure 13).
The engine oil pressure indicator lamp will be activated at
pressure less then 7 psi when engine RPM is over 325.

Lube Oil Pressure Specifications1

At Low Idle [700 rpm At High Idle2
(non-adjustable)]
3
103 kPa (15 psi) min. (Typical)

1 Engine at normal operating temperature with SAE 10W-30 oil.

2 Refer to Section 6, Engine Specifications (Governed Speed No Figure 13 Oil Pressure Gauge
Load, rpm) for High Idle rpm.
3 276–483 kPa (40–70 psi)
OIL TEMPERATURE GAUGE
CAUTION: TO AVOID DAMAGE TO YOUR ENGINE, IF THE
GAUGE FLUCTUATES OR DROPS TO 241 kPa (35 psi) OR The engine oil temperature gauge indicates operating oil
LESS AT 2300 rpm (UNDERLOAD), STOP THE ENGINE temperature of the engine.
IMMEDIATELY AND CORRECT THE CAUSE.
The engine oil temperature lamp will be activated at engine
temperature above 110°C (230°F).

Page 27
 SECTION 4 – INSTRUMENTS AND INDICATORS

OIL TEMPERATURE GAUGE (cont.)

NOTE: When this feature is utilized the system must be reset

after each oil change. Refer to Section 7 “Change Engine Oil"
for resetting procedure.

Figure 14 Oil Temperature Gauge Figure 15 Change Oil Lamp Message Location

CHANGE ENGINE OIL MESSAGE

The Change Engine Oil Message is a standard vehicle feature.

This feature is inactive unless it was ordered active.
The change oil message (located below odometer) will illuminate
after a preselected parameter limit has been achieved. The
message can be programmed in terms of vehicle miles, hours
or calculated fuel consumption. These service interval limits
may be adjusted at the owners discretion (consult an authorized
International dealer).

Page 28
 SECTION 4 – INSTRUMENTS AND INDICATORS

Air Cleaner Restriction Indicator

The amount of air cleaner restriction may be detected by either
an air cleaner restriction indicator and/or a vacuum gauge that
reads in inches of water.
The vehicle is equipped with either an air cleaner mounted
restriction indicator or a dash mounted restriction indicator
(Figure 16). Each functions identically, however the dash Figure 16 Air Cleaner Restriction Indicator — Mounted
mounted version has the reset button mounted on the face of (left) or Air Cleaner Dash Mounted (right) Versions
the gauge.
The air restriction indicator indicates how much engine air
cleaner filter capacity has been used and how much filter When the filter element reaches maximum allowable restriction,
capacity remains. It measures maximum restriction of the filter the yellow indicator reaches the top of window and automatically
element when the engine is operated at full load and locks at locks in this position (Figure 17). The indicator remains fully
that point. exposed even after engine shutdown. The filter element must be
properly serviced at this time to prevent low power complaints or
The vacuum gauge and/or indicator should be tested periodically engine damage.
to insure proper indication. This can be accomplished with a
master vacuum gauge.

NOTE: It is not necessary that the engine be shut down when the
yellow indicator in the gauge reaches the maximum restriction
(red zone) but indicates air cleaner service is required.

Page 29
 SECTION 4 – INSTRUMENTS AND INDICATORS

Air Cleaner Restriction Indicator (cont.)

Figure 17 Indicator — Maximum Restriction

Figure 18 Normal Clean Filter (3–15 inches of water)

NOTE: After starting engine, indicator may be seen in lower part

of window. This is normal and should not be mistaken as a signal
for element service.
The initial restriction with a new air filter element will vary with air
cleaner design and installation.
After servicing the filter element, reset the yellow indicator by
pushing the reset button and releasing it. The yellow indicator
will drop below the window so the air restriction gauge can be
reused.
AIR RESTRICTION INDICATOR TEST
Check indicator periodically to be sure it is operating. To test
the air restriction indicator, hook an accurate vacuum gauge
(calibrated in inches of water) or a water manometer to the
indicator. The “pop-up" gauge should lock in the highest
restriction encountered and should be serviced and reset at 6.2
kPa (25 in H2O) for turbocharged engines. The gauge should
read the same as the master vacuum gauge.

Page 30
 SECTION 5 – OPERATION

Before Starting the Engine

PRECAUTIONS

WARNING: To avoid 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 the engine or vehicle.
Before starting the engine, the operator should fully understand
the use and function of all controls, instruments and equipment.
This engine has been given predelivery and delivery service by
your International dealer and is ready for operation.
Before starting engine the following steps should be made:
1. Check the cooling system level and fill if necessary. Refer
to “Service Cooling System" in Section 7 of this manual or
refer to the vehicle Operator's Manual.
2. Check that engine crankcase is filled to the proper level Figure 19 Checking Oil Level
and with proper grade of oil for the prevailing temperature.
Refer to “Engine Specifications" and “Engine Lubrication
Requirements" in Section 6. 3. Fill the tank with the recommended fuel. Refer to “Fuel
Requirements" in Section 6.
NOTE: DO NOT OVERFILL. 4. Check air cleaner and piping for tightness and proper
installation of filter element.
5. Make sure all electrical connections are tight.
6. Check belt for proper tension and condition.

Page 31
 SECTION 5 – OPERATION

Before Starting the Engine (cont.)

PRECAUTIONS (cont.)

NOTE: Starting procedure may vary slightly depending upon

accessory package.

WARNING: To avoid damage to the engine and the

possibility of personal injury, do not use volatile starting
aids, such as ether, propane, or gasoline in the engine air
intake system.

ENGINE STARTING

The engine starting procedure is divided into two temperature

categories:
1. Ambient temperatures above -12°C (10°F).
2. Ambient temperature below -12°C (10°F) with ether injector.

NOTE: Engine and vehicle may be equipped with optional

features of ether injection, frost plug block heater, oil pan
heater, fuel heater as well as vehicle cold starting/warm-up aids.
Consult your International dealer for cold weather products.

Page 32
 SECTION 5 – OPERATION

Starting The Engine

STARTING THE ENGINE ABOVE -12°C (10°F) AMBIENT
TEMPERATURE

Figure 20 Starting the Engine Above –12°C (10°F)

NOTE: Starting procedure may vary slightly depending upon 1. Set parking brake and place transmission control lever into
accessory package. the park or neutral position.

Page 33
 SECTION 5 – OPERATION

Starting The Engine (cont.)

STARTING THE ENGINE ABOVE -12°C (10°F) AMBIENT
TEMPERATURE (cont.)

2. Depress the clutch pedal, if equipped. DO NOT DEPRESS CAUTION: Do not increase the engine speed until the oil
THE ACCELERATOR PEDAL. pressure gauge indicates normal. To avoid damage to your
engine, shutdown the engine if oil pressure is not registered on
3. Turn key clockwise to the “ON" position.
the gauge within 20-30 seconds.
4. Continue to turn key to the “START" position. (If the vehicle
8. If oil pressure does not meet the minimum limit, stop engine,
has push button starting, press and hold the starter button.)
locate and correct the problem.
5. As soon as the engine starts, release the key (or starter
9. After the engine has reached operating temperature and
button, if applicable). The key switch will return to the “ON"
rated speed, the oil pressure should be at 276 kPa (40 psi)
position and the engine will continue to run.
minimum. If oil pressure does not meet the minimum limit,
CAUTION: To avoid damage to your engine, if engine fails stop the engine, locate and correct the problem.
to start within 30 seconds, release starter switch and wait
2-3 minutes to allow the starter motor to cool. repeat above NOTE: If engine starts then stops, repeat engine starting
procedure. If after three (3) attempts the engine does not procedure, if more than three attempts are required, investigate
start, investigate and determine the cause for the engine not for causes of no-start.
starting. Starter motor damage may result if starting attempts
are continued.
6. Low idle speed is 700 rpm (non-adjustable). Extended
idling periods should be avoided, refer to “Extended Idling
Periods" in this section for further information. Check all
gauges during warm-up.
7. Within seconds after starting engine, oil pressure should
exceed 103 kPa (15 psi) minimum.

Page 34
 SECTION 5 – OPERATION

Starting The Engine (cont.)

STARTING THE ENGINE BELOW -12°C (10°F) AMBIENT
TEMPERATURE WITH OPTIONAL ETHER INJECTOR

Figure 21 Starting the Engine Below –12°C (10°F)

NOTE: Use only an Navistar, Inc. approved ether injection kit. NOTE: Before starting, check that the ether canister has enough
fluid to start the engine.

Page 35
 SECTION 5 – OPERATION
Starting The Engine (cont.)
STARTING THE ENGINE BELOW -12°C (10°F) AMBIENT
TEMPERATURE WITH OPTIONAL ETHER INJECTOR (cont.)
NOTE: The ether injector valve inlet must be sealed against dirt
at all times. Either install the ether container or a dust cap.
WARNING: Ether starting fluid is highly flammable and
toxic. Observe the precautions printed on the container
when using, storing and discarding ether fluid containers.
Also, see “safety precautions" in the introductory section
of this manual.
Use the following steps to start the engine (Figure 21).
NOTE: The Starting procedure may vary slightly depending on
the accessory package.
1. Set parking brake and place transmission control lever into
the park or neutral position.
2. Depress the clutch pedal, if equipped. DO NOT DEPRESS
THE ACCELERATOR PEDAL.
3. Turn key clockwise to the ON position.
CAUTION: Releasing ether into the cylinder, prior to the engine
cranking, may damage the piston rings and cause engine
damage.
4. Continue to turn key to the “START" position. (If the vehicle
has push button starting, press and hold the starter button.)
Page 36
Simultaneously press the ether injector switch button. Allow
one to two seconds for a measured shot of ether to fill the
cylinders then release the ether injector switch.
5. Once the engine starts, release the key (or start button,
if equipped) immediately. The engine will continue to run
at 700 rpm (minimum). Monitor gauges and warm-up
the engine until all systems reach normal operating
temperatures.
CAUTION: To avoid engine damage, if the engine fails to start
within 30 seconds, release starter switch and wait 2-3 minutes
to allow the starter motor to cool. Repeat above procedure. If
after three (3) attempts the engine does not start, investigate and
determine the cause for the engine not starting. Starter motor
damage may result if starting attempts are continued.
6. If the engine fails to start, repeat steps 3 thru 6.
7. Within seconds after starting the engine, the oil pressure
should exceed 103 kPa (15 psi) minimum.
CAUTION: Do not increase the engine speed until the oil
pressure gauge indicates normal. To avoid engine damage,
shut down the engine if oil pressure is not registered on the
gauge within 20-30 seconds.
 SECTION 5 – OPERATION

Starting The Engine (cont.)

STARTING THE ENGINE BELOW -12°C (10°F) AMBIENT
TEMPERATURE WITH OPTIONAL ETHER INJECTOR (cont.)

8. After the engine has reached operating temperature and

rated speed, the oil pressure should be 276 kPa (40 psi)
minimum. If oil pressure does not meet the minimum limit,
stop engine, locate and correct the problem.

NOTE: Cold ambient engine warm up time can be reduced

by operating the vehicle under load at reduced engine speed.
Commence normal operation when engine systems reach
operating temperature.

Page 37
 SECTION 5 – OPERATION
Emergency Starting
WARNING: To avoid serious personal injury, possible
death, and engine damage, the following procedures must
be performed exactly as outlined. Failure to do so may in
injury due to fire or acid from battery explosion. Property
damage may also result.
WARNING: To avoid serious personal injury, possible
death, and engine damage:
• It is imperative that lighted tobacco, flames or sparks
be kept away from the vent openings of the battery. The
gas mixture in the battery cells, which escapes through
the vents, could ignite and/or cause an explosion. This
is particularly true when jumper cables are being used.
• Be aware that, inhaling hydrogen gas produced by the
normal operation of the battery could result in partial or
permanent damage to the respiratory system.
• Whenever disconnecting battery terminals, always
disconnect ground terminal first. When reconnecting,
always connect ground terminal last.
Page 38
WARNING: To avoid serious personal injury, possible
death, and engine damage, always wear eye protection
when working around batteries. Do not attempt to jump
start a vehicle having a frozen battery, because the battery
may rupture or explode. If a frozen battery is suspected,
examine all fill vents on the battery. If ice can be seen,
do not attempt to start with jumper cables as long as the
battery remains frozen. Thaw out battery and recharge.
1. To prevent shorting of the electrical system, remove metal
rings or watches and do not allow metal tools to contact
positive terminal of battery.
2. Place transmission in PARK or NEUTRAL and set the
parking brake (in both vehicles).
3. Shut off the lights, heater, air conditioner and any other
electrical loads (in both vehicles).
4. Eye protection should be worn if available. If not available,
shield eyes when near the batteries.
5. Vehicle bodies or bumpers must not be in contact.
6. Connect one end of the first jumper cable to positive (+)
terminal of the dead battery or the positive (+) terminal of
the jump start stud and then the other end to the positive (+)
terminal of the booster battery.
 SECTION 5 – OPERATION
Emergency Starting (cont.)
CAUTION: To avoid damage to vehicle's electronic components,
voltage supplied to a vehicle's electrical system must never
exceed 16.0 volts. This voltage must not be exceeded when the
ignition switch is in the off, acc or ign position or during engine
cranking. The most reliable means for jump starting a vehicle is
to use batteries connected so as to provide 12 volts. Never use
an electric welder.
7. Connect one end of the second jumper cable to negative (-)
terminal of the booster battery and the other end to chassis
frame of the vehicle with the dead battery. Do Not attach
the other end to the negative (-) battery terminal, because a
spark could occur and cause an explosion of gases normally
present around the battery.
8. Reverse the above procedure when removing the jumper
cables.
Operating Instructions
Prevent overspeeding of the engine when going down long and
steep grades. The governor has no control over engine speed
when it is being pushed by the loaded vehicle. Operate in a gear
that will permit an engine speed not in excess of high idle RPM.
Operating the engine beyond high idle speed can cause severe
damage.
COLD WEATHER OPERATION
In order to operate the engine in temperatures of 0°C (32°F) or
lower, observe the following instructions:
1. Make certain that the battery is of sufficient size and is fully
charged. Check that all other electrical equipment is in
optimum condition.
2. Use permanent-type antifreeze solution to protect against
damage by freezing.
3. At the end of each daily operation, drain water from water
separator, if equipped. Allow engine to cool, then, fill fuel
tank to prevent condensation.
4. Be sure to use proper cold weather lubricating oil, and be
sure the crankcase contains a sufficient amount.
5. At temperatures of -20°C (-4°F) and below, it is
recommended that you use a crankcase mounted cup plug
coolant heater to improve cold starting.
Page 39
 SECTION 5 – OPERATION
COLD WEATHER OPERATION (cont.)
6. If operating in arctic temperatures of -29°C (-20°F) or lower,
consult your International dealer for information about
special cold weather equipment and precautions.
HOT WEATHER OPERATION
1. Make sure that the battery has the proper amount of
electrolyte, if it IS NOT a maintenance free battery.
2. Keep the cooling system filled with clean permanent
antifreeze solution to protect against damage by
overheating.
3. At the end of each daily operation, drain water from water
separator, if equipped. Allow engine to cool, then, fill fuel
tank to prevent condensation.
4. Keep the external surfaces of the engine, radiator and
accessories clean to avoid dirt build up.
EXTENDED IDLING PERIODS
Low idle speed for the DT530 and HT530 engine is 700 rpm
(non-adjustable). A Cold Ambient Protection (CAP) system
has been added to the vehicle's Engine Control Module (ECM)
(except units with idle shutdown enabled). This software aids in
engine warm-up and maintaining engine heat during extended
idling periods.
If, after 5 minutes of idle time and the intake air temperature is
below 0°C (32°F), the CAP system will slowly ramp up the engine
Page 40
idle speed. The engine speed will increase or decrease in rpm to
maintain a coolant temperature between 65°C (149°F) and 71°C
(160°F).
Diesel engine efficiency is improved when the cylinder
temperature remains high. If cylinder temperatures are too low,
the following may occur:
1. Unburned fuel, which has the dark colored appearance of
lubricating oil, may seep from the exhaust manifold gaskets
and vehicle exhaust system connections.
2. Cylinder temperature will be too low to allow complete
combustion and unburned fuel will wash lubricating oil from
the cylinder sleeves. Unburned fuel will be carried into the
lubricating oil causing the viscosity of the oil to change. This
is known as fuel dilution.
3. Fuel injector tips will form carbon and cause plugging.
4. Carbon deposits will form on the turbine wheel of the
turbocharger causing reduced turbocharger efficiency.
WARNING: To avoid serious personal injury, possible
death, and engine damage, when parking your diesel
vehicle, do not leave the transmission in gear. Use the
parking brake when parking on a grade, block the wheels
or turn them to the curb. Failure to follow these procedures
could result in an unattended vehicle moving.
 SECTION 5 – OPERATION

CAP SHUTOFF heat to be dissipated from iron masses and evenly distributed
throughout the various systems.
The cycle described in the paragraph above will continue until
one or a combination of any of the following occurs: AUTOMATIC ENGINE IDLE SHUTDOWN
1. Engine load is greater than 45%.
Vehicles may be equipped with an optional feature which
2. Brake pedal is applied or brake switch fault is detected. provides engine shutdown which can be programmed from 3-
to 120-minute idle time. Thirty (30) seconds before engine
3. Clutch pedal is depressed or clutch pedal switch fault is
shutdown, the “OIL/WATER" light will begin flashing and an
detected (manual transmissions, if equipped with a clutch
audible alarm will sound, until the engine shuts down or the low
switch).
idle shutdown timer is reset.
4. Shift selector is moved from park or neutral (automatic
The engine shutdown time will reset when one or a combination
transmissions). Shift selector must be in neutral for CAP to
of any of the following occurs:
work.
1. Power Take Off (PTO) is active.
5. PTO switch, also used for electronic hand throttle, is turned
on. 2. Engine speed is not at idle speed (700 rpm).
6. Accelerator pedal is depressed or accelerator pedal sensor 3. Vehicle movement or a VSS Sensor fault is detected.
fault is detected.
4. Accelerator Pedal movement or an APS fault is detected.
7. Timed idle shutdown is enabled.
5. Engine coolant operating temperature is below 60°C
8. Engine Coolant Temperature (ECT) sensor fault is detected. (approx. 140°F).
9. Intake Air Temperature (ambient temperature) sensor fault 6. Ambient temperature below 16°C (60°F) or above 44°C
is detected. (110°F).
7. Brake pedal movement is detected or a brake switch fault is
ENGINE SHUTDOWN
detected.
Good practice calls for idling the engine for several minutes prior
to shutdown, particularly after a long run where engine has been
producing maximum horsepower and heat load. This allows

Page 41
 SECTION 5 – OPERATION

AUTOMATIC ENGINE IDLE SHUTDOWN (cont.)

8. Clutch pedal is depressed or clutch pedal switch fault is PARKING

detected (manual transmissions, if equipped with a clutch
switch).
WARNING: To avoid serious personal injury, possible
9. Shift selector is moved from park or neutral (automatic death, and engine damage, when parking your diesel
transmissions). vehicle, do not leave the transmission in gear. Use the
parking brake. When parking on a grade also block the
SHUTDOWN WARNING LIGHT OR AUDIBLE ALARM wheels or turn them to the curb. Failure to follow these
procedures could result in an unattended vehicle moving.
Vehicles may be equipped with an automatic shutdown system
which stops the engine in the event of high coolant temperature,
low coolant level, or low engine oil pressure. A warning light
on the instrument panel along with an audible alarm or bell
will indicate high coolant temperature, low coolant level or low
oil pressure. If the temperature and/or pressure continues to
change beyond the warning point to a predetermined level, the
engine will automatically shut down. Vehicles equipped with the
automatic shutdown system are also equipped with an override
feature which will allow the engine to be restarted so that the
vehicle can be moved, if mechanically capable. The engine
should be run no longer than absolutely necessary. Activate the
override system by turning the key to the OFF position. Then
turn the key to the ON position to restart the engine. If the
Oil Pressure Low, Coolant Temperature High or Coolant Level
Low warnings activate, the engine will run for an additional 30
seconds.

Page 42
 SECTION 5 – OPERATION

ROAD OPERATION shutdown enabled). This software aids in engine warm-up and
maintaining engine heat during extended idling periods. Refer
To receive satisfactory engine performance with maximum to “Extended Idling Periods” for further information.
fuel economy and service life, the following general engine
guidelines should be followed.
WARNING: To avoid serious personal injury, possible
Start the vehicle in motion by utilizing the highest gear speed in death, and engine damage, provide proper ventilation when
the transmission that will enable the engine to easily start the operating engine in a closed area to remove deadly exhaust
load without slipping the clutch. Accelerate smoothly and evenly fumes. Breathing exhaust fumes may prove fatal.
to engine rated speed. Rapid acceleration will result in high fuel
consumption with no increase in performance.
Engine speed should not be permitted to drop below peak torque
(refer to Section 6) when pulling at full throttle to avoid lugging
conditions. When approaching a hill, depress the accelerator
smoothly to start the upgrade at full power, then shift down as
needed to maintain maximum vehicle speed.

DOWNHILL OPERATION

Prevent overspeeding of the engine when going down long and

steep grades. Operate in a gear that will permit an engine speed
not in excess of high idle RPM. Operating engine beyond high
idle speed can cause severe damage.

IDLE SPEEDS

Low idle speed for the DT530 and HT530 engine is 700 rpm
(non-adjustable).
A Cold Ambient Protection (CAP) system has been added to the
vehicle's Engine Control Module (ECM) (except units with idle

Page 43
 SECTION 5 – OPERATION

Page 44
 SECTION 6 – SPECIFICATIONS AND CAPACITIES

WARNING: To avoid 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 the engine or vehicle.

Table 1 2001 through 2003 Model Year DT530 and HT530 Series Diesel Engine Specifications
Engine Model: (50 States) DT530 and HT530
Number of Cylinders: 6
Configuration: In-line
Bore: 116.5 mm (4.59 in)
Stroke: 135.9 mm (5.35 in)
Displacement: 8.7 liter (530 cu in)
Compression Ratio: 16.9:1
Firing Order: 1–5–3–6–2–4
Valve Tappet Clearance (cold):
Intake: 0.635 mm (0.025 in)
Exhaust: 0.635 mm (0.025 in)
Engine Lube Oil Pressure
(engine at operating temperature with SAE 10W-30 oil)
Low idle (700 rpm, non-adjustable): 103 kPa (15 psi), minimum (Typical)
High idle (non-adjustable) 276 – 483 kPa (40 – 70 psi)

Page 45
 SECTION 6 – SPECIFICATIONS AND CAPACITIES

Table 1 2001 through 2003 Model Year DT530 and HT530 Series Diesel Engine Specifications (cont.)
Power Ratings and Speed Settings
Model: (50 States) DT530 and HT530
Brake Horsepower @ rpm: Refer to Exhaust Emission Label Located on Top of Engine Valve Cover/Intake Manifold for Rating

Peak Torque @ rpm (lb-ft):
Idle Speed No Load (rpm):
Thermostat Opening Temperature:
Crankcase Capacity — Lube Oil
(without oil filter):
Crankcase Capacity — Lube Oil
(with oil filter):
NOTE: SAE J1995 Horsepower: No deration required up to 3048 meters (10,000 ft)
Refer to Exhaust Emission Label Located on Top of Engine Valve Cover/Intake Manifold for Rating
700 (non-adjustable)
86°C - 89°C (187°F - 192°F)
With Front Drive Steer Axle 22.7 liters (24 quarts)
Without Front Drive Steer Axle 24.6 liters (26 quarts)
With Front Drive Steer Axle 26.4 liters (28 quarts)
Without Front Drive Steer Axle 28.4 liters (30 quarts)

Fuel Requirements
RECOMMENDED FUEL FOR ON-HIGHWAY NAVISTAR®
DIESEL ENGINES

This fuel information will help the operator obtain maximum

performance for the lowest cost when using a Navistar® diesel
engine. The specifications are broad enough to permit the use
of low cost fuels yet are restrictive enough to prevent use of low
quality fuels which could lead to frequent overhauls.

Page 46
 SECTION 6 – SPECIFICATIONS AND CAPACITIES

Fuel Requirements (cont.)

RECOMMENDED FUEL FOR ON-HIGHWAY NAVISTAR®
DIESEL ENGINES (cont.)

Fuel Grade: Use only Grade No. 1-D or Grade No. 2-D diesel emissions standards. If <10,000 ppm (1%) sulfur fuels are used,
fuels. Specifications for these fuels are listed in ASTM D975. reduce engine oil change interval (page 72).

Expected Temperature Preferred Fuel Grade

Above +20°F (-7°C) Grade No. 2-D
Below +20°F (-7°C) Grade No. 1-D
NOTE: If grade No. 1-D is not available, use a “winterized" or
“climatized" Grade No. 2-D fuel, made by blending No. 1-D with
No. 2-D fuel to match the temperature conditions in your area. Use
diesel fuel with a minimum 45 Cetane number.

If your engine suddenly becomes noisy after a fuel fill, you

possibly received substandard fuel with a low cetane rating.
Whenever feasible, buy diesel fuel from a reputable supplier
who sells a large amount of diesel fuel.
Sulfur Content: Diesel fuels with a maximum sulfur content of
0.0015 percent are required by U.S. EPA Emission Standards.

FUEL FOR EXPORT ONLY NAVISTAR® DIESEL ENGINES

Navistar, Inc. approves the use of high sulfur diesel fuels that
contain no more than 10,000 parts per million (ppm) (1%) sulfur
in engines for EXPORT ONLY. The use of <10,000 ppm (1%)
sulfur diesel fuels does not conform to U.S. EPA on-highway

Page 47
 SECTION 6 – SPECIFICATIONS AND CAPACITIES

Fuel Requirements (cont.)

ADVISORY

Navistar, Inc. DOES NOT recommend or in any way advocate

the blending of engine oil with diesel fuel in any application
equipped with an Navistar® diesel engine. Blending engine oil
with diesel fuel constitutes the use of fuels NOT recommended
for the engine and will significantly increase exhaust emissions.
It is also likely using such blends will increase the rate of internal
engine wear. Any malfunctions or failure of the engine to meet
Federal, California or any other emissions standards due to
non-recommended fuel usage, is not covered by the emission
control system warranty. Refer to Section 3 for warranty
statement.

DIESEL FUEL/GASOLINE BLENDS

Navistar, Inc. DOES NOT recommend the blending of

gasoline, and/or alcohol with diesel fuel due to the hazards Figure 22 Mixing Diesel Fuel and Gasoline
of fire/explosion and the detrimental effects on engine
performance.
Only two percent volume gasoline mixed with diesel fuel will
HAZARDS OF FIRE AND EXPLOSION create a flammable/explosive mixture in the fuel tank vapor
space, which will pose an extreme fire/explosion hazard during
WARNING: To avoid serious personal injury, possible refueling or engine operation.
death, and engine damage, do not mix gasoline, gasohol
and/or alcohol with diesel fuel. This practice creates
an extreme fire hazard and under certain conditions an
explosive hazard.

Page 48
 SECTION 6 – SPECIFICATIONS AND CAPACITIES
Engine Performance Problems
CAUTION: To avoid engine damage, avoid using lower viscosity
fuel. Low viscosity fuel may reduce engine power and fuel
economy, and increases the possibility of excessive fuel system
wear or failure.
CAUTION: Lower Cetane number could cause hard starting and
slower warm-up, and could increase engine noise and exhaust
emissions. Use diesel fuel with a minimum 45 Cetane number.
Cooling System
REQUIREMENTS
CAUTION: To Avoid Engine Damage
• An antifreeze concentration greater than 68% has a
higher freezing point than 68% antifreeze. This will
adversely affect freeze protection and heat transfer
rates which may result in restriction of engine coolant
passages, causing overheating and subsequent engine
damage.
• Use coolant which has an ethylene glycol base.
Propylene glycol base antifreeze is also an approved
antifreeze. Both of these antifreezes must be of low
silicate (less than 0.10%) that meets ASTM D6210
specification. (Be aware that ROTELLA extended
life coolant, which is red in color, does not contain
silicates.) Your diesel engine warranty could be
adversely effected should automotive high silicate
antifreeze be used.
CAUTION: To avoid engine damage, do not mix “Extended
Life Coolants" (red in color) with Conventional Coolants (green
or purple in color). Fleetrite® extended life coolant or coolant
meeting specification B-1, Type III, can be used in Navistar®
diesel engines. See your International dealer for details.
CAUTION: To avoid engine damage, do not add propylene
glycol antifreeze to any Navistar® diesel engine or truck cooling
system containing ethylene glycol antifreeze or vice versa.
Page 49
 SECTION 6 – SPECIFICATIONS AND CAPACITIES

Cooling System (cont.)

REQUIREMENTS (cont.)

CAUTION: To avoid engine damage, do not use extended contaminated or not strawberry red in color, it should be tested
life coolant or ROTELLA Extended Life Engine Coolant or its using Extended Life Coolant Test Strip Kit (ELCTS). This kit can
equivalent coolant (red in color) for engines identified with a “B” be obtained by calling 18007435582.
model code.
Chart 1 ROTELLA Extended Life Engine Coolant
NOTE: ROTELLA Extended Life Engine Coolant or its equivalent Part Numbers
(red in color) has been approved by Navistar, Inc. for use in
55 Gallon Extended Life 55 Gallon 50/50 (Premix)
cooling systems for engines with the “C” model code 2000
Coolant (Concentrate) ROTELLA ROTELLA 94042000055
through 2003 later model year DT530 and HT530 diesel
940410055
engines.
1 Gallon Extended Life Coolant 1 Gallon 6/Package 50/50
ROTELLA EXTENDED LIFE COOLANT (RED IN COLOR) (Concentrate) ROTELLA Premix ROTELLA 9404206021
9404106021
Cooling systems should be checked twice a year to ensure
2000 Gallon 50/50 Premix 1 Quart 6/Package 50/50
proper water/glycol concentrations. A 50/50 mixture is
ROTELLA 9404200001 Extender ROTELLA
recommended and provides freeze protection down to -36°C
9404306031
(-32°F) as well as optimum corrosion protection. For vehicles
operating in extremely cold climates, a concentration of 60% will
provide freeze protection down to -50°C (-58°F). Concentrations NOTE: Do not mix “Extended Life Coolants" (red in color) with
greater than 67% are not recommended. The use of ROTELLA conventional coolants (green or purple in color). Fleetrite®
pre-diluted 50/50 to make up for coolant loss will ensure the extended life coolant or coolant meeting specification B-1,
glycol/water concentrations stay in balance. type III, can be used in Navistar® diesel engines. See your
International dealer for details.
When freeze point testing is conducted, a visual inspection of
the coolant should be made. The coolant should be strawberry
red in color and should be free of dirt, debris, rust, and
other contaminants. If the coolant appears to be significantly

Page 50
 SECTION 6 – SPECIFICATIONS AND CAPACITIES

Cooling System Specifications Chart 2 Quantity of ROTELLA Extender (ROTELLA

9404306031) needed at 6,000 hours, 30 months or
MAINTAINING REQUIRED INHIBITOR CONCENTRATION 241,000km (150,000 miles) of use
(FOR EXTENDED LIFE ANTIFREEZE [RED IN COLOR])
Cooling System Capacity ROTELLA Extender
Extended life and conventional coolants contain additives and Quantity
Liters Gallons
inhibitors that deplete making it necessary to add supplemental
22-30 6-8 0.5 quart
coolant additives. The inhibitors in extended life coolant deplete
more slowly, thereby extending service intervals to 5 years, 30-49 8-13 1 quart
300,000 miles (483,000 kilometers) or 12,000 hours, with the 49-83 13-22 1.5 quart
addition of extender chemistry only at the half way point: 30
months, 150,000 miles (241,000 kilometers) or 6,000 hours.
Extended life coolant does not require a filter. If a filter is COOLANT TESTING FOR INHIBITOR CONCENTRATION –
installed, only a blank filter containing no supplemental coolant (FOR EXTENDED LIFE [RED] COOLANTS)
additive (0.0 units of DCA-4), International® P/N 1833690C1
Regular coolant testing of inhibitor concentration for extended
or Fleetrite® P/N WF 2140, should be used. The coolant filter,
life coolants (ROTELLA) is not necessary due to the slow
when used with extended life coolant, should be replaced at
depletion of carboxylate inhibitors. No test kit is required.
6,000 hours, 30 months or 241,000 km (150,000 miles).
Vehicles factory filled with extended life coolant will be equipped NOTE: When the cooling system is maintained properly and
with a filter replacement cap. The optional filter, Fleetrite® P/N ROTELLA or equivalent is used for top off, there is no need to
1833690C1 should be replaced every 6000 hours, 30 months or conduct routine testing for inhibitor levels.
241,000 km (150,000 miles).
When freeze point testing is conducted, a visual inspection of
the coolant should be made. The coolant should be strawberry
NOTE: DCA-4 Coolant additive should not be used with
red in color and should be free of dirt, debris, rust, and
extended life coolant (red in color).
other contaminants. If the coolant appears to be significantly
contaminated or not strawberry red in color, it should be tested
using the Extended Life Coolant Test Strip Kit. This kit can be
obtained by calling 1-800-743-5582.

Page 51
 SECTION 6 – SPECIFICATIONS AND CAPACITIES
Cooling System Specifications (cont.)
COOLANT TESTING FOR INHIBITOR CONCENTRATION –
(FOR EXTENDED LIFE [RED] COOLANTS) (cont.)
CAUTION: To avoid engine damage, do not add propylene
glycol antifreeze to any Navistar diesel engine cooling system
containing ethylene glycol antifreeze or vice versa. Do not mix
conventional coolant (green or purple) and extended life coolant
(red).
COOLING SYSTEM REQUIREMENTS – (FOR
CONVENTIONAL COOLANT (GREEN OR PURPLE IN
COLOR)
ETHYLENE GLYCOL ANTIFREEZE
For cooling system capacities, refer to the vehicle operator's
manual. Ethylene glycol antifreeze may be added in 45% - 55%
concentration for protection below -29°C (-20°F). Concentrations
above 60% and not over 68% are acceptable only for very
cold climates where freeze protection of -48°C (-54°F) to -61°C
(-78°F) respectively are required.
Chart 3 Ethylene Glycol Antifreeze Part Numbers
Gallon 2JJ996723A
55 Gallon Drum 2JJ996900C
Premix (50/50) 9404206021
Page 52
PROPYLENE GLYCOL ANTIFREEZE
Should a serviceman choose to empty all ethylene glycol from
the engine, under this circumstance propylene glycol may be
used. Blends of propylene glycol antifreeze and water containing
50 to 55% antifreeze concentrate are recommended for normal
applications. These correspond to freeze points of -32°C (-26°F)
and -40°C (-40°F) respectively. Concentrations above 60% and
not over 68% are acceptable only for very cold climates where
freeze protection of -48°C (-54°F) to -61°C (-78°F) respectively
are required.
MAINTAINING REQUIRED CONDITIONER
CONCENTRATION (FOR CONVENTIONAL COOLANT
[GREEN OR PURPLE IN COLOR])
All cooling system conditioners, including those in antifreeze
solutions, become depleted through normal operation. If
conditioners in antifreeze are allowed to become depleted, the
antifreeze becomes corrosive. The antifreeze solution then
attacks the metal surface of the cooling system causing leaks
and deposit build up, which reduces heat transfer. To maintain
an acceptable conditioner concentration, additional chemicals
must be supplied to the cooling system.
 SECTION 6 – SPECIFICATIONS AND CAPACITIES

Cooling System Specifications (cont.)

MAINTAINING REQUIRED CONDITIONER
CONCENTRATION (FOR CONVENTIONAL COOLANT
[GREEN OR PURPLE IN COLOR]) (cont.)

Cooling Conditioner, recommended for use (Green or purple Chart 5 Coolant Filter Part Number
coolant) in the DT530 and HT530 Diesel Engines, is a complete
International® P/N Fleetrite® P/N DCA-4 Units in Filter
inhibitor system. It is a phosphate-molybdate and nitrite based
formulation which provides corrosion protection, prevents liner 1815591C1 WF 2075 15.0
pitting, controls pH, neutralizes acids and contains additives 1815588C1 WF 2074 12.0
which prevent the formulation of mineral deposits.
1815589C1 WF 2073 8.0
Approved Cooling System Conditioner part numbers are
1815590C1 WF 2072 6.0
displayed in (Chart 4). Appropriate coolant filters are displayed
in (Chart 5). 1822627C1 WF 2071 4.0

Chart 4 Supplemental Cooling Additive/Part Number COOLANT FILTER/CONDITIONER

Quantity Fleetrite® P/N DCA-4 Units in
Container Some DT530 and HT530 Series Diesel Engines are equipped
with a coolant filter and should be serviced per (Chart 6) shown
Pint (16 ounces) DCA60L 5 on the following pages. For Cooling System Capacity, refer to
0.5 Gallon (64 ounces) DCA65L 20 vehicle operator's manual.
5.0 Gallon (640 ounces) DCA75L 200 Engines in high hour and low mileage applications, such as
55 Gallon Drum (7040 DCAR880L 2,200 refuse packers and transit mixers, which operate frequently
ounces) at low engine speeds and engine temperatures, are best
maintained according to hour intervals rather than mileage
intervals.

Page 53
 SECTION 6 – SPECIFICATIONS AND CAPACITIES

Cooling System Specifications (cont.)

COOLANT FILTER/CONDITIONER (cont.)

Anytime, make-up coolant is added to the cooling system, liquid Chart 6 Coolant Conditioner Filter Maintenance Schedule
Cooling System Conditioner should be added at a minimum
Every 15,000 miles (24,100 km) or 550 engine hours, test
rate of 227 ml (8 ounces) (2.5 units) per one gallon of make-up
SCA (DCA-4) level. Replace coolant filter every 30,000 miles
coolant. After adding conditioner, operate engine until it is
(48,300 km) or 1100 engine hours and add liquid DCA-4
warmed up enough to circulate the conditioner through the
to bring to a safe level, if necessary.
cooling system.
Total cooling Service with Coolant Filter Units of
COOLANT TESTING FOR CONDITIONER CONCENTRATION system DCA-4 in
– (FOR CONVENTIONAL [GREEN OR PURPLE] COOLANTS) capacity 28-56 Filter
quarts (7-14
International® Fleetrite® P/N 4.0
When the cooling system is maintained as recommended, the gallons)
P/N
conditioner concentration should be satisfactory. A Coolant
Test Kit, P/N CC2602 is available to determine the chemical 1822313C1 WF 2106
concentration level.
CAUTION: To avoid engine damage, the SCA (DCA-4) level
In general, a good reading indicates that the conditioner
should be brought to a level of 1.5 - 3.0 units per gallon at
contained in the coolant is sufficient to insure cooling system
time of service. This will help ensure that a safe level will be
protection. Test kit measurements are in units per gallon.
maintained until the next service interval. It is recommended
Recommended level is 1.5 to 3.0 units per gallon. It is
that SCA concentration level be checked at regular Preventative
recommended that the conditioner concentration be checked
Maintenance service intervals.
with the test kit at a minimum of every four (4) months, every
time the filter is changed or anytime there is a large loss of
NOTE: The use of form EGED-140 is helpful in determining the
coolant. Refer to (Chart 6).
amount of liquid DCA-4 that needs to be added, if required. The
Refer to (Chart 7) for the coolant capacity and coolant filter reverse side of form EGED-140 provides a simple three (3) step
needed. method to determine the total units per gallon at any level of
protection desired.

Page 54
 SECTION 6 – SPECIFICATIONS AND CAPACITIES

Cooling System Specifications (cont.)

COOLANT TESTING FOR CONDITIONER CONCENTRATION
– (FOR CONVENTIONAL [GREEN OR PURPLE] COOLANTS)
(cont.)

CAUTION: To avoid engine damage, it is vital that the above

change intervals, filters and conditioner be followed precisely. It
is recommended that the coolant conditioner concentration level
be maintained between 1.5 - 3.0 units per gallon of DCA-4. If
not, the concentration of conditioners in the coolant may become
depleted or over concentrated, both of which can be detrimental
to the cooling system and engine. SCA levels should not
exceed 3.0 units per gallon. Coolant filters and cooling system
conditioners other than those recommended by Navistar, Inc.
may not provide the proper concentration of conditioners and
may not be compatible with the cooling system.

NOTE: One unit of DCA-4 conditioner is equal to 3.2 liquid

ounces.

CAUTION: To avoid damage to your engine, do not follow the

time intervals and quantities specified on the liquid conditioner
bottles. Follow the maintenance schedule specified in this
manual.

Page 55
 SECTION 6 – SPECIFICATIONS AND CAPACITIES

Cooling System Specifications (cont.)

COOLANT TESTING FOR CONDITIONER CONCENTRATION
– (FOR CONVENTIONAL [GREEN OR PURPLE] COOLANTS)
(cont.)
Chart 7
Every 200,000 miles (322,000 km), 3,800 engine hours or 2 years (whichever comes first) and after any complete drain.
Drain and flush system, install new coolant, new coolant filter and add liquid DCA-4 as needed.
Cooling System Capacity Service with Coolant Filter Additional DCA-4 Units Liquid Ounces
per Gallon
28-32 quarts (7.0-8.0 gallon) 0.4 - 0.5 = 1.3 - 1.6
33-36 quarts (8.25-9.0 gallon) 0.6 - 0.8 = 1.9 - 2.5
37-40 quarts (9.25-10.0 gallons) 1 820 361 C1 0.9 - 1.0 = 2.3 - 3.2
OR
41-44 quarts (10.25-11.0 gallons) 1.0 - 1.2 = 3.2 - 3.8
WF2104
45-48 quarts (11.25-12.0 gallons) (15 DCA Unit Filter) 1.1 - 1.3 = 3.5 - 4.1
49-52 quarts (12.25-13.0 gallons) 1.2 - 1.4 = 3.8 - 4.5
53-56 quarts (13.25-14.0 gallons) 1.3 - 1.5 = 4.2 - 4.8
NOTE: One unit of DCA-4 conditioner is equal to 3.2 liquid ounces.

Page 56
 SECTION 6 – SPECIFICATIONS AND CAPACITIES
Cleaning The Cooling System
CORROSION PREVENTION
NOTE: An Alkaline Cooling System Cleaner will clean silicate
gel from the cooling system as long as the silicate gel has
not hardened. An acid type cleaner will clean heavy rust and
corrosion from the cooling system.
CAUTION: To avoid engine damage, the system must be
flushed with clean water after using an alkaline or acid type
cooling system cleaner.
CAUTION: To avoid engine damage, coolant conditioner alone
should not be added to the cooling system if the unit has been
run for a long period of time without coolant conditioner. Coolant
conditioner could loosen deposits which might cause radiator
plugging.
The cooling system should be drained and thoroughly
flushed. See Service Cooling System in Section 7 for further
information.
Unless the cooling system is treated with a corrosion
preventative, rust and scale will eventually clog up passages in
the radiator and waterjackets. This condition is aggravated in
some localities by formation of insoluble salts from the water
used.
Commercial cleaning solutions are available which have proven
very successful in removing accumulation or rust, scale,
sludge and grease. They should be used according to the
recommendation on the container. See Service Cooling
System in Section 7 for procedure.
NOTE: Do not use chemical mixtures to stop radiator leaks
except in an emergency. Never use such solutions instead of
needed radiator repair.
WARNING: To avoid serious personal injury, possible
death, and engine damage, use only the following
procedure to remove the pressure cap from the cooling
system. Always allow the engine to cool first. Wrap a thick,
heavy cloth around the cap. Push down, loosen cap slowly
to its first notch position; then pause a moment. This will
avoid possible scalding by hot water or steam. Continue to
turn cap to the left and remove.
CAUTION: To avoid serious personal injury, possible death, and
engine damage, use only the following procedure to remove the
pressure cap from the cooling system. Always allow the engine
to cool first. Wrap a thick, heavy cloth around the cap. Push
down, loosen cap slowly to its first notch position; then pause a
moment. This will avoid possible scalding by hot water or steam.
Continue to turn cap to the left and remove.
RADIATOR FINS
Check the radiator fins periodically to make sure they are free
of bugs, leaves and other debris, and that they are not bent or
damaged. Clogged or damaged fins prohibit the flow of air to the
radiator and hamper efficient cooling system operation.
Page 57
 SECTION 6 – SPECIFICATIONS AND CAPACITIES
Cleaning The Cooling System (cont.)
COOLANT HOSES
Only coolants with an ethylene glycol or a propylene base
are recommended for use in Navistar® engine or truck cooling
systems. Other base coolants may damage rubber hoses,
especially those made of silicone rubber. Type of rubber can
usually be determined by color. Silicone hoses are made in
COLOR while other rubber hoses are BLACK. If a coolant
other than recommended here is used, you need to consult the
manufacturer on the effect it could impose on the various types
of hoses used.
The cooling system will most likely be filled with propylene glycol.
It is recommended that an propylene glycol coolant be added to
the system when required.
CAUTION: To avoid engine damage, do not add propylene
glycol antifreeze to any Navistar® diesel engine or truck cooling
system containing ethylene glycol antifreeze or vice versa. Do
not mix conventional coolant (green or purple) and extended life
coolant (red).
THERMOSTAT
Your new engine is equipped at the factory with a high
temperature thermostat.
Permanent type antifreeze must be used with high temperature
thermostats.
Page 58
Coolant Contamination
The maximum permissible contamination of extended life
coolant (red) with convention coolant (green or purple) is 10%.
If contamination level is exceeded either consider the cooling
system as filled with conventional coolant or drain coolant and
thoroughly flush cooling system with an alkaline or acid type
cooling system cleaner. Refill the cooling system with clean
water and the appropriate coolant.
Engine Lubrication Requirements
OIL QUALITY
Oil quality is described by API (American Petroleum Institute)
engine service categories. API categories are defined by oil
performance (deposits and wear) measured in standardized
engine tests. The API “S" category (SJ) describe oils for spark
ignition (gasoline) engines, while “C" categories (CF-4, CG-4
and CI-4) describe oils for diesel engines. Oils with both “S"
and “C" categories (such as CG-4/SJ/SH) are suitable for both
spark ignition and diesel engines.
 SECTION 6 – SPECIFICATIONS AND CAPACITIES
Engine Lubrication Requirements (cont.)
OIL QUALITY (cont.)
Use API licensed oil meeting API category CI or CI-4 PLUS.
API licensed oils can be recognized by the Identification Symbol
(Figure 24) displayed on the container. CH-4 engine oils should
only be used when CI-4 and CI-4/SL oils are not available. Refer
to shaded areas in , SAE Vicosity Grades and Temperature
Ranges, which indicates the preferred oil for the expected
temperature range. Low viscosity or winter grade oils are
desirable for low temperature engine operation.
NOTE: API has licensed a new oil category designated CJ-4.
Fleetrite® Premium 15W-40 meets this requirement. It may also
be used in conjunction with Ultra Sulphur diesel fuel (15 ppm
maximum sulphur).
Recently the Association des Constructucteurs Europeens
D'Automilies (ACEA), the Engine Manufacturers Association
(EMA), and the Japan Automobile Manufacturers Association
(JAMA) jointly developed a recommended guideline for
heavy-duty diesel engine oils, Global DHD-1.
Global DHD-1 is now available and is intended to provide a
consistent oil performance worldwide. It may be recommended
by engine manufacturers to maintain durability wherever their
engine is being used.
CAUTION: To avoid engine damage:
• Do not use oils specifically marketed by suppliers for
marine or railroad diesel engines, or for stationary
engines that use either diesel fuel or natural gas.
Such oils can cause excessive valve train wear and
combustion chamber deposits. (These types of oil are
sold only in drums and in bulk quantities.)
• DO NOT USE oil from drums or pumps that display the
star-burst symbol and the following words printed on it
“FOR GASOLINE ENGINES.”
OIL VISCOSITY
Oil viscosity (thickness) is described by SAE (Society of
Automotive Engineers) Viscosity Grade. Colder temperatures
require lower viscosity oils to ensure good flow during starting,
while hotter temperatures require higher viscosity oils for
satisfactory lubrication. Based upon the temperature range you
expect before your next oil change, use the chart (Figure 23)
and the notes below to choose the proper viscosity grade.
CAUTION: Selection of oil grades outside the recommended
ranges could cause engine damage.
Page 59
 SECTION 6 – SPECIFICATIONS AND CAPACITIES

Engine Lubrication Requirements (cont.)

OIL VISCOSITY (cont.)

OIL CHANGE INTERVAL

Refer to Maintenance Instructions for the recommended oil

change interval for your engine. Use of oils exceeding the
required quality level, synthetic oils or other oils claiming longer
service intervals does not justify extending oil change intervals
beyond those recommended.
For Navistar® diesel engines, the recommended oil change
intervals are based on the U.S. EPA Emission Standards with
a maximum sulfur content of 0.05% in the fuel. Know your fuel
sulfur content. Ask your supplier, or have fuel analyzed. If fuel
contains more than 0.05% sulfur, reduce oil change interval
(page 72).

NOTE: It is NOT necessary to reduce filter change intervals

when oil change intervals are reduced to accommodate fuels
with more than 0.05% sulfur content.

IDENTIFICATION SYMBOL
Figure 23 SAE Viscosity Grades and Temperature Ranges
An oil container symbol system has been developed to help you
choose the proper oil. The top portion of the symbol shows the oil
Increase in oil consumption may be expected when SAE 0W-30,
quality, such as API Service CI-4 in the example (Figure 24). The
5W-30, 5W-40, and 10W-30 oils are used. CHECK OIL LEVEL
symbol may show additional categories, such as API Service
MORE FREQUENTLY.
CI-4/SL or CH-4. The center portion will show the SAE viscosity
grade, such as SAE 15W-40 in the example.

Page 60
 SECTION 6 – SPECIFICATIONS AND CAPACITIES

Engine Lubrication Requirements (cont.)

IDENTIFICATION SYMBOL (cont.)

DT530 AND HT530 SERIES DIESEL ENGINE CRANKCASE

REFILL CAPACITIES FOR UNIT WITH FRONT
DRIVE/STEERING AXLE AND SHORT FILTER

25.6 Liters (27 quarts) with filter change

21.8 Liters (23 quarts) without filter change

Figure 24 Example — Identification Symbol

DT530 AND HT530 SERIES DIESEL ENGINE CRANKCASE

REFILL CAPACITIES FOR UNIT WITHOUT FRONT
DRIVE/STEERING AXLE

28.3 Liters (30 quarts) with filter change

24.6 Liters (26 quarts) without filter change

Page 61
 SECTION 6 – SPECIFICATIONS AND CAPACITIES

Engine Lubrication Requirements (cont.)

CHECKING ENGINE OIL LEVEL

NOTE: Never check the oil level with the engine running or
immediately after engine shutdown as an inaccurate reading
will be obtained. Allow 15 minute drain down time.

CAUTION: To avoid engine damage, keep oil level within the

operating range on the oil level gauge. Never operate an
engine with oil level outside of the operating range. DO NOT
OVERFILL!

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 SECTION 7 – MAINTENANCE INSTRUCTIONS

General CAUTION: To avoid damage to your engine, disconnect engine

and chassis harness connectors at the Engine Control Module
(ECM) before any welding is to be performed on the vehicle.
WARNING: To avoid serious personal injury, possible damage to the ECM will result if the ECM is not disconnected.
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 the engine or vehicle.
Maintenance Operations
For effective emission control and low operating cost, it is The following information and explanation of the required
important that maintenance operations listed on the following maintenance operations are numbered to correspond with the
pages be performed at the specified intervals indicated. operations listed on the Maintenance Schedule Chart.
Service intervals are based upon average operating conditions.
Where dusty, frequent start and stop or heavily laden operations
are encountered, more frequent servicing will be required.
As the owner, you are responsible for the performance of all
scheduled maintenance. The required maintenance operations
may be performed by the owner or a service establishment
of the owner's choosing. Any replacement parts used for
required maintenance services or repairs should be genuine
International® parts or equivalent in quality and performance to
genuine International® parts. Use of inferior replacement parts
hinders operations of the engine and emissions control system.
Receipts covering the performance of regular maintenance
should be retained in the event questions arise concerning
maintenance. The receipts should be transferred to each
subsequent owner of the engine (vehicle).

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 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations (cont.)

Table 2 Maintenance Schedule Chart For DT530 and HT530 Series Diesel Engines
Inspection Intervals (Whichever Miles, Kilometers, Hours, Months, or
Gallons of Fuel Used Occurs First)
Op. Maintenance Operation D Every 24,100 km Every 48,300 Every 24 Every 193,100 km Every 290,000 to Annually Every 322,000 km Every 241,000 km Every 500,000 km or
No. a (15,000 Miles) 550 km (30,000 Months (120,000 Miles) 322,000 km (180,000 or 200,000 miles or 150,000 miles 300,000 miles or 12,000
i Hours, 6 Months Miles) 1,100 5,000 Hours to 200,000 Miles) OR or 3,800 hours or or 6,000 hours or hours or 5 years
l OR 2100 Gallons Hours, 12 6,700 to 7,500 Hours 2 years 2–1/2 years
y Months OR

4200 Gallons
1 X
Check Oil Level1
2 Check Coolant
1 X
Level
3 Drain Water
Separator (Fuel X
1
System) 2
4 Inspect Air to Air
1 X
Cooler
5 Inspect for
1 X
External Leakage
6 Inspect Air
Restriction X
Indicator3
7 1 X
Inspect Belt
8 Change Engine Refer to
Oil And Filter4 Operation 8
(page 72)

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 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations (cont.)

Table 2 Maintenance Schedule Chart For DT530 and HT530 Series Diesel Engines (cont.)
Inspection Intervals (Whichever Miles, Kilometers, Hours, Months, or
Gallons of Fuel Used Occurs First)
Op. Maintenance Operation D Every 24,100 km Every 48,300 Every 24 Every 193,100 km Every 290,000 to Annually Every 322,000 km Every 241,000 km Every 500,000 km or
No. a (15,000 Miles) 550 km (30,000 Months (120,000 Miles) 322,000 km (180,000 or 200,000 miles or 150,000 miles 300,000 miles or 12,000
i Hours, 6 Months Miles) 1,100 5,000 Hours to 200,000 Miles) OR or 3,800 hours or or 6,000 hours or hours or 5 years
l OR 2100 Gallons Hours, 12 6,700 to 7,500 Hours 2 years 2–1/2 years
y Months OR
4200 Gallons
9 Check
Coolant SCA
Concentration X
(Conventional
1
Coolant Only)
10 Inspect Air
Intake Piping and X
1
Clamps
11 Measure Air Intake
1 3 ,5 X
Restriction ,
12 Change Fuel
X
Filters6
13 Change Coolant X
X X
Filter (If (Green or
7 ,9 (Red) (Red)
Equipped) purple)
14 Pressurize
1
Induction System X
,5

15 Inspect Vibration
1 ,8 X
Damper

Page 65
 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations (cont.)

Table 2 Maintenance Schedule Chart For DT530 and HT530 Series Diesel Engines (cont.)
Inspection Intervals (Whichever Miles, Kilometers, Hours, Months, or
Gallons of Fuel Used Occurs First)
Op. Maintenance Operation D Every 24,100 km Every 48,300 Every 24 Every 193,100 km Every 290,000 to Annually Every 322,000 km Every 241,000 km Every 500,000 km or
No. a (15,000 Miles) 550 km (30,000 Months (120,000 Miles) 322,000 km (180,000 or 200,000 miles or 150,000 miles 300,000 miles or 12,000
i Hours, 6 Months Miles) 1,100 5,000 Hours to 200,000 Miles) OR or 3,800 hours or or 6,000 hours or hours or 5 years
l OR 2100 Gallons Hours, 12 6,700 to 7,500 Hours 2 years 2–1/2 years
y Months OR
4200 Gallons
Adjust Valve Lash
5 ,8 X
16
17 Measure
Crankcase X
5
Pressure
18 Inspect
1 X
Turbocharger
19 Inspect Electrical
1 X
System
20 Service Cooling X
7 X
System (Green or
(Red)
purple)
21 Extended Life
X
Coolant9

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 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations (cont.)

Table 2 Maintenance Schedule Chart For DT530 and HT530 Series Diesel Engines (cont.)
1 Correct if necessary.
2 If equipped.
3 Service Air Cleaner elements as required.
4 If fuel contains more than 0.05% sulfur reduce oil change intervals (page 72)
5 Refer to current Engine Diagnostic Manual sections.
6 Change according to transfer pump minimum specifications.
7 Refer to appropriate manual charts in Section 6 for cooling system maintenance schedules.
8 Refer to EGES-210-1, DT466 and DT530 Diesel Engine Service Manual. (Manual Specified with latest revision.)
9 Extended life coolant does not require a filter. If a filter is installed, only a blank filter containing no supplemental coolant additive should be used.

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 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations — 1 through 6

Daily Maintenance Schedule
OPERATION 1 – CHECK OIL LEVEL (DAILY)

1. Check the oil level by removing the oil level gauge from
the oil fill tube and observe. Oil should be checked after
engine was at operating temperature and allow for 15
minute drain down time. BE SURE the oil level is within the
“OPERATING RANGE" mark on the oil level gauge. The
“OPERATING RANGE" is designated by the cross hatched
area of the oil level gauge. The “ADD" mark indicates that
three quarts of oil should be added. If the oil level is below
“OPERATING RANGE", fill with proper grade of oil for the
prevailing temperature. Refer to the “Engine Lubrication Figure 25 Checking Oil Level
Requirements" in Section 6. DO NOT overfill past the
“OPERATING RANGE" mark.
OPERATION 2 — CHECK COOLANT LEVEL (DAILY)

1. Observe the level of coolant in the deaeration tank. The

coolant level should be mid point, between the HOT and
COLD level of the deaeration tank. If the level is below the
COLD mark of the tank refer to “Cooling System" in Section
6 for the proper requirements and specifications.
2. Refer to Service Cooling System in this section for the
filling procedure.

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 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations — 1 through 6 Daily

Maintenance Schedule (cont.)
OPERATION 3 — WATER SEPARATOR, FUEL SYSTEM - OPERATION 4 — INSPECT AIR-TO-AIR COOLER (DAILY)
IF EQUIPPED (DAILY)
1. With the engine off, visually inspect the air-to-air cooler core
Drain water from fuel system as follows: assembly for debris and clogging of external fins.
1. Loosen valve on bottom of water separator and allow water 2. Prior to engine operation, remove any debris blocking the
to drain out. core (Figure 26).
2. Tighten drain valve.

Figure 26 Chassis Mounted Air-to-Air Cooler

Page 69
 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations — 1 through 6 Daily

Maintenance Schedule (cont.)
OPERATION 5 — INSPECT FOR EXTERNAL LEAKAGE 3. Visually inspect air cleaner housing for damage or distortion
(DAILY) which could allow unfiltered air to enter the engine. Correct
as required.
NOTE: With engine turned-off, parking brake applied and wheels
4. Install a new air cleaner element.
blocked.
5. Reset the indicator by pushing the reset button and releasing
Visually inspect for leakage as follows :
it. The yellow indicator will drop below the window so the
1. Hoses (for cracking and loose clamps). gauge can be reused.
2. Water stains.
3. Oil stains.
4. Wetness at water pump.

OPERATION 6 — INSPECT AIR CLEANER RESTRICTION

INDICATOR (DAILY)

Refer to “Air Cleaner Restriction Indicator" in Section 4 of this

manual, for inspection procedure.
Service the air cleaner as follows:
1. Remove dirty air cleaner element and discard.
2. Clean any accumulation of dirt from the air cleaner housing.
DO NOT USE SHOP AIR FOR THIS CLEANING. Use a
clean rag.

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 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations – 7 through 10

Inspection Interval: Every 24,100 km
(15,000 miles), 550 hours, 6 months or
2100 Gallons of Fuel; Whichever Occurs First
OPERATION 7 — INSPECT BELT

Check belt for worn, grease, oil soaked and missing material.
Replace as necessary.
Replacement Guidelines
Install new belt as follows:

NOTE: When installing belt be sure to place it around inside edge

of belt tensioner.
1. Place belt around pulleys.
2. Attach breaker bar to square hole of belt tensioner.
3. Pull breaker bar counter-clockwise, install belt over
tensioner pulley, then release pulley in a clockwise direction. Figure 27 Setting Belt Tensioner
Belt tensioner is automatically adjusted. Remove breaker
bar.

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 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations – 7 through 10

Inspection Interval: Every 24,100 km (15,000
miles), 550 hours, 6 months or 2100 Gallons of
Fuel; Whichever Occurs First (cont.)
OPERATION 8 — CHANGE ENGINE OIL AND OIL FILTER Engine Oil Change Intervals For Vehicles
With Drive/Steering Front Axle (Short Oil
Filter) 28 Quart Capacity
For vehicles without Drive/Steering Front Axle (long oil filter) the
engine oil change limits are: MPG Miles Hours Gallons of
Fuel
Engine Oil Change Intervals For Vehicles Over > 7.0 12,000 475 1800
Without Drive/Steering Front Axle (Long
Between 7.0 11,000 375 1800
Oil Filter) 30 Quart Capacity
to 6.0
MPG Miles Hours Gallons of
Less Than < 9,500 325 1800
Fuel
6.0
Over > 7.0 15,000 550 2100
Between 7.0 12,500 450 2100
to 6.0 If operating engine with fuel greater than 0.05% (500 ppm) of
sulfur, reduce the oil change interval per the following Adjusted
Less Than < 10,000 400 2100 Oil Change Intervals for Higher Sulfur Fuels table (page 73).
6.0
NOTE: Sulfur Content: U.S. Federal law requires all
On-Highway certified Diesel engines to use a non-dyed fuel
containing a sulfur level of 0.0015% (15 ppm) or less.
For vehicles with Drive/Steering Front Axle the engine oil
change limits are:

Page 72
 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations – 7 through 10

Inspection Interval: Every 24,100 km (15,000
miles), 550 hours, 6 months or 2100 Gallons of
Fuel; Whichever Occurs First (cont.)
OPERATION 8 — CHANGE ENGINE OIL AND OIL FILTER
(cont.)

Adjusted Oil Change Intervals for Higher Oil Change NOTE: Do not overtighten filter. A damaged filter may fracture
Sulfur Fuels Interval or leak.
Percent % Sulfur parts per 4. Fill engine to specified capacity with the appropriate oil type
Sulfur million (ppm) as specified in Section 6.
Less Than <0.05% <500 ppm Normal 5. Start engine and run at low idle rpm.
Between 0.05% to 0.10% 500 to 1000 ppm 3/4 Normal Check lube oil pressure gauge reading. If there is no gauge
Over >0.10% >1000 ppm 1/2 Normal reading, shut engine off immediately. Check for oil filter
leaks.
1. Run engine until operating temperature is achieved, then Lube oil pressure gauge reference is a minimum of 103 kPa
shut down. (15 psi) minimum @ 700 RPM.
2. Drain oil pan and reinstall drain plug, using a new gasket if Let engine run until operating temperature is reached.
required. Check for leaks.
3. Install new oil filter as follows: 6. Shut down engine, wait 15 minutes.
a. Remove old oil filter and dispose of according to local 7. Recheck oil level and add oil (if needed) to bring oil level
regulations (Figure 28). within the cross hatched operating range on gauge.
b. Lubricate new oil filter gasket with clean engine oil. 8. DO NOT overfill the top of cross hatch of operating range.
c. Install new oil filter and hand-tighten one (1) full turn after
gasket first contacts filter header.

Page 73
 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations – 7 through 10

Inspection Interval: Every 24,100 km (15,000
miles), 550 hours, 6 months or 2100 Gallons of
Fuel; Whichever Occurs First (cont.)
OPERATION 8 — CHANGE ENGINE OIL AND OIL FILTER
(cont.)

NOTE: After changing the engine oil, if the vehicle utilizes the
Change Oil Message feature, reset the system as follows:

RESET CHANGE OIL MESSAGE

1. Set park brake (Required for correct ESC signal).

2. Turn key switch to the IGN/ON position.
3. Depress and release both the Cruise On and Cruise
Resume/Accel buttons simultaneously four (4) times within
six (6) seconds.
4. Depress and hold both the Cruise On and Cruise
Resume/Accel buttons simultaneously for three (3)
seconds.
5. Release both Cruise buttons.

NOTE: The entire sequence MUST BE completed within twelve

(12) seconds. The Change Oil Message will now turn off and will
reactivate when the next oil change is due.
Figure 28 Oil Filter

Page 74
 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations – 7 through 10

Inspection Interval: Every 24,100 km (15,000
miles), 550 hours, 6 months or 2100 Gallons of
Fuel; Whichever Occurs First (cont.)
OPERATION 9 — CHECK COOLANT SCA CONCENTRATION

1. It is recommended that SCA concentration level be checked

at regular Preventative Maintenance service intervals.
Refer to Coolant Testing for Conditioner Concentration
in section 6 for further information.

NOTE: This operation is required only for those units equipped

with Conventional (Green or purple in color) Coolant.

OPERATION 10 — INSPECT AIR INTAKE PIPING

Inspect air intake pipe as follows (Figure 29):

1. Check for loose hoses and clamps.
2. Check for ruptured hoses.
3. Check air cleaner housing for cracks. Figure 29 Air Intake Piping

4. Check air to air intercooler for holes or damage.

Page 75
 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations – 11 thru 12
Inspection Interval: Every 48,300 Km
(30,000 miles), 1,100 hours, 12 months or
4200 Gallons of Fuel; Whichever Occurs First
OPERATION 11 — MEASURE AIR INTAKE RESTRICTION
NOTE: Often a low power and poor fuel economy complaint is
simply due to a dirty air cleaner. As the air cleaner accumulates
dirt, restriction to air flow increases. If the service indicator is
locked at maximum restriction, replace the air cleaner element
or elements.
1. Refer to Section 4 and review Air Cleaner Restriction
Gauge and Indicator Operation.
2. Inspect the element(s) for damaged gaskets or dents in the
element(s). If they exhibit either they should be repaired.
3. If low power is still experienced after replacing the air
cleaner, see your International dealer.
such as dump and mixer applications (Figure 30) and (Figure
31).
The current dual element air cleaner assembly restriction
indicator is located between the primary and the secondary
element in the bottom of the air cleaner housing. This
arrangement allows only the primary (outer) element to be
sensed by the restriction indicator or dash mounted vacuum
gauge. The inner element is not recorded on the restriction
indicator or dash mounted vacuum gauge.
However, a separate inner element indicator senses restriction
of that element. Dependent upon the manufacturer, either a
rectangular wing nut with a built in indicator (Figure 30) is used
or an element with an indicator located on the inner element
end cap (Figure 31). When all green disappears on the wing
nut indicator, replace the inner element. When the green dot
disappears from the indicator built into the inner element end
cap, replace the inner element.

NOTE: The air cleaner is to be serviced only when the restriction

reaches the maximum allowable limit. The restriction can be
measured by the service indicator.

OPTIONAL DUAL ELEMENT CLEANER

The dual element air cleaner provides a large primary (outer)

filter element and optional small secondary (inner) filter element.
The secondary element should be used in dusty environments

Page 76
 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations – 11 thru 12 Inspection

Interval: Every 48,300 Km (30,000 miles), 1,100
hours, 12 months or 4200 Gallons of Fuel;
Whichever Occurs First (cont.)
OPTIONAL DUAL ELEMENT CLEANER (cont.)

Service the inner secondary element as follows:
1. Remove hold-down nut. Remove the secondary filter
element carefully and slowly. Discard the old element. (BE
CAREFUL NOT to bump the filter while in the housing; it
can raise a cloud of dust that can enter the clean side piping
to turbocharger).
2. Wipe inside of air cleaner housing with a clean damp cloth.
Be sure to clean the gasket sealing surface. DO NOT use
compressed air for this cleaning! Prevent dust from entering
turbocharger inlet piping during the wiping and element
replacement process.
3. Visually inspect the air cleaner housing for damage or
distortion which could allow unfiltered air to enter the engine.
Inspect to be sure that the rubber dust unloader valve
at bottom of housing is in place and not cracked. Make
corrections as required.
4. Inspect the new filter element for a damaged or non-resilient
rubber gasket. Inspect the filter element body for dents
or excessive pleat bunching. If any of the mentioned
conditions exist, obtain a new service element, consult your
International dealer.
5. Install the new filter element.
6. Install retaining nut (with seal washer if applicable) and
torque nut to value shown in (Figure 30) and (Figure 31).
7. Reassemble the air cleaner end cover to air cleaner housing
making sure that cover seats squarely on housing and the
clamp is neither too loose or too tight. A loose condition
is the result of an element that is too short. A tight or
“no-clamp" situation is the result of an element that is
too long. (Obtain an outer service element, consult your
International dealer).
8. Check all clean air ducts between air cleaner and
turbocharger. All connections must be tight, no leaks.
9. When servicing is completed, reset air restriction gauge
by pushing the reset button and releasing it. The yellow
indicator will drop below the window. Now the air restriction
gauge is ready for the next operating cycle.
NOTE: After starting engine, the indicator may be seen in the
lower part of the window. This is normal and should not be
mistaken as a signal for element service.

Page 77
 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations – 11 thru 12 Inspection

Interval: Every 48,300 Km (30,000 miles), 1,100
hours, 12 months or 4200 Gallons of Fuel;
Whichever Occurs First (cont.)
OPTIONAL DUAL ELEMENT CLEANER (cont.)

Figure 30 Top View of Optional Dual Element Air Cleaner

with Retaining Nut Indicator
Figure 31 Top View of Optional Dual Element Air Cleaner
with Indicator in End Cap

Page 78
 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations – 11 thru 12 Inspection

Interval: Every 48,300 Km (30,000 miles), 1,100
hours, 12 months or 4200 Gallons of Fuel;
Whichever Occurs First (cont.)
OPERATION 12 — CHANGE FUEL FILTER AND STRAINER
ASSEMBLY

Fuel with more than average impurities may require changing

filter and strainer assembly at shorter intervals.

WARNING: To avoid damage to the engine and the

possibility of personal injury, be sure to dispose of fuel in a
proper container clearly stating diesel fuel.
Change the fuel filter and strainer assembly as follows:

Figure 32 Remove Fuel Filter

1. Using an appropriate filter wrench/strap, loosen and remove

the fuel filter from the header and dispose of according to
local regulations (Figure 32).

Page 79
 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations – 11 thru 12 Inspection

Interval: Every 48,300 Km (30,000 miles), 1,100
hours, 12 months or 4200 Gallons of Fuel;
Whichever Occurs First (cont.)
OPERATION 12 — CHANGE FUEL FILTER AND STRAINER
ASSEMBLY (cont.)
2. Remove the primary fuel filter/strainer assembly as follows:
(Figure 33)
a. Remove plastic strainer cover from filter strainer
assembly using a 1-1/8 inch or 29 mm (12 point) socket.
b. Clean or replace strainer after inspection and reinstall
strainer and cover to header assembly.

NOTE: Install strainer with open end toward filter header.

Figure 33 Removal of Strainer Assembly

1. Strainer Cover
2. O-ring
3. Strainer

Page 80
 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations – 11 thru 12 Inspection

Interval: Every 48,300 Km (30,000 miles), 1,100
hours, 12 months or 4200 Gallons of Fuel;
Whichever Occurs First (cont.)
OPERATION 12 — CHANGE FUEL FILTER AND STRAINER
ASSEMBLY (cont.)
b. Tighten until gasket touches fuel filter header.
c. Tighten by hand an additional 1/2 turn.

Figure 34 Installing Fuel Filter

NOTE: Install new fuel filter dry. Do not add fuel to new fuel filter.
3. Install a new fuel filter as follows: (Figure 34)
a. Lubricate fuel filter gasket with clean diesel fuel.

Page 81
 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operations – 11 thru 12 Inspection

Interval: Every 48,300 Km (30,000 miles), 1,100
hours, 12 months or 4200 Gallons of Fuel;
Whichever Occurs First (cont.)
BLEEDING AIR FROM FUEL SYSTEM
2. Operate priming pump until pump action provides solid fuel
at the bleeder valve.
3. Disconnect the Camshaft Position (CMP) sensor.
4. Crank engine three times for 15 seconds each. Reapply the
hand primer after each cycle.

NOTE: DO NOT crank the engine for more than 15 second

intervals. If engine does not start repeat steps 1, 2,& 3.
5. Once the hand primer is hard, reconnect the CMP and start
the engine. If the hand primer is not hard, repeat step 4.
6. Start engine and operate until engine runs smoothly.

Maintenance Operation —13

Replacement Intervals Depend On Type of
Figure 35 Bleeder Valve Location Coolant Used. Coolant Types Are Extended Life
1. Bleed Screw (Red In Color) and Conventional (Green or Purple
2. Side-Mounted Quick Disconnect Fitting In Color).
See Section 7, Table 2 For Replacement Interval.
1. Remove the plastic cap then depress bleeder valve pin at
the fuel filter header. (Figure 35)

Page 82
 SECTION 7 – MAINTENANCE INSTRUCTIONS
Maintenance Operation —13 Replacement
Intervals Depend On Type of Coolant Used.
Coolant Types Are Extended Life (Red In Color)
and Conventional (Green or Purple In Color).
(cont.)
CHANGE COOLANT FILTER (IF EQUIPPED)
Figure 36 Coolant Filter
Perform the following steps when changing the coolant filter:
1. Remove deaeration tank pressure cap and close valve.
(Figure 36) shows filter header in coolant RUN position.
Remove coolant filter using a filter wrench/strap. The filter
is located on the engine right-hand side, rear of the front
cover.
2. Apply a thin coat of coolant to filter gasket and install onto
filter header.
3. Tighten until gasket touches the coolant filter header.
Tighten by hand an additional one (1) full turn. Turn shut off
valve parallel to coolant filter to resume coolant flow. Install
deaeration tank pressure cap.
Maintenance Operation — 14
Inspection Interval: Every 24 Months
PRESSURIZE INDUCTION SYSTEM
Air Induction System Pressure Test
1. At the appropriate interval, have your International dealer
pressure test the air induction system.
3
2. Refer to EGES-215 , DT466E and DT530 Diesel Engine
Diagnostic/Troubleshooting Manual for the inspection
procedures.
Page 83
 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operation — 15 Maintenance Operations 17 And 18

Inspection Interval: Every 193,100 Km (120,000
Miles), 5,000 Hours; Whichever Occurs First
INSPECTION VIBRATION DAMPER
1. At the appropriate inspection interval, have the vibration
damper inspected by your International dealer for
deterioration of rubber, dents, leaks of viscous fluid and
runnout. Replace as required.
3
2. Refer to EGES-210–1 , DT466E and DT530 Diesel Engine
Service Manual for the inspection procedures.
Inspection Interval: Every 290,000 To 322,000 Km
(180,000 to 200,000 miles), 6,700 To 7,500 Hours;
Whichever Occurs First
OPERATION 17 — MEASURE CRANKCASE PRESSURE
1. At the appropriate interval, have your International dealer
check crankcase pressure.
5
2. Refer to EGES-215 , DT466E and DT530 Diesel Engine
Diagnostic/Troubleshooting Manual for the inspection
procedures.

OPERATION 18 — INSPECT TURBOCHARGER

Maintenance Operation — 16
Inspection Interval: Annually 1. Clean, then remove the turbocharger compressor inlet
connections.
ADJUST VALVE LASH 2. Visually inspect the compressor wheel for:
1. At the appropriate interval, have your International dealer a. Dirt
adjust valve lash. b. Wheel rub.
4
2. Refer to EGES-210–1 , DT466, DT466E, DT530, DT530E, c. Wheel blade damage (bent or broken tips).
HT530 Diesel Engine Service Manual for the inspection
procedures. 3. Consult with an International dealer if there is doubt as to
turbocharger condition.

3
Manual specified with latest revision.
4
Manual specified with latest revision.
5
Manual specified with latest revision.

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 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operation — 19
Inspection Interval: Annually WARNING: To avoid personal injury use only the
following procedure to remove the pressure cap from the
INSPECT ELECTRICAL SYSTEM cooling system. Always allow the engine to cool first. wrap
a thick, heavy cloth around the cap. push down, loosen
Inspect electrical system as follows: cap slowly to its first notch position; then pause a moment.
This will avoid possible scalding by hot water or steam.
1. Check wiring harness for cracks, rubbing and loose continue to turn cap to the left and remove.
connections.
2. Check sensors for loose connections, corrosion or cracks. CAUTION: If the coolant should get extremely low and the
engine very hot, let the engine cool for approximately 15
3. Check battery cables for: minutes before adding coolant; then, with the engine running,
a. Broken insulation add coolant slowly. Adding cold coolant to a hot engine may
crack the cylinder head or crankcase. never use water alone.
b. Rubbing/chafing
Drain and fill the cooling system as follows: For All
c. Corroded or loose connections Applications Except “School Bus"
1. Position the vehicle so the engine is level. This will permit
all coolant to drain from the cooling system. Set the parking
Maintenance Operation — 20 brake.
Inspection Interval: Every 322,000 Km (200,000
Miles), 3,800 Hours Or 2 Years; Whichever 2. Remove deaeration tank pressure cap and open radiator
drain.
Occurs First
3. Remove coolant drain plugs: two 1/2" plugs on left side
SERVICE COOLING SYSTEM of crankcase (one directly behind the fuel filter and one to
the left of the filter) or if equipped with an air compressor,
NOTE: Inspection Interval refers to use of Conventional Coolant remove inlet and outlet hose elbows in place of plugs. Also,
(Green or Purple in Color). all applications, on the right side of the engine remove 1/4"
plug at the bottom of the oil cooler rear header, and bleeder
Also see Cooling System Information in Section 6.
valve in crossover. Open petcock on thermostat housing.

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 SECTION 7 – MAINTENANCE INSTRUCTIONS
Maintenance Operation — 20 Inspection Interval:
Every 322,000 Km (200,000 Miles), 3,800 Hours
Or 2 Years; Whichever Occurs First (cont.)
SERVICE COOLING SYSTEM (cont.)
4. After the cooling system has been thoroughly drained, close
all drains.
5. Slowly fill the cooling system until coolant pours from
thermostat housing petcock. Close petcock and continue
to fill until coolant is at the mid point between the HOT and
COLD level marks on the deaeration tank.
6. Start the engine.
7. Allow the engine to operate until the engine reaches its
normal operating temperature. Watch for overheating
during this step.
8. After the engine reaches normal operating temperature,
observe the level in the deaeration tank. Add to the HOT
level mark if required.
Drain and fill the cooling system as follows:
Page 86
FOR SCHOOL BUS
WARNING: To avoid personal injury use only the
following procedure to remove the pressure type cap from
the cooling system. Always allow the engine to cool first.
Wrap a thick, heavy cloth around the cap. Push down,
loosen cap slowly to its first notch position; then pause a
moment. This will avoid possible scalding by hot water or
steam. Continue to turn cap to the left and remove.
CAUTION: If the coolant should get extremely low and the
engine very hot, let the engine cool for approximately 15
minutes before adding coolant; then, with the engine running,
add coolant slowly. adding cold coolant to a hot engine may
crack the cylinder head or crankcase. never use water alone.
1. Position the vehicle so the engine is level. This will permit
all coolant to drain from the cooling system. Set the parking
brake.
2. Remove deaeration tank pressure cap and open radiator
drain.
 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operation — 20 Inspection Interval:

Every 322,000 Km (200,000 Miles), 3,800 Hours
Or 2 Years; Whichever Occurs First (cont.)
FOR SCHOOL BUS (cont.)

3. Remove coolant drain plugs: two 1/2" plugs on left side
of crankcase (one directly behind the fuel filter and one to
the left of the filter) or if equipped with an air compressor,
remove inlet and outlet hose elbows in place of plugs. Also,
all applications, on the right side of the engine remove 1/4"
plug at the bottom of the oil cooler rear header and bleeder
valve in crossover.
4. Open petcock on thermostat housing.
5. After the cooling system has been thoroughly drained, close
all drains, open cab (body) heater valve and all other chassis
(body) heater shut-off valves.
9. After the engine reaches its normal operating temperature,
open the air bleed valve (if available) to expel any air trapped
in the cooling system.
10. When air has been expelled from the cooling system, close
the bleed valve and with the engine still running, slowly add
sufficient coolant to fill the system.
CLEAN COOLING SYSTEM
Clean cooling system as follows:
1. Drain the system completely (as described above).

6. Slowly fill the cooling system until coolant is expelled from
the petcock on thermostat housing. Then close the petcock
and continue to fill the system until coolant reaches the
bottom of filler opening. Install deaeration tank cap.
7. Start the engine.
2. Flush the cooling system with water. If system is dirty or
rusty, use an alkaline or acid type cooling system cleaner,
following the procedures listed in Section 6.
3. Refill the system with water, conditioner and antifreeze, as
specified in Section 6.

8. Allow the engine to operate at a fast idle until the engine

reaches its normal operating temperature. Watch for
overheating during this step.

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 SECTION 7 – MAINTENANCE INSTRUCTIONS

Maintenance Operation — 21
Inspection Interval: Every 500,000 Km (300,000
Miles), 12,000 Hours Or 5 Years; Whichever
Occurs First
CHECK EXTENDED LIFE COOLANT INHIBITOR
CONCENTRATION.

Refer to Section 6: Cooling System Specifications.

Page 88
 SECTION 8 – SERVICE RECORDS

Emission Maintenance Service Record
This chart provides space for recording the dates and mileage
(odometer readings) when the required emission control
maintenance operations were performed.
To prove proper maintenance of the vehicle engine records, work
orders and receipts should be retained showing that scheduled
maintenance has been performed. Failure to maintain such
records may affect your warranty coverage.

Table 3 Emission Maintenance Service Record

Date Service Month Service Hours km (Miles) Item Serviced

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 SECTION 8 – SERVICE RECORDS

Emission Maintenance Service Record (cont.)

Table 3 Emission Maintenance Service Record (cont.)
Date Service Month Service Hours km (Miles) Item Serviced

Page 90
 SECTION 8 – SERVICE RECORDS

Emission Maintenance Service Record (cont.)

Table 3 Emission Maintenance Service Record (cont.)
Date Service Month Service Hours km (Miles) Item Serviced

Page 91
 SECTION 8 – SERVICE RECORDS

Emission Maintenance Service Record (cont.)

Table 3 Emission Maintenance Service Record (cont.)
Date Service Month Service Hours km (Miles) Item Serviced

Page 92
 SECTION 9 – DAILY MAINTENANCE REPORT

Description • Unusual engine noise.

Daily Care And Report
A daily check of the engine should be made to prevent premature
engine failure. If corrective steps are taken immediately on
discovery of loose or worn parts, fewer forced stops and a more
economical operation will result. If any substandard readings or
observations are found, be sure to report it to proper authorities.
Points to be checked daily are as follows:
• Oil, air, water or fuel leaks.
• Excessive use of crankcase lubricating oil, coolant, battery
fluid or fuel.
• Service air cleaner when yellow piston reaches the
maximum restriction, and remains in the up position.
• Dirt should not be allowed to accumulate on the engine. A
few minutes spent daily in keeping it clean are well repaid
in improved appearance, and greater ease and safety in
operation and maintenance.

• Cooling system, clean radiator core, add coolant or

antifreeze as necessary. Be sure filler cap seal is in good
condition and the cap is installed tightly.

Table 4 Daily Care and Report

Model
Serial No.
Date Miles Fuel Lube Parts Labor Service Performed
Oil
Qty. Cost Parts Cost Time Cost

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 SECTION 9 – DAILY MAINTENANCE REPORT

Description (cont.)
Table 4 Daily Care and Report (cont.)
Model
Serial No.
Date Miles Fuel Lube Parts Labor Service Performed
Oil
Qty. Cost Parts Cost Time Cost

Page 94
 SECTION 9 – DAILY MAINTENANCE REPORT

Description (cont.)
Table 4 Daily Care and Report (cont.)
Model
Serial No.
Date Miles Fuel Lube Parts Labor Service Performed
Oil
Qty. Cost Parts Cost Time Cost

Page 95
 SECTION 9 – DAILY MAINTENANCE REPORT

Description (cont.)
Table 4 Daily Care and Report (cont.)
Model
Serial No.
Date Miles Fuel Lube Parts Labor Service Performed
Oil
Qty. Cost Parts Cost Time Cost

Page 96
 SECTION 9 – DAILY MAINTENANCE REPORT

Description (cont.)
Table 4 Daily Care and Report (cont.)
Model
Serial No.
Date Miles Fuel Lube Parts Labor Service Performed
Oil
Qty. Cost Parts Cost Time Cost

Page 97
 SECTION 9 – DAILY MAINTENANCE REPORT

Description (cont.)
Table 4 Daily Care and Report (cont.)
Model
Serial No.
Date Miles Fuel Lube Parts Labor Service Performed
Oil
Qty. Cost Parts Cost Time Cost

Page 98
 SECTION 9 – DAILY MAINTENANCE REPORT

Description (cont.)
Table 4 Daily Care and Report (cont.)
Model
Serial No.
Date Miles Fuel Lube Parts Labor Service Performed
Oil
Qty. Cost Parts Cost Time Cost

Page 99