Engine Description

■ The DT466E International 530 are 6-cylinder in-

line diesel engines. And they are equipped with
a turbocharger, valves, intake air cooler, guides,
seats, intake valves and
exhaust.
■ Engine block has cast water and oil galleries and
wet, replaceable cylinder liners
 Engine Description
■ Wet Shirt ~

■ It is the one that is directly bathed in

by cooling water. It must therefore be sealed with
respect to the cylinder block. The cylinder liner has a
flange or collar in its upper part. The use of wet liners
has the advantage that during a repair the work is
simplified with a change of liners.
■ The oil pump is installed in the front cover, is
driven by the crankshaft at the same engine
speed and is equipped with a cooler.
■ The intake air cooler is installed on the chassis
in front of or next to the

adiator
ADMISSIO COMPRESSIO BURST EXHAUS
N N T

Engine Description
■ The
The Turbo Feeder
turbocharger is a == centrifugal air compressor
driven by exhaust gases. His
The purpose is to increase the power output of the
engine by supplying it with compressed air.
■ With a turbocharger it is possible to increase the power
of an engine by up to 40% or 50%, requiring correct
selection and/or adaptation of the engine. Failure to
make the choice can lead to overheating of the engine,
excessive pressures and temperatures in the
combustion chamber that affect the life of the engine
causing failure of components, such as: pistons, liner,
valves, bushings, etc.
 ■ The Turbo Feeder
Due to these characteristics, the two great
—= concern is to take into account when handling these engines:
■
idle
1.Once the engine has been started, it must be allowed to
two to five minutes, especially in cold weather, to give time for
the oil from the engine lubrication system to reach the
turbocharger, lubricate the shaft and prevent it from seizing
due to lack of oil.
■ 2.Before stopping the engine, let it idle for a few minutes so
that the temperature of the turbocharger drops. Otherwise, the
appearance of carbon particles could occur in it when the oil
burns due to excess temperature, which would clog the
lubrication pipes and block the shaft, causing a major
breakdown.
 Contaminated sediment inside the turbo, blocking
the lubrication holes, causing scratches on the shaft, central
casing and bushings, causing oil loss and subsequent turbo
failure.
Constantly check the state and condition of the air filter as
well as the hoses and clamps that go from it to the turbo, since
the ingestion of foreign objects causes damage to the turbine
and compressor wheel, causing unbalance, rotational instability
and turbo failure as well. It will prevent oil leaks in the turbo - - -
-. --
- -
/ the loss of power in your engine. of -
Yo_ - - - : to. AI increasing the
amount of fuel in the injection
pump because this excess fuel raises the temperature of
your engine until the pistons and turbo melt.
 The Turbo Feeder
The turbo is designed in such a way that it usually lasts as long
as the engine. It does not require special maintenance; limiting
its inspections to periodic checks. To ensure that the life of the
turbo corresponds to that of the engine, the following must be
strictly adhered to:

Engine maintenance instructions provided

maker:
Intervals d
maintenance of the oil filter system.
■ Oil pressure control.
■ ...Air filter system maintenance
 The Turbo Feeder

He . 90% of all failures that occur in turbos are due to the

following causes:
■ Penetration of foreign bodies into the turbine or the
compressor
■ Dirt in the oil.
Inadequate oil supply (oil pressure/filter system).
■ High exhaust gas temperatures (fuel system)
starter/injection system)
The bow frequent
| 7 perform system maintenance
maintenance
Care must be taken not to introduce
 The Turbo Feeder

Fragments of material in the turbocharger .

 The Turbo Feeder

■ Inspection
■ First it is necessary to check the
compressor drive wheel and the turbine
wheel for worn, —— bent, broken or
deposited vanes.
■ Deposits on the drive wheel and
Causes:
 Which allows the passage of oil from the
turbocharger housing leaving oil deposits
■ Excessive oil consumption
Which results in carbon deposits on the turbine
wheel
■ Excess fuel to the engine
which results in high operating temperatures that
uede cause the components to melt
and remain between the
turbine wheel.
 The Turbo Feeder
Diagnosis d — —

If the engine does not run correctly, it should not be assumed that
the failure is caused by the turbocharger. It often happens that
turbochargers are replaced that work perfectly even though
the fault is not in them, but in the engine.
Only after verifying all these points should the presence of
faults in the turbocharger be verified. As components of the
turbocharger, they are manufactured on high-precision
machines with minimum tolerances and
edas gi speeds up to 300,000 rpm, s ■ should
only be inspected by specialists who
have special tools.
The Turbo Feeder
The Turbo Feeder
 The Turbo Feeder

■ ADVANTAGES OF THE TURBO IN THE

ENGINE
DIESEL
■ • - More efficient combustion
■ • - Fuel savings
■ • - Increased power
■ • - Does not reduce engine power with
 The Turbo Feeder

in relation to height above sea level

 The Turbo Feeder

To avoid excessive increase in revolutions of the

turbine and compressor as a consequence of a
higher gas pressure as the engine revolutions
increase, a safety valve is necessary (also
mada: discharge valve or waste valve
and). This n derivation, and
goes apart from the exhaust gases directly
to the exhaust outlet without passing through the
turbine.
 ---
this or a capsule
pressure sensitive composed of
form ---—---
a spring (3), a chamber of —
pressure and a diaphragm or membrane
(2). The opposite side of the diaphragm
is permanently conditioned by the
pressure of the intake manifold as it is
connected to it by a tube (1). When the
pressure in the intake manifold exceeds
the maximum safety value, it deflects
the membrane and compresses the
valve spring, detaching it from its seat.
The exhaust gases then stop passing
through the supercharger turbine (they
pass through the bypass (9)) until the
supply pressure drops and the valve
closes.
The Turbo Feeder
 The Turbo Feeder

■ The maximum pressure at which the turbo can work is

determined by the manufacturer. In the case where
If the discharge valve fails, excess pressure is created
on the turbine that makes it pick up more and more
revolutions, which can cause insufficient lubrication and
the lubrication film between the common shaft and the
bearings where it rests. . Increasing the temperature of
the entire assembly and causing these components to
melt.
 Cooling system
The solution to improve the performance of these supercharged
engines is the incorporation of an Intercooler whose purpose is
to cool the air from the turbocharger before its admission into the
engine. For this reason we can define the Intercooler as the
intake air radiator.
Refrigerated air has a greater density than hot air as it has a
smaller volume than the latter, so the filling with this refrigerated air
in the indros is greater, also improving its content in
--
igen. It
hear compression ratio increases and
increases ---.-——--.
performance by 25% compared to an engine that does not
incorporate it, improving engine performance as important as
consumption or reduction of polluting emissions.
 Cooling system
The intercooler or heat exchanger, as its translation into Spanish would be,
is a device that has the same operation as a conventional water radiator,
although, while it lowers the temperature of the engine cooling water by passing
a stream of air at room temperature , the heat exchanger lowers the
temperature of the intake air, which has risen a lot when passing through the
turbine. With this process, performance is improved by increasing the density of
the air and, therefore, being able to introduce a greater amount into the
chamber, so it can be mixed with a greater amount of fuel. There are various
types of heat exchangers, although the most used is the air-air type, that is, a -
-----------

--
A current of air at a hot temperature is passed through the
radiator, which cools
cases,the deion air. Its assembly varies, but, in many
cases, it is , taking advantage of a
air intake that is made on the hood, although it can also be placed on
the front, next to the water radiator.
 Lubrication system
– The oil is stored at the
bottom of the engine or
crankcase.
– The oil is absorbed to be
pumped through the filter.
– From the filter the oil is
directed through the
lubrication channels
towards the main
bearings, connecting rod
and upper parts of the
engine.
– In some engines the rims
and piston walls are
splash lubricated.
 Lubrication system
Oil functions

AVOID RUST

SEALS TOLERANCES DOES NOT PRODUCE

FOAM

07/08/2017
 Lubrication system
■ In the case of this engine, there are two channels
or galleries for the oil flow on the lower right side
of the block, one is for unfiltered oil and the other
is filtered (one on top of the other).
■ For this type of lubrication work, this engine is
supported by two valves, which are:
 Lubrication system
■ Discharge valve
Its function is to prolong the life of the engine by controlling
the volume and pressure of oil to the engine, it is located
in the front part of the engine.
The same one that serves to protect the cooler and the
filter when the pressure is extremely high, which occurs
during cold starts and especially at low temperatures. In
this case, the valve will move allowing the oil to circulate
and return to the crankcase, relieving the pressure. in the
system
 Lubrication system
■ Check valve
When all lubrication points inside the engine
are supplied, the flow restriction causes an
increase in pressure in the valve, causing it
to slide inward, allowing excess oil to go
directly to the crankcase.
 Lubrication system
Val vu g
C I use the filter oelement
ubecomes clogged esby impurities
and the filter differential
pressure increases above a
predetermined level, the bypass
valve opens and allows oil to
bypass the filter element. In this
a, the oil is supplied

I exactly to the s in
will r of
say the engine sticks.
 Lubrication system
■ Cooler bypass valve . When a cold engine is
started, the oil cooler, due to the amount of oil
it contains, causes an increase in the time
necessary for the circuit to reach its nominal
pressure. With this valve we ensure that the oil
does not pass through the cooler while the oil
not
canza u te
a
 Cooling system
■ The function of the cooling system is to maintain the ==
engine within the specified temperature regime
■ The main components are
Radiator
Water Pump
Thermostat
oil cooler
 Cooling system

■ The cooling system serves to collect heat from critical parts and keep the
engine at a temperature suitable for maximum performance. The hottest
points that must be constantly cooled are: the combustion chamber, the
upper part of the cylinder, the piston head, the intake and exhaust valves
and the injector nozzle. Inside there are water conduits that surround the
critical points. Water is forced to circulate through the cylinder liners, so
that they collect heat. It first passes through the ducts of the block, engine
head, thermostat, and hoses, to take it to the radiator where it is cooled to
a temperature of no less than 71° C and no greater than 93° C. At the
bottom it is taken by the water pump, to force its continuous circulation
through the system. In order for the engine to warm up more quickly in
cold climates, there is a thermostat that acts on the water flow or the air
flow. In the first case, the thermostat closes the flow of water to the
radiator and, through a bypass, circulates it only through the engine
jackets, which allows the engine to reach an adequate temperature.
 Cooling system
■The thermostat starts to open at 82. and is
completely open at 94.C An internal gallery
inside the engine block directs the coolant
from front to rear, distributing it evenly
between the lower sections of the cylinder
liners and then being directed tangentially,
causing upward turbulence towards the head.
This effect improves heat dissipation
 Cooling system
Tato thermoses
The thermostat works automatically to maintain a constant
coolant temperature. This is installed in the coolant circuit,
between the radiator and the engine. When the coolant
temperature is low, the thermostat closes the valve, allowing
coolant to circulate around the inside of the engine. When the
coolant temperature becomes high, the thermostat opens the
valve, allowing coolant to circulate to the radiator.
 Cooling system
The radiator cools the coolant when it reaches a high temperature. It is
made of many passages with fins on
them, through which the coolant flows
before it returns to the engine. The
radiator is cooled by the air that is sucked
in by the fan or by the wind that hits it in
front.

this
endo.
 Injection system
■ This system uses powered injectors
—== hydraulically and electronically controlled to
deliver fuel to each cylinder. The hydraulic fluid
used to power them is engine oil.

■ The oil is sucked from the crankcase through tube

through the engine oil pump, which is driven by the
camshaft
oil is delivered by the high e
supply pump and then into
drilled ducts in the head
 Injection system
■ When an injector is energized a
electronic solenoid installed in the
injector opens a stem valve, allowing
pressurized oil to flow into the injector
When the solenoid is de-energized the
pressure is relieved by the stem valve
Knowledge of injectors
Components
The injectors consist of four main elements:
- Solenoid
-Valve stem
-Intensifier piston and plunger
-Dispensing unit
 Knowledge of injectors

The solenoid is a very fast-acting electromagnet that, when

energized, pulls the valve stem from its seat.
■ stem valve
This valve is held in its seat by a spring. In this closed position
the high pressure oil inlet is blocked and the intensifier
channel is opened to drain.

I go the solenoid is energized

of his of the closed and
for high pressure oil it is open
 Knowledge of injectors
■ Intensifier piston and plunger
When the valve stem opens the inlet hole,
high-pressure oil enters the injector and acts
on the upper part of the intensifier and the
plunger, pushing it downwards, this downward
movement
The plunger pressurizes the fuel in the avity
of the plunger causing the nozzle
pump opens
 fuel system
■ The injection control is a closed loop operating
system. It is controlled by the
injection control pressure regulator
( IPR ), by the injection control pressure ( ICP )
sensor and the programming of the electronic
control module ( ECM )
Knowledge of injectors

The dispensing unit is of traditional design with the exception of

the filling check ball, this element seals during the downward
stroke to prevent fuel leaks. This allows the nozzle valve to
open by atomizing high pressure fuel through the nozzle tip.
The three working stages of the injector are:
 Engine sensors
■ Sensorr MAP ( on abso
e This sensor monitors the pressure in the fuel admission.
manifold. For this, a
ceramic material is applied. These pressure readings are used
to calculate the mass of air entering the engine. Such
calculations are used by the computer to determine the amount
of fuel required for proper combustion.
In case of pressure increase, mixture enrichment and ignition
time calculations are carried out.
Common faults
When is it stops generating a signal. A
---.---
 --
An occasional glitch can interrupt the signal for a very short time,
which would cause jolting and jolting if the driver tried to
accelerate during the fault.
 Engine sensors
■ Fail munes --
There
the may be a short in the sensor circuit, short to ground or open in the
circuit as well as an obstruction in the sensor.
If the fault is intermittent, check the cables. If it does not fall, replace the
MAP sensor.
-Power loss
-Excessive exhaust emissions
-Low engine performance (i.e. high fuel consumption)

sensors that measure pressure

Barometric pressure BAP
sion of the
oil ICP injection control 1
 Engine sensors
■ ICP Sensor (Injection Control Pressure Sensor)
It is a ceramic diaphragm sensor to measure oil pressure that
controls fuel injection, it is located on the left side of the
engine or in the middle of the supply manifold.
This sensor provides the computer with a feedback signal for
closed-loop pressure control.
check the injectors
 Engine sensors

■
Common faults
There may be a short in the sensor circuit,
short to ground or open in the circuit as well
as an obstruction in the sensor.
If the fault is intermittent, check the cables. If it
does not fall, replace the ICP sensor.
 Engine sensors
CMP ( Sen of cam
I
It is a Hall effect s
sensor placed on top of a magnet.
It responds to a rotating actuator or toothed belt placed on the
camshaft gear, this element passes through windows that produce a
wave impulse that the computer interprets as engine speed and the
position of the camshaft to control the amount of fuel, Injection timing
and engine shutdown due to excessive speed are located at the front.

When this sensor fails due to electrical problems, it presents

symptoms of intermittent jerking, backfiring, and the engine not
starting.
 Engine sensors
■ Common failures
A problem of this type can exist for a long time
without ever producing any code.
If no other cause can be found for such symptoms
replace the sensor
There may also be a short in the sensor circuit, short
to ground or to im
'esmm.,emcneuseum"mme
circuit as well as an obstruction in the sensor
Engine sensors
 Engine sensors
ECT Sensor ( Coolant Temperature Sensor) This sensor is a negative
temperature coefficient thermistor .
temperature, placed near the thermostat and measures the engine
temperature. It is a variable resistor whose resistivity decreases as the
motor temperature increases. The computer uses this information to
adjust the air/fuel ratio and ignition timing. A cold engine requires and
accepts a richer mixture and advance

an in this sensor open circuit occurs internally

which could generate fuel consumption being visible in the exhaust gas
outlet
 Engine sensors

For this sensor to

work correctly, the engine must have a thermostat installed.
It also occurs that the engine takes a while to start when cold and
hot, problems with overheating and low engine pressure occur.
 Engine sensors
■ IPR valve (Injection Control Pressure Regulator)
It is a valve that regulates the injection control pressure.
The IPR is modulated by pulse duration, which controls
the control pressure of the injectors through a signal
from the computer. Common faults

incorrect, faulty ground

 Engine sensors
ac temperature sensor
engine )
It is a variable resistance thermistor type sensor whose resistivity
decreases as the engine oil temperature increases and is close to
the high pressure pump.
Provides the computer with a signal of engine temperature for
control, fuel rationing and timing adjustments to prevent serious
internal damage.

open
connections of
the
 Engine sensors
■ Power meter
The potentiometer is a variable voltage divider, which is
used to perceive or detect the physical location of a
mobile device.
Rotary or linear mechanical motion moves the indicator
along a resistance Potentiometer Examples
-Throttle position sensor (APS)
-EGR valve position sensor (EGRP)
 Engine sensors
■ EOP Sensor (Engine Oil Pressure Sensor)
It is a sensor with a ceramic diaphragm used to indicate
low engine oil pressure through a signal from the
computer.
 Engine sensors
■ Engine coolant level system
The purpose of the coolant level monitoring system is
to warn the driver in case of a low level. Depending on
the control module's programming, it may also shut
down the engine to prevent damage due to low coolant
level.
There are two types of coolant level sensors.

-Driver tester
 Engine sensors
■ The magnetic switch type sensor is used and located in
plastic surge tanks. The switch is open when the
coolant level in the tank is full.
■ The conductive tester type sensor is used and located
in steel surge tanks. The tester conductor is connected
to ground
——-—-——--
when ——-—---——---
and
e — - - — - coolant in the
■ To carry out all the Coolant level sensor connector removed, ignition switch ON

Points of
tests in case of failure Proof Specification Comments

it is necessary that to ground

12 +/- 1,5
Volts Open circuit or faulty EC

the coolant level is Circuit shorted or to another

filled to the level

B to ground 0 Volts circuit

12 +/- 1,5
(A) to (B) Volts Grounded or open

Code 236 = The ECM has detected an open circuit or short circuit

Code 323 = The 12 volt circuit in the ECM has been connected to ground. What indicates low coolant fluid, check the level
 Engine sensors
■These engines use an electronic accelerator pedal
assembly that includes an accelerator position sensor
(APS) and an idle validation switch (IVS).
These two functions are integrated into a component
installed in the pedal
The ECM determines the position of the accelerator
pedal by processing input signals from the accelerator ■
sensor and the idle enable switch.
 Engine sensors
■ EGR valve '
■ This valve is responsible for channeling inert
exhaust gases that lack oxygen or fuel. In said
chamber they act as heatsinks to reduce some
of the heat from the combustion process =----=
 Engine sensors
■Variable capacity sensors measure pressure. The
measured pressure is applied to a ceramic material.
Pressure pushes the ceramic material closer to a thin
metal disc, this action changes the capacity of the
sensor.
■The sensor connects to the computer using three
cables
-REF voltage
-Signal return
-Signal ground
 Engine sensors
■The operating range of a variable capacity sensor is
related to the thickness of the ceramic disc. The thicker
the ceramic disc, the greater the Pressure that the
sensor can measure.
■Examples of variable capacity sensors -Barometric
Pressure ( BAP ) -Pressure motorcycle item

injection control ( ICP )

-Manifold absolute pressure ( MAP )
 Engine sensors

It is a complex component used to control the electronic

system of the engine and the
The fuel injection system generally does not present
failures, but in the event that they occur, the most
vulnerable memories are the PROM and the ROM.
This module requires a power source of
12 volts ■ to perform its functions, it receives this
operating power directly from the batteries through the
relay contacts of the
NDE
 Engine sensors
■ The ECM internally monitors battery voltage. If
the ECM continuously receives less than 6.5
volts or more than 18 volts, a fault code is
defined. The fault code does not cause the
warning light to come on if the condition is
termitent a code
 Engine sensors

— Within this element there are three microprocessors

that are used for memory storage and decision
making
-Read only memory ( ROM )
-Memory of him. programmable only ( PROM )
 Engine sensors
Read only memory ( ROM ) sma
■ The ROM contains the basic program of the
ECM, it is the part where it says “when I see
this happen I must do that”. ROM contains
non-volatile memory when
e removes power supply eretains its
programming and memory
 Engine sensors
■ Memory of l. programmable only ( PROM )
The ■ PROM, also known as the calibration unit, is the non-volatile, fine-
tuned microprocessor. This chip contains specific information about the
unit such as.
-Size
-Weight
-Wind resistance
-Rolling resistance
engine handle —T- .
final
elation of i
-Type of tea
-Emission control device
 Engine sensors
Random access memory ( RAM ) smma
This memory is used for temporary storage of
information. It also stores information on the
engine's air/fuel ratio and what is detected in its
fuel system circuits and sensors.
 Engine sensors
Random access memory ( RAM )
■ This memory has three basic functions:
-Serves as a notebook to store records of mathematical results
and comparisons made by the unit
-Stores census data and operating parameters obtained in the
network of sensors and actuators
store code when a
 Engine sensors

—= -Handling problems
-When electric shocks happen
-Low battery voltage
-Loose connections
-Failure in the charging system
-Failure in some of your memories
-Classification preconfigured by the
 BASIC PRINCIPLES OF
LOCA LIZA TION FAIL S
OF
 Fault location
moto tour but no A
rcycl or circuit faulty C
- MAP sensor
- Lack of fuel pressure or incorrect pressure
- Empty fuel tank
- Water in fuel
-Faulty or restricted injectors
-Low battery
loose connections or terminals

-ICP sensor or circuit

 Fault location
■ Engine difficult to start – hot
-Discharged or low battery
-Clogged air filter
-EOT sensor or circuit defective
-MAP sensor or circuit defective
-Poor motor ground connection
-Incorrect fuel pressure
 Fault location
■ The engine starts but does not run
-Defective CMP sensor or circuit -Loose or
damaged electrical connections -Defective IPR
sensor or circuit -Defective MAP sensor or circuit
-Defective ECT sensor or circuit
-Insufficient fuel flow 1 -Intake manifold
vacuum leaks
 Fault location
■ The engine decelerates to idle speed (cold or
-Incorrect ignition timing
- vacuum leak
- Air leak through intake duct
-Dirty injectors
- Fuel pump with low pressure MAP sensor
or faulty
IPR circuit
sensor
or ICP or faulty circuit
 Fault location
■ Engine fails at idle speed
-Clogged fuel filter
-Vacuum leaks in the intake manifold
-Incorrect ignition timing
-Low or uneven cylinder compression
-ECT sensor or circuit defective
sor I IPR or faulty circuit
 Fault location
■ The engine fails in all driving speed ranges
-CMP sensor or circuit defective
-IPR sensor or circuit defective
-ICP sensor or circuit defective
-MAP sensor or circuit defective
-Defective ignition system, low pressure in the fuel pump
low or uneven engine pressures
 Fault location
■ Choking on acceleration
-MAP sensor or circuit defective
-ECT sensor or circuit defective
-IPR sensor or circuit defective
-ICP sensor or circuit defective
-Clogged fuel filter
-Vacuum leak through intake manifold
to fuel pump
pr
 Fault location
■ Lack of power or poor engine performance
-MAP sensor or circuit defective
-IPR sensor or circuit defective
-ICP sensor or circuit defective
-Clogged air filter
-Clogged exhaust system
incorrect
synchronization nois
e
-Vacuum leak
 Fault location

-Tank too full

-Leaking fuel lines
-Injectors stuck in open position
-Injectors with internal or external leaks
Low and fuel
pressure