International HS 2.8L Service Manual
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International HS 2.8L Service Manual

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SERVICE MANUAL
International HS 2.8L

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  • Page 1 SERVICE MANUAL International HS 2.8L...
  • Page 2 Following the instructions and specifications of this manual, the maintenance and repairing will be made in the most correct and safety way possible. INTERNATIONAL ENGINES SOUTH AMERICA LTDA reserves the right of changing the content of this publication without warning, whenever innovations are necessary to be introduced in its products.

  • Page 3: Table Of Contents

    Index International HS 2.8L INDEX Safety Precautions ............................3 Environment ..............................5 Technical Features ............................8 Operation and Maintenance Recommendations ..................11 Cooling System ............................20 Fuel System ..............................27 Lubrication System ...........................41 Cylinder Head ............................47 Engine Block .............................63 Pistons and Connecting Rods ........................68 Crankshaft ..............................76 Crankshaft Pulley ............................83...

  • Page 4: Safety Precautions

    International HS 2.8L SAFETY PRECAUTIONS INTERNATIONAL ENGINES 8120081 - 05/02 - Service Manual...
  • Page 5 Safety Precautions International HS 2.8L SAFETY PRECAUTIONS Warning: The texts emphasized with the symbol means direct or indirect personal injuries risk. Read carefully this manual and keep it always on hand to clarify any doubts. Do not try to operate the equipment without knowing all controls and understanding the operation of the main systems.

  • Page 6: Environment

    International HS 2.8L ENVIRONMENT INTERNATIONAL ENGINES 8120081 - 05/02 - Service Manual...
  • Page 7 All these subjects constitute the mark of a wide environment protection program, which is considered since the beginning of a new product project. The International HS 2.8L engine was released in the market and accomplishes without problems all these requirements.
  • Page 8 DESTINATION OF THE USED COMPONENTS OF THE ENGINE INTERNATIONAL ENGINES SOUTH AMERICA LTDA is applying in its engines, more and more, materials of easy recycling, making easy this way, in the end of the component life, its sale or re-fusion.

  • Page 9: Technical Features

    International HS 2.8L TECHNICAL FEATURES INTERNATIONAL ENGINES Service Manual - 8120081 - 05/02...
  • Page 10 International HS 2.8L Technical Features TECHNICAL FEATURES ENGINE TYPE INTERNATIONAL HS 2.8L PL number 8B60 8B61 Turbocharger Variable Nozzle (VNT) With Wastegate Number and Cylinder 4 in line Arrangement Cylinder Nominal Bore 93.0 mm Stroke 102.50 mm Cycle Diesel, 4 stroke Compression Relation 19.5 : 1...
  • Page 11 Technical Features International HS 2.8L LOCATION AND IDENTIFICATION OF THE ENGINE NUMBER Location Front Left side view Identification B61 (WG) B60 (VNT) 536265 SERIAL NUMBER PARTS LIST NUMBER • For engines manufactured in Brazil - nr 000001 to 499999. • For engines manufactured in Argentina - nr from 500000 on.

  • Page 12: Operation And Maintenance Recommendations

    International HS 2.8L OPERATION AND MAINTENANCE RECOMMENDATIONS INTERNATIONAL ENGINES 8120081 - 05/02 - Service Manual...
  • Page 13 Operation and Maintenance Recommendations International HS 2.8L OPERATION AND MAINTENANCE RECOMMENDATIONS START AND STOP Before starting the engine 1. Check “Daily Maintenance” items, see PERIODIC MAINTENANCE. 2. Turn start key to contact position and check if Key Positions battery charge and engine oil pressure indicator lamps are switched on.
  • Page 14 • Do not accelerate the engine. • Turn key to “off” position. RUNNING-IN The technology that INTERNATIONAL ENGINES SOUTH AMERICA LTDA uses on its engines production, as well as on tests in dynamometer, eliminate the necessity of large run-in periods.
  • Page 15 Operation and Maintenance Recommendations International HS 2.8L During running-in follow these recommen- dations: • DO NOT OPERATE THE ENGINE AT OVER THAN 85% OF THE MAXIMUM SPECIFIED SPEED (3800 rpm), see TECHNICAL SPECIFICATIONS. • WHEN IN A TRIP, VARY THE ROTATION TO AVOID CONSTANT SPEEDS DURING LONG PERIODS.
  • Page 16 International HS 2.8L Operation and Maintenance Recommendations INSTALLATION REVISION ITEM CHECK Alternator belt Tension Water and lubricant oil Level (complete if necessary) Operation temperature and speed at General performance maximum load Intake system Intake air temperature and restriction If the piping is unobstructed and free of vibrations,...

  • Page 17: Periodic Maintenance

    Operation and Maintenance Recommendations International HS 2.8L PERIODIC MAINTENANCE PERIODS CHECK Daily Check engine oil level (complete if necessary). Daily Check water “reservoir” level (complete if necessary). Drain impurities from the fuel filter and Daily sedimentation filter. Daily Check air filter hoses and connections conditions.
  • Page 18 (in turbocharged International HS 2.8L engines) and later on to the engine cylinders. Having a higher pressure in the intake, the work done by the cylinders is positive, in other words, the cylinders spent a smaller amount of energy in the intake.
  • Page 19 If the panel of the equipment accuses high temperature and / or battery low charge, check if the belt is loose or ruptured. Two belts equip the turbocharged International HS 2.8L engine. It is very important that the belts be installed exactly as shown in the illustration.
  • Page 20 International HS 2.8L Operation and Maintenance Recommendations CAMSHAFT BELT The engine timing pulleys are moved by a flexible rubber belt, which must be replaced in predetermined intervals depending on the use conditions severity. Note: If the belt is not replaced within the correct intervals, it may present failures, causing serious damages to the engine.

  • Page 21: Cooling System

    International HS 2.8L COOLING SYSTEM INTERNATIONAL ENGINES Service Manual - 8120081 - 05/02...
  • Page 22 International HS 2.8L Cooling System COOLING SYSTEM Circuit drainage If it is necessary to totally drain the coolant water, follow the instructions below: Warning: Do not drain cooling water while the engine is still hot and the system pressurized. 1. Remove lower and upper radiator hoses.
  • Page 23 Cooling System International HS 2.8L 4. Remove cooling system expansion reservoir cover (tank). 5. Remove disaeration plug, located in the upper part of the thermostat housing. 6. With the engine stopped, fill the system through expansion reservoir, until liquid leaks through the disaeration plug (see illustration).
  • Page 24 International HS 2.8L Cooling System 8. Manually reinstall thermostat housing disaeration plug, just to seal the liquid outlet hole. A. Fill system until reaching the maximum level of the tank. B. Tighten expansion reservoir cover and check for leakages. C. Run engine at idle speed for 10 seconds and let the liquid spill through the disaeration plug, eliminating all air bubbles from the system.
  • Page 25 Cooling System International HS 2.8L FAN PULLEY Removal 1. Remove fan, see FAN - Removal. 2. Loosen pulley fixation bolts. 3. Remove accessories belt, see ACCESSORIES BELTS. 4. Remove pulley. Reinstallation 1. Reinstall in the inverse order, tightening bolts within 22 to 28 Nm.
  • Page 26 International HS 2.8L Cooling System Reinstallation 1. Reinstall water pump in the inverse order of the removal, using a new gasket. 2. Use two prisoners as guide to position the new gasket, reinstall the assembly support in the inverse order.
  • Page 27 Cooling System International HS 2.8L Note: The preliminary specified test in this manual for the thermostat evaluation helps the diagnosis of a possible failure in the engine. Therefore, it is recommended to send the thermostat to laboratorial analysis after the tests (if positive).

  • Page 28: Fuel System

    International HS 2.8L FUEL SYSTEM INTERNATIONAL ENGINES 8120081 - 05/02 - Service Manual...
  • Page 29 Fuel System International HS 2.8L FUEL SYSTEM PREVENTIVE MAINTENANCE Fuel is an important factor to ensure the good operation of the engine for a long time and without failures. The fuel must be clean, free of water and impurities. If the fuel used in the engine has to be stored, see FUEL STORAGE.
  • Page 30 International HS 2.8L Fuel System 3. In periods of intense cold (under 0 ºC) (32 °F), 20% of aviation kerosene can be added to the diesel fuel. This procedure will avoid that the existence of paraffin in the diesel fuel obstruct the fuel piping. In the filling, first put the kerosene and then the fuel.
  • Page 31 Fuel System International HS 2.8L FUEL FILTER ELEMENT Removal 1. Loosen filter fuel inlet (1) and outlet (2) pipes (position pipes to avoid leakages). 2. Loose fuel filter fixation clamp. 3. Raise fuel filter and loosen electric connection of the water-in-fuel sensor.
  • Page 32 International HS 2.8L Fuel System LACK OF FUEL 1. Fill fuel tank with 3 liters minimum. 2. Open fuel filter upper plug and loosen the 4 nozzle nuts. 3. Crank engine until that fuel drips through the filter upper plug and through the nozzle nuts (approximately 10 seconds).
  • Page 33 Fuel System International HS 2.8L Reinstallation 1. Clean pump and block contact surfaces. 2. Install pump in cylinder block with a new gasket, ensuring of the correct location of the lever with the camshaft. 3. Fix with bolts tightening according to specification.
  • Page 34 International HS 2.8L Fuel System 6. Reinstall valves cover to avoid particulates penetration. 7. Remove flywheel-housing plug. 8. Install tool nr. 8130632 in the flywheel housing, without inserting center pin. 9. Continue turning crankshaft clockwise until that center pin fits in the flywheel timing hole.
  • Page 35 Fuel System International HS 2.8L 16. Remove accelerator cable at the fuel injection pump. 17. Disconnect connector from electric stop control solenoid. 18. Remove banjo bolts from fuel return pipes and “boost control”, reinstalling them after the pipes disconnection. 19. Remove the two bolts from the pump assembly support (*).
  • Page 36 International HS 2.8L Fuel System 3. Remove special tool pin from the pump. 4. Clean pump and timing housing contact surfaces. 5. Install pump in timing housing with a new gasket and fix it with nuts tightening according to specification.
  • Page 37 Fuel System International HS 2.8L 20. Using adequate anti-adherent compound, install the flywheel housing plug and tighten it according to specification. 21. Install inspection cover with a new gasket on timing housing cover and tighten bolts according to specification. 22. Reinstall nozzle-holders pipes.
  • Page 38 International HS 2.8L Fuel System FUEL NOZZLE-HOLDERS SET Removal 1. Remove high-pressure pipes set from nozzle-holders and from fuel injection pump. 2. Remove return pipe from nozzle-holders. 3. Close nozzle-holders pipes and connections to prevent against dust and strange materials penetration.
  • Page 39 Fuel System International HS 2.8L 5. Install nozzle-holder set with the return outlet turned outside. 6. Fix it with the plate and nut, tightening according to specification. Note: The fixation plates are slightly curved and must be installed with the convex side upwards.
  • Page 40 International HS 2.8L Fuel System 5. Turn crankshaft to the valves of the cylinder nr. 4 to be swinging (1st cylinder piston at TDC in compression stroke). 6. Continue turning crankshaft clockwise until fit the center pin. 7. Install the tool pin nr. 8130633 in the fuel injection pump pulley.
  • Page 41 Fuel System International HS 2.8L 12. Assembly accelerator cable at fuel injection pump. 13. Bleed fuel system. See FUEL SYSTEM - Bleeding. 14. Install plug in housing, tightening within of 22 to 28 Nm. Note: Remove special tools 8130632 and 8130633.

  • Page 42: Lubrication System

    International HS 2.8L LUBRICATION SYSTEM INTERNATIONAL ENGINES 8120081 - 05/02 - Service Manual...
  • Page 43 Lubrication System International HS 2.8L LUBRICATION SYSTEM PREVENTIVE MAINTENANCE The lubrication system is responsible for the durability and internal cleaning of the engine. Beyond of lubricating, the oil has the function of absorbing the heat generated by the friction of the mobile parts.
  • Page 44 International HS 2.8L Lubrication System 1. Run the engine until reach the ideal operation temperature. 2. Stop the engine, clean the filling inlet cover and oil pan plug. Remove and let oil drain freely. 3. Check if the breather pipe is obstructed. If necessary, remove and clean it.
  • Page 45 Lubrication System International HS 2.8L Assembly 1. Lubricate new filter seal with clean engine oil. 2. Screw manually the filter until the sealing ring touches the surface, manually tighten ½ turn more, without tightening excessively. OIL COOLER Removal 1. Drain cooling system.
  • Page 46 International HS 2.8L Lubrication System Installation 1. Clean oil pan contact surfaces, timing housing and engine block. 2. Install new liquid gasket (LOCTITE 5900). 3. Fix oil pan to the block with bolts according to the illustrated tightening sequence, tightening them according to specification.
  • Page 47 International HS 2.8L LUBRICANT OIL PUMP Removal The lubricant oil pump of the Turbocharged International HS 2.8L Engines is attached to the timing housing. 1. Remove timing housing, see TIMING HOUSING - Removal. 2. If it is necessary to replace oil pump, it is recommended to replace the whole timing housing, see TIMING HOUSING.

  • Page 48: Cylinder Head

    International HS 2.8L Cylinder Head CYLINDER HEAD INTERNATIONAL ENGINES 8120081 - 05/02 - Service Manual...
  • Page 49 Cylinder Head International HS 2.8L CYLINDER HEAD Removal Warning: Loosen radiator lower and upper hoses. Remove reservoir cover and loosen water outlet hose from thermostat housing. Drain Cooiant water. Warning: Loosen exhaust duct from the manifold. Remove outlet elbow and thermostat.
  • Page 50 International HS 2.8L Cylinder Head 12. Disconnect heating pipe from hoses and remove it. 13. Remove wiring support fixation bolt in the cylinder head. 14. Loosen nuts and bolts and remove rocker arms shaft, see ROCKER ARMS - Removal. 15. Remove camshaft tappet push rods, identifying them to reinstall in the same position later.
  • Page 51 Cylinder Head International HS 2.8L Note: The maximum allowed distortion is 0.05 mm; over this value, cylinder head must be replaced. 5. Check nozzle maximum projection: 6. Resurfacing can be made only if the maximum nozzle projection to the cylinder head does not surpass the specified dimension (1.82 - 2.10 mm).
  • Page 52 International HS 2.8L Cylinder Head Reinstallation 1. Make sure that the engine block surface is perfectly clean. 2. Using a dial indicator gauge with a magnetic base, check pistons height, to specify the cylinder head gasket. 3. There are available 3 (three) types of gaskets for the cylinder head assembly, identified by holes in the left side, from front viewing.
  • Page 53 Cylinder Head International HS 2.8L 5. Install gasket with the identification holes turned back and with “TOP” mark upwards. 6. Clean engine block contact surface. 7. Lower cylinder head on the engine block, making sure of the correct guide-pins position.
  • Page 54 International HS 2.8L Cylinder Head Note: Use special tool nr. 8130625 (Goniometry). 12. Install valve caps rods. 13. Install camshaft rods on their original positions. 14. Install rocker arm shaft, see ROCKER ARM SHAFT - Installation. 15. Adjust valves clearance, see VALVES CLEARANCE ADJUSTMENT.
  • Page 55 Cylinder Head International HS 2.8L TURBOCHARGER Removal 1. Loosen clamp and disconnect turbocharger inlet pipe from intake manifold. 2. Loosen clamp and disconnect breather hose from turbocharger inlet elbow. 3. Loosen clamp and disconnect air filter hose. 4. Remove inlet elbow, loosening support bolts.
  • Page 56 International HS 2.8L Cylinder Head 5. Loosen intake manifold lower fixation nuts, positioned under the exhaust manifold. 6. Remove intake manifold upper fixation bolts. 7. Raise intake manifold only, covering the openings in the cylinder head with a clean cloth to prevent the fall of any component in the engine.
  • Page 57 Cylinder Head International HS 2.8L Reinstallation 1. Install new gasket on manifold prisoners. 2. Install exhaust manifold and fix it with the two upper and the three lower central nuts. 3. Tighten exhaust manifold fixation nuts according to specification. ROCKER ARM Removal 1.
  • Page 58 International HS 2.8L Cylinder Head Disassembly 1. Remove rocker arms, springs, brackets and spacers. Cleaning and inspection 1. To clean shaft, remove the plugs of the edges. Check lubricant, rocker arms and shaft passage holes, unblocking them if necessary. 2. Check rocker arms bushing. If its clearance...
  • Page 59 Cylinder Head International HS 2.8L VALVES Disassembly 1. Remove cylinder head, see CYLINDER HEAD - Removal. 2. With tool nr. 8130001, compress springs and remove valves locks. 3. Remove springs seats, springs, springs washers, seals and valves. 4. While removing or replacing valves, mark with electric pencil the corresponding number of each cylinder.
  • Page 60 International HS 2.8L Cylinder Head Seals and springs replacement with cylinder head installed 1. Set the piston of the replacement corresponding cylinder at TDC. 2. Loosen valve rocker arm adjustment bolt. Displace rocker arm, allowing the access of the tool nr. 8130 002 and compress springs.
  • Page 61 Cylinder Head International HS 2.8L Guide replacement 1. Use tool nr. 8130631 and a press to quit guide. 2. Press the guide with the tool nr. 8130634 and the spacer nr. 8130644. 3. Check clearance specification between valve and guide, see TECHNICAL SPECIFICATIONS.
  • Page 62 International HS 2.8L Cylinder Head Assembly 1. In the pressing, the seat can be cooled in liquid nitrogen. Use a press, with 2 to 3 ton capacity. Do not use hammer or similar to press. 2. Position seat with its base turned to the housing.
  • Page 63 Cylinder Head International HS 2.8L Clearances Adjustment Intake Exhaust conditions valve valve COLD ENGINE 0.20 mm 0.20 mm Procedure Balance valves of Adjust valve of cylinder nr. cylinder nr. Note: Swinging is the moment when exhaust valve is closing and intake valve is opening. At this situation, the piston of the respective cylinder will be at TDC.

  • Page 64: Engine Block

    International HS 2.8L ENGINE BLOCK INTERNATIONAL ENGINES 8120081 - 05/02 - Service Manual...
  • Page 65 Engine Block International HS 2.8L ENGINE BLOCK Removal Warning: Drain lubricant oil. Warning: Remove tank cap and loosen water hoses from radiator. Warning: Remove drain plug and drain cooling system. 1. Loosen electric cables from starter motor, lubricant oil pressure and engine temperature gauges.
  • Page 66 International HS 2.8L Engine Block 18. Remove accessories support. 19. Remove rear seal and crankshaft. 20. Remove pistons and connecting rods. Cleaning and inspection 1. Remove oil gallery rear plug. 2. Remove all water gallery plugs and lubricant oil filter support.
  • Page 67 Engine Block International HS 2.8L 2. Remove camshaft rear seal. Cleaning, inspection and assembly 1. Check camshaft bushing housing bores. 2. Position bushing in engine block. 3. Assembly bushing, making sure that lubrication hole is aligned with the hole in the block.
  • Page 68 International HS 2.8L Engine Block CYLINDER FINISHING Mandrill and burnishing 1. Adjust the machine to operate at 293 rpm and advance of 0.15 to 0.30 mm / turn. The final bore must be gotten in only one pass of the broach.

  • Page 69: Pistons And Connecting Rods

    International HS 2.8L PISTONS AND CONNECTING RODS INTERNATIONAL ENGINES Service Manual - 8120081 - 05/02...
  • Page 70 International HS 2.8L Pistons and Connecting Rods PISTONS AND CONNECTING RODS Removal 1. Remove cylinder head. 2. Remove oil pan, suction and lubricant oil flux pipes. 3. Position the block in the horizontal position. 4. Before removing piston, remove carbon deposits accumulated on liner top.
  • Page 71 Pistons and Connecting Rods International HS 2.8L Cleaning and inspection 1. Check if the pistons have risks or damages in lateral and upper faces. Carefully remove carbon residues from the grooves. 2. Assembly a new ring and check its clearance in the groove.
  • Page 72 International HS 2.8L Pistons and Connecting Rods 6. In case of any irregularity, replace the part and make a new position number demarcation of the connecting rod in the engine block. Example of connecting rod that will work in the first cylinder, marked with electric pencil.
  • Page 73 Pistons and Connecting Rods International HS 2.8L 10. Check clearance between piston rings ends in cylinder. Clearance must be checked separately. Use piston to introduce the ring between 40 and 50 mm below block surface. Cylinder bore must be within specified measures.
  • Page 74 International HS 2.8L Pistons and Connecting Rods 3. Assembly ring spring in piston 3rd groove and next ring, with ends in opposite position from spring ends. Install 2nd and 1st rings with TOP mark or inner chamfer upwards. Note that 2nd and 1st grooves rings have different thickness.
  • Page 75 Pistons and Connecting Rods International HS 2.8L 6. Complete lubricant oil injector for cylinder inside and piston pin lubrication is shown below. 7. Assembly new shell in connecting rod cap, correctly positioning locks. Lubricate shell and crankshaft crankpin. 8. Assembly cap on connecting rod...
  • Page 76 International HS 2.8L Pistons and Connecting Rods 10. Position piston at TDC. Check piston height in relation to engine block surface with dial indicator gauge and tool nr. 8130004, see CYLINDER HEAD SPECIFICATIONS. 11. Assembly suction, flux pipes and lubricant oil pan.

  • Page 77: Crankshaft

    International HS 2.8L CRANKSHAFT INTERNATIONAL ENGINES Service Manual - 8120081 - 05/02...
  • Page 78 International HS 2.8L Crankshaft CRANKSHAFT Removal 1. Remove engine. 2. Remove cylinder head and push rods. 3. Remove accessories support. 4. Remove oil pan. 5. Remove timing housing and camshaft. 6. Remove flywheel housing and flywheel. 7. Remove pistons and connecting rods.
  • Page 79 Crankshaft International HS 2.8L 4. Remove crankshaft and shells. 5. Position crankshaft in vertical fitted in the flywheel in order to avoid warping. Cleaning and inspection 1. Remove remains of gasket from rear seal housing and from engine block. 2. Clean main journals and crankpins, checking for risks and damages.
  • Page 80 International HS 2.8L Crankshaft 4. Check for cracks and remove crankshaft magnetization. 5. Clean the lubrication holes. 6. Check with micrometer main journals and crankpins length, see TECHNICAL SPECIFICATIONS - Crankshaft. 7. Check again crankshaft main journals eccentricity. 8. Check main journals and crankpins fillets with caliper.
  • Page 81 Crankshaft International HS 2.8L 3. Lubricate upper shells and crankshaft main journals and crankpins, 4. Lubricate the two upper thrust washers, positioning lubrication channels to crankshaft and slip them in their block housing. 5. Assembly crankshaft. Do not turn crankshaft before bearing caps fixation.
  • Page 82 International HS 2.8L Crankshaft 3. Install a new housing with seal rear in crankshaft flange and free seal lip protection (plastic - disposable). Note: Check seal lip positioning uniformity in crankshaft flange, avoiding edges bit. 4. Point housing fixation bolts in the block.
  • Page 83 Crankshaft International HS 2.8L 6. Flex side rods of tool nr. 8130648, pressing against crankshaft flange. Note: This procedure will guarantee perfect seal housing concentricity in relation to crankshaft flange. 7. Fix bolts, following tightening - torque sequence, see TIGHTENING SPECIFICATIONS.

  • Page 84: Crankshaft Pulley

    International HS 2.8L CRANKSHAFT PULLEY INTERNATIONAL ENGINES 8120081 - 05/02 - Service Manual...
  • Page 85 Crankshaft Pulley International HS 2.8L CRANKSHAFT PULLEY Removal 1. Drain coolant water. 2. Remove radiator upper hose. 3. Remove fan, see FAN -Removal 4. Remove moving belt, see ACCESSORIES MOVING BELT - Removal. 5. Install tool nr. 8130638 in crankshaft pulley and fix it with 4 bolts.
  • Page 86 International HS 2.8L Crankshaft Pulley Reinstallation 1. Reinstall in inverse order of removal, using new gaskets, installing fixation bolts as shown in the illustration and tighten according to specification. DISTRIBUTION BELT Removal 1. Remove timing housing cover. See TIMING HOUSING COVER - Removal.
  • Page 87 Crankshaft Pulley International HS 2.8L 6. Install tool nr. 8130633 pin in the fuel injection pump pulley and fit it in pump flange. Note: If camshaft teeth pulley has to be removed during these operations, its fixation bolts must be loosen before the distribution belt removal.
  • Page 88 International HS 2.8L Crankshaft Pulley Note: The belts must be stocked with the edges in a clean surface and in such way that the folds do not have a radius lower than 50 mm. Do not fold belts in an acute angle or with ray lower than 50mm, otherwise it may occur premature failures.
  • Page 89 Crankshaft Pulley International HS 2.8L 3. Loosen the 3 (three) fuel injection pump pulley fixation bolts (Ref. D), letting pulley slightly loose to allow belt accommodation. 4. Install distribution belt on the pulleys. 5. Slightly press belt tensor, screwing tensor bolt.

  • Page 90: Engine Timing

    International HS 2.8L ENGINE TIMING INTERNATIONAL ENGINES 8120081 - 05/02 - Service Manual...
  • Page 91 Engine Timing International HS 2.8L ENGINE TIMING Camshaft pulley and timing housing Crankshaft pulley and timing housing (gib upwards) Fuel injection pump pulley and synchronizer pin Loosen pulley bolts, to accommodate belt INTERNATIONAL ENGINES Service Manual - 8120081 - 05/02...
  • Page 92 International HS 2.8L Engine Timing CRANKSHAFT GEAR Removal 1. Remove distribution belt, see DISTRIBUTION BELT - Removal. 2. Use tool nr. 8130628 if the crankshaft gear cannot be manually removed. 3. Remove “o” ring. 4. If necessary remove oil seal from timing housing.
  • Page 93 Engine Timing International HS 2.8L CAMSHAFT PULLEY AND OIL SEAL COVER Removal 1. Remove camshaft pulley central bolt. 2. Remove camshaft pulley. 3. Remove oil seal from timing housing, using tool nr. 8130640. Installation 1. Lubricate the new camshaft seal with clean engine oil.
  • Page 94 International HS 2.8L Engine Timing FUEL INJECTION PUMP PULLEY Removal 1. Follow distribution belt removal procedure, see DISTRIBUTION BELT - Removal, but only loosen tensor bolt and remove belt after the following steps. 2. Loosen the three pulley central bolts.
  • Page 95 Engine Timing International HS 2.8L TIMING HOUSING Removal 1. Remove distribution belt and toothed pulleys, see DISTRIBUTION BELT - Removal. 2. Remove fuel injection pump, see FUEL INJECTION PUMP Removal. 3. Remove crankshaft gear, see CRANKSHAFT GEAR- Removal. 4. Remove oil pan, see ENGINE OIL PAN Removal.
  • Page 96 International HS 2.8L Engine Timing Accessories moving belts Note: A new belt must be installed if tensor lever marks and housing spring are aligned. Removal 1. Position a tool on the fixation bolt of the pump and alternator moving belt tensor.
  • Page 97 Engine Timing International HS 2.8L Reinstallation 1. Reinstall moving belts in the inverse order of removal. 2. Fix tensor bolt according to specification. Camshaft Removal 1. Remove timing housing, see TIMING HOUSING Removal. 2. Remove cylinder head. 3. Remove tappets and tappets rolls.

  • Page 98: Flywheel

    International HS 2.8L FLYWHEEL INTERNATIONAL ENGINES 8120081 - 05/02 - Service Manual...
  • Page 99 Flywheel International HS 2.8L FLYWHEEL 1. Remove gearbox. 2. Remove starter motor. 3. Remove clutch. 4. Install two long bolts of 8 mm in clutch bolt holes diametrically opposites, to use as handles when removing flywheel from crankshaft. 5. Install tool nr. 8130638 in crankshaft pulley...
  • Page 100 International HS 2.8L Flywheel 3. Check eccentricity to do not exceed from 0,05 mm to 0,07 mm. If eccentricity is excessive, remove flywheel and check again for irregularities on flywheel, crankshaft and guide thrust surfaces. 4. Check with dial indicator gauge, concentricity between flywheel diameter and crankshaft.
  • Page 101 Flywheel International HS 2.8L RING GEAR REPLACEMENT Warning: Following operations evolve heat, and may cause burinings. Disassembly 1. Put flywheel in a recipient, with clean water and support ring gear on four metal blocks, so ring gear stays approximately 6,5 mm...

  • Page 102: Accessories

    International HS 2.8L ACCESSORIES INTERNATIONAL ENGINES 8120081 - 05/02 - Service Manual...
  • Page 103 Accessories International HS 2.8L ACCESSORIES POWER STEERING PUMP Removal 1. Remove radiator upper hose from thermostat. 2. Remove fan, see FAN Removal. 3. Loosen power steering pump pulley bolts. 4. Remove moving belt, see ACCESSORIES MOVING BELTS Removal. 5. Remove power steering pump pulley.
  • Page 104 International HS 2.8L Accessories Reinstallation 1. Reinstall in the inverse order of the removal, applying Loctite 271 and tighten bolts within 26 to 34 Nm. 2. Complete reservoir with recommended fluid. 3. Start the engine and complete turn steering wheel from one side to the other.
  • Page 105 International HS 2.8L VACUUM PUMP Removal Vacuum pump of turbocharged International HS 2.8L Engines is attached to the alternator. 1. Remove alternator, see ALTERNATOR, Removal. 2. If it is necessary to repair vacuum pump, it is recommended to send the complete set (alternator and vacuum pump) to Bosch Network.
  • Page 106 International HS 2.8L Accessories Accessories support Removal 1. Remove water pump and power steering pump pulleys bolts. 2. Remove accessories moving belt tensor, see ACCESSORIES MOVING BELT Removal. 3. Remove water pump hoses. 4. Remove power steering pump, see POWER STEERING PUMP Removal.

  • Page 107: Technical Specifications

    International HS 2.8L TECHNICAL SPECIFICATIONS INTERNATIONAL ENGINES Service Manual - 8120081 - 05/02...
  • Page 108 International HS 2.8L Technical Specifications TECHNICAL SPECIFICATIONS COMPONENTS: MEASURES, ADJUSTS AND TOLERANCES ENGINE BLOCK MILIMETERS Total height, between finished surfaces 348.28 - 348.46 Cylinder bore, after burnished 93.000 - 93.013 0.45 µm - 0.70 µm Rugosity, after burnished (CLA) Burnishing angle 38 - 42°...
  • Page 109 Technical Specifications International HS 2.8L CRANCKSHAFT MILIMETERS Main journals diameter, standard 63.471 - 63.491 Undersize (0.25 mm) 63.217 - 63.237 Main journal length nr. 1 - standard 31.090 - 31.850 Main journal length nr. 2 - standard 34.393 - 34.645 Main journal length nr.
  • Page 110 International HS 2.8L Technical Specifications CONNECTING ROD SHELLS MILIMETERS Outer diameter (assembled) 62.433 - 62.446 Inner diameter, after assembly 58.779 - 58.780 Thickness 1.827 1.833 Oversize (0.25 mm) 1.952 1.958 Shells width 24.750 - 25.000 Clearance between shell and main journal (diametrical) 0.025...
  • Page 111 Technical Specifications International HS 2.8L CYLINDER HEAD MILIMETERS Height 127.87 - 128.13 Valve guides hole diameter: Standard 14.000 - 14.018 Intake valve seat housing diameter: Standard 40.400 - 40.416 Intake valve seat housing depth 11.000 - 11.100 Exhaust valve seat housing diameter: Standard 38.000 - 38.016...
  • Page 112 VE4/12F1900R905-1 (WG) Pump service code (Bosch) VE4/12F1900R905-1 (VNT) Pump piston displacement 1.44 mm Fuel injection pump International Nr. 77529 N° Bosh: 0460424237 (WG) Fuel injection pump International Nr. 77528 N° Bosh: 0460424234 (VNT) INTERNATIONAL ENGINES 8120081 - 05/02 - Service Manual...
  • Page 113 Technical Specifications International HS 2.8L NOZZLE HOLDER Mark Bosch Type DSLA 140P112 International: 77530 Set number Bosh: 1st stage opening pressure 200 bar 2nd stage opening pressure 330 bar Nozzle height (in relation to cylinder head) 1.82 mm - 2.10 mm...

  • Page 114: Tightening Specifications

    International HS 2.8L TIGHTENING SPECIFICATIONS INTERNATIONAL ENGINES 8120081 - 05/02 - Service Manual...
  • Page 115 Tightening Specifications International HS 2.8L TIGHTENING SPECIFICATIONS GROUP ILLUSTRATION Engine Block Timing Housing Rocker Arm Shaft / Camshaft Rear Seal Fan and Camshaft Pulley Oil Cooler / Filter Piston and Connecting Rods Cylinder Head Belt and Tensor Oil Pan Cylinder Head Cover / Engine Breather...
  • Page 116 International HS 2.8L Tightening Specifications INTERNATIONAL ENGINES 8120081 - 05/02 - Service Manual...
  • Page 117 Tightening Specifications International HS 2.8L INTERNATIONAL ENGINES Service Manual - 8120081 - 05/02...
  • Page 118 International HS 2.8L Tightening Specifications INTERNATIONAL ENGINES 8120081 - 05/02 - Service Manual...
  • Page 119 Tightening Specifications International HS 2.8L INTERNATIONAL ENGINES Service Manual - 8120081 - 05/02...

  • Page 120: Additional Instructions

    International HS 2.8L ADDITIONAL INSTRUCTIONS INTERNATIONAL ENGINES 8120081 - 05/02 - Service Manual...
  • Page 121 Additional Instructions International HS 2.8L ADDITIONAL INSTRUCTIONS INACTIVE ENGINES CONSERVATION In order to avoid engine corrosion if it stays inactive during long period, it is necessary to take the following providences: 1. Clean correctly the outer parts of the engine.
  • Page 122 International HS 2.8L Additional Instructions 14. Clean starter motor and alternator terminals and apply a light layer of grease. If the vehicle is exposed to the weather, alternator, starter motor, and instruments panel must be protected. Engine preparation to return to operation...
  • Page 123 15. Bleed fuel system. Notes: If these instructions are followed the return to work will not damage the engine. INTERNATIONAL ENGINES SOUTH AMERICA LTDA is not responsible for damages in the engine, caused by the incorrectly made procedures. FUEL STORAGE...
  • Page 124 International HS 2.8L Additional Instructions Warning: To install fuel storage tanks the following checks must be followed: 1. Location, dimension and safety of the area where it is installed. 2. The local must be flat, preferently far from houses, animal shelters, electric installations,...
  • Page 125 Additional Instructions International HS 2.8L 12. Inclination in relation to ground level must be from 20 to 50 mm to each meter of length. 13. If gallons are used, these must not be internally galvanized. 14. Gallons must be protected from sun, rain and...

  • Page 126: Special Tools

    International HS 2.8L SPECIAL TOOLS INTERNATIONAL ENGINES 8120081 - 05/02 - Service Manual...
  • Page 127 Special Tools International HS 2.8L TOOLS NUMBER APLICATION Valves assembly / disassembly device 8130001 with disassembled cylinder head. Valves assembler / extractor with 8130002 assembled cylinder head (Standard) Base for height and depth check with 8130004 dial indicator gauge. (Standard)
  • Page 128 International HS 2.8L Special Tools TOOLS NUMBER APLICATION 8130631 Valve guides extractor pin 8130632 Flywheel timing adjustment tool Fuel injection pump gear fixation 8130633 device 8130634 Valve guides assembler pin 8130635 Camshaft bushing extractor Flange for camshaft bushing extraction 8130636...
  • Page 129 Special Tools International HS 2.8L TOOLS NUMBER APLICATION Crankshaft front seal assembler / oil 8130637 seal fixation part assembler 8130638 Crankshaft pulley fixation tool Camshaft oil seal fixation tool 8130639 8130640 Camshaft oil seal extractor 8130641 Compression tester adapter 8130643...
  • Page 130 International HS 2.8L Special Tools TOOLS NUMBER APLICATION Guide for connecting rods assembly 8130644 8130646 Spacer for valves guide Ribbon for pistons assembly in 8130647 cylinders (Standard) 8130648 Rear crankshaft seal assembly device 8130649 Engine belt tensioning device INTERNATIONAL ENGINES...

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