International HS 2.8L User manual

SERVICE MANUAL
International HS 2.8L

International HS 2.8L Presentation
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8120081 - 05/02 - Service Manual
INTERNATIONAL ENGINES
PRESENTATION
This Service Manual has technical specifications necessary to a correct maintenance and repairing of the
InternationalHS2.8Lengines.
As a strictly technical literature, it has been avoided the inclusion of theory concepts and basic definitions,
due to this publication purpose.
It is important to learn how to correctly operate, to maintain and to repair these engines, as well to know
the issues that may cancel warranty due to a bad operation, unauthorized adaptations, unoriginal parts
use or any other procedures that affect it way any.
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.
INTERNATIONAL ENGINES SOUTH AMERICA LTDA
Strategic Planning and Control Management
After Sales Department
Estrada dos Casa, 3155
S.B. do Campo - SP - Brazil
ZIP 09840-000 - Post Office Box 951
Phone: [phone] - Fax [phone]
site:www.nav-international.com.br
PublicationNr. 8120081 - 05/02.

International HS 2.8LIndex
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INDEX
Safety Precautions......................................................................................................................................3
Environment ................................................................................................................................................5
Technical Features......................................................................................................................................8
Operation and Maintenance Recommendations.......................................................................................11
Cooling System.........................................................................................................................................20
Fuel System ..............................................................................................................................................27
Lubrication System ...................................................................................................................................41
CylinderHead............................................................................................................................................47
Engine Block .............................................................................................................................................63
Pistons and Connecting Rods ..................................................................................................................68
Crankshaft.................................................................................................................................................76
Crankshaft Pulley ......................................................................................................................................83
EngineTiming............................................................................................................................................89
Flywheel ....................................................................................................................................................97
Accessories ............................................................................................................................................101
Technical Specifications ..........................................................................................................................106
Tightening Specifications.........................................................................................................................113
AdditionalInstructions .............................................................................................................................119
Special Tools ...........................................................................................................................................125

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SAFETY PRECAUTIONS

International HS 2.8L
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Safety Precautions
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INTERNATIONAL ENGINES
SAFETYPRECAUTIONS
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.
Take all precautions of safety indicated next, because they are your protection during
the work.
•Do not change the original features of the engine.
• Do not smoke while filling fuel tank.
• Clean immediately all and any spilled fluid. Put the material used on cleaning in a safe position and
discard according the Local Legislation.
• Do not fill, while engine is running, unless it is absolutely necessary.
• Never clean, lubricate or adjust an engine in operation.
• Do not adjust anything, if you do not know how to do it correctly.
• Do not operate the engine in closed rooms, because the exhaust gases are extremely “prejudicial” to
thehealth.
• Do not allow people or animals to stay close to the engine, vehicle or equipment while in operation.
• Do not allow people with loose clothes or long and loose hair to stay close to the mobile parts.
• Stay away from the rotary parts. Remember that helices, for example, cannot be well seen while the
engine is running.
• Do not remove radiator cap if the engine is still hot, because cooling water, under pressure, is
extremely dangerous, and may spill and cause serious injuries.
• Do not use salty water or any other substance that can cause corrosion in the cooling system.
• Avoid sparks or fire near batteries, especially while they are charging, because they can cause
explosions. The solution of the batteries could boil and its contact with the skin and eyes is dangerous.
• Disconnect battery terminals before doing any repair in the electric system.
• Seek medical assistance if diesel fuel, under high pressure, penetrates the skin.

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ENVIRONMENT

International HS 2.8LEnvironment
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INTERNATIONAL ENGINES
ENVIRONMENT
ENVIRONMENTALPOLICY
INTERNATIONAL ENGINES SOUTH AMERICA LTDA is committed with the continuous search of the
environment preservation in Diesel engines production for the worldwide market, through an efficient
administration of its resources, processes and products.
GUIDELINES:
To attend the legislation, applicable environmental rules and other requirements that the Company has
joined.
To develop products and procedures to reduce environmental impacts and to avoid pollution.
To apply an efficient administration system that promotes the continuous improvement to reach
environmental objectives and targets.
To promote, in the Company, the sense of individual responsibility in relation with the environment.
To involve its suppliers and service suppliers in the development of habits which cooperate in the
preservation of the environment.
ENVIRONMENT
The environment preservation is a basic point in the managerial philosophy of INTERNATIONAL
ENGINES SOUTH AMERICA LTDA.
It has been approved a program of actuation that includes activities as natural resources conservation,
elimination and residues recycling, water protection, noise reduction and acoustic isolation, air purity
conservation and contaminants residues elimination.
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.
The systematical accomplishment of this philosophy can be appreciated especially in the main aspects,
like disassembly easiness, less number of materials, usage of plastics of easy recycling.
It means, equally, that materials harmful to the environment are not used, like amianthus, cadmium and
hydro-carbidefluor-chlorined.
In the same field, gases and acoustics emissions reduction are considered, as well as the improvement
of the active and passive safety.
This environment protection program is not limited only to the production process, because it is extended
to the complete cycle of useful life of the engine, considering also its wear after a long operation period.
We have assumed a commitment with the planet we live in.A commitment that we take very seriously.

International HS 2.8L Environment
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ENVIRONMENTAL POLLUTION CONTROL
INTERNATIONAL ENGINES SOUTH AMERICA LTDA, through its Environmental Administration
System, has improved more and more its engines contributing to pollution reduction (Program ofAir
Pollution Control forAuto-Motorized Vehicles - PROCONVE) and attending, in this way, to the resolutions
ofCONAMA (National Council of theEnvironment).
Warning: The engine adjustment values specified in this manual, must be strictly observed,
because, besides to offer a better performance to the vehicle, also reduce noises and
harmful gases emissions to the atmosphere.
Warning: Any change in the fuel injection or air intake system, or even the exhaust system, may
affect directly the homologated values.
DESTINATION OF THE USED COMPONENTS OF THE ENGINE
INTERNATIONALENGINES SOUTHAMERICALTDAis 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.
PlasticandMetallic Components / Packing
This type of component must be sent to a Scrap Trade where the parts will be sold and re-melted.
LubricantOil
This fluid has a high polluting potential and it cannot be discarded, never, in the sewer. Send it to
companies that make the re-process (re-refine).

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TECHNICALFEATURES

International HS 2.8L Technical Features
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TECHNICALFEATURES
ENGINETYPE INTERNATIONALHS2.8L
PL number 8B60 8B61
Turbocharger Variable Nozzle (VNT) With Wastegate
Number and Cylinder
Arrangement 4 in line
Cylinder Nominal Bore 93.0 mm
Stroke 102.50 mm
Cycle Diesel, 4 stroke
Compression Relation 19.5 : 1
Total Displacement 2,8 Liters
Combustion System Direct Injection
Rotation Sense (front view) Clockwise
Firing Order 1 - 3 - 4 - 2
OpeningBeginning 86 - 90 ºC
Operation Temperature 86 -102 ºC
Lubricant oil Pressure (at
Maximum Specified Speed With
the Engine at Normal Operation
Temperature)
3.5 bar
MaximumSpeedUnload 4640 rpm
IdleSpeed 800 rpm ± 20
Static Injection Beginning at TDC 0º
EngineCooling Liquid
Power (NBR5454) 135 hp (99 kW) at 3800 rpm 133 hp (97 kW) at 3800 rpm
Torque(NBR5454) 38.2 kgfm (375 Nm) at 1400 rpm 36.2 kgfm (355 Nm) at 1600 rpm
Weight (basic unit) 208 kg 205 kg

International HS 2.8LTechnical Features
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LOCATIONAND IDENTIFICATION OF THE
ENGINE NUMBER
Location
Identification
B61 (WG)
B60 (VNT) 536265
SERIALNUMBER
PARTSLIST NUMBER
• For engines manufactured in Brazil -
nr 000001 to 499999.
• For engines manufactured inArgentina -
nr from 500000 on.
PS: (WG) - Wastegate Version
(VNT)-Variable Nozzle Turbocharger Version
Left side view
Front

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OPERATIONAND MAINTENANCE
RECOMMENDATIONS

International HS 2.8L
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Operation and Maintenance Recommendations
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OPERATIONANDMAINTENANCE
RECOMMENDATIONS
START AND STOP
Before starting the engine
1. Check “Daily Maintenance” items, see
PERIODICMAINTENANCE.
2. Turn start key to contact position and check if
battery charge and engine oil pressure
indicator lamps are switched on.
If the engine has been stayed inactive for a long
period, bleed the fuel system.
KeyPositions
1. Off
2. Contact
3. Start
Start
Warning: POSITION TRANSMISSION
LEVER TO NEUTRAL.
1. Position key in start position for seven
seconds, at the maximum.
If engine doesn’t work, repeat operation after 30
(thirty) seconds.
Note: Do not keep the key turned too much long, because it will damage the starter.
In turbocharged engines, after to start, do not
accelerate over than 1000 rpm, during the firsts
30 (thirty) seconds. This allows turbocharger
lubrication line pressure equalization avoiding
damages to this equipment.

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2. Check the panel instruments, engine noise
and exhaust gases.
In case of any irregularity, stop the engine
and immediately look for our Distributors
Network and / orAuthorized Services.
Note: Do not extremely load the engine, while it is not at the normal operation temperature.
Stop
Warning: Let the engine in idle speed and
transmission lever in neutral.
In turbocharged engines, in order to do not
damage the turbocharger shaft, the engine must
run during 30 (thirty) seconds under 1000 rpm
before stopped.
• Do not accelerate the engine.
• Turn key to “off” position.
RUNNING-IN
Thetechnology that INTERNATIONALENGINES
SOUTHAMERICALTDAuses on its engines
production, as well as on tests in dynamometer,
eliminate the necessity of large run-in periods.
Generally, it is considered the firsts 2500 km
(1550 mi) of work as the necessary period for the
run-in, which can vary according to each
application that each product is used.

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Operation and Maintenance Recommendations
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During running-in follow these recommen-
dations:
• DO NOT OPERATE THE ENGINE AT OVER
THAN85% OF THE MAXIMUMSPECIFIED
SPEED (3800 rpm), see TECHNICAL
SPECIFICATIONS.
• WHEN IN ATRIP, VARYTHE ROTATION TO
AVOID CONSTANT SPEEDS DURING LONG
PERIODS. DO NOT BRUSQUELY
ACCELERATETHE ENGINE.
During useful life of the engine:
• Before starting, check lubricant oil, cooling
system water and fuel levels.
• Do not warm the engine up in idle speed but
varying its speed.
• To reach the normal operation temperature,
move the vehicle without extremely loading
and without exceeding 3800 rpm.
• Do not let the engine running in idle speed
withoutneed.
• Keep the engine operation temperature
between 86 and 102 °C (187 and 216 °F)
engine.
Note: It is operator responsibility the correct use of the product during the running-in. The not
execution of the recommendations above mentioned will provoke the decrease of the
product useful life, with consequent increase of the lubricant oil consumption to higher
levels than the ones defined by the project.
REVISIONPROGRAMS
The engine warranty is conditioned to the
accomplishment of the delivery revisions, and
more the revisions mentioned in the Warranty
Certificate.
Our Distributors and / or Authorized Services Net
must make all obligatory and periodic revisions
operations according to the instructions of this
Manual.
Optional equipment installation, not originals from
factory, will cancel warranty and may cause
serious damages to the engine, with consequent
decrease of its useful life.
For a better engine performance, always use
genuine parts.

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INSTALLATIONREVISION
ITEM CHECK
Alternatorbelt Tension
Water and lubricant oil Level (complete if necessary)
General performance Operation temperature and speed at
maximum load
Intake system Intake air temperature and restriction
Fuel system circuit If the piping is unobstructed and free of vibrations,
extreme heat areas and leakages occurrences
Exhaust system If there isn’t restriction to the exhaust gases
Command system Accelerator course
Enginefixation Alignment among engine and transmition
Instrumentpanel Indicators, warning lamps and sensors functioning
Cooling system Radiator, hoses, piping and clamp conditions

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Operation and Maintenance Recommendations
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PERIODICMAINTENANCE
PERIODS
CHECK
15,000 km
(9,300 mi)
Check engine oil level (complete if necessary).
30,000 km
(18,600 mi)
45,000 km
(27,900 mi)
60,000 km
(37,300 mi)
75,000 km
(46,600 mi)
90,000 km
(55,900 mi)
105,000 km
(65,200 mi)
120,000 km
(74,600 mi)
Daily
Check water “reservoir” level (complete if necessary).Daily
Drain impurities from the fuel filter and
sedimentation filter.
Daily
Check air filter hoses and connections conditions.Daily
Retighten engine rubber pads.
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•Replace lubricant oil and filter.
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•Replace fuel filter element.
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•Adjust valves clearance.
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•Check idle speed*.
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•Check teeth belt conditions, through the inspection
lateralplug.
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Check external belts conditions.
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•Cooling system: check anti-freezing
(replace at each 2 years).
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•Check oil - fuel - cooling piping conditions.
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•Replace external belts.
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•Replace toothed belt.
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•Evaluate starter, alternator and turbocharger**.
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After the first change at 15.000 km (9,300 mi) lubricant oil and oil filter must be obligatory changed at
each 15.000 km (9,300 mi) or 6 months maximum (which one first occurs). Fuel filter must be replaced
and fuel tank clean (maximum) at each 6 months, even without reached the limit of 15.000 km (9,300 mi)
(recommended for the fuel filter change).
* Services that have to be made by Distributors / Authorized Services Net.
** Services that have to be made by part manufacturer.
Remark:For vehicles that work predominantly in regions where sulfur index in fuel is over than
1%, lubricant oil change intervals must be at each 7.500 km.
Check the terminals and battery level.
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TURBOCHARGER
The turbocharger is compound of a rotary turbine
and a air compressor, located in opposite sides
of a same shaft. The compressor and turbine
rotors are covered by housing denominated
compressor and turbine, which function is to
direct the gases flow through the rotors shovels.
These gases having energy in pressure,
temperature and speed form, cause the rotation
of the turbine rotor and consequently of the
compressor rotor.
With the rotation, the atmospheric air (that must
be properly filtrate) is aspired, and later on,
compressed to the compressor rotor from where
goes to turbocharging (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.
InturbochargedInternationalHS 2.8L engine, the
turbocharger is also composed by a Wastegate
valve or VNT, which controls the maximum
pressure to be provided by the compressor, to
avoid damages in the engine.
Other advantage:
Existing a larger mass of air, we can fire a larger
amount of fuel, besides we get a better
combustion of the mixture.
The operation of an engine equipped with
turbocharger does not require any special
procedure.
Anyway, to assure the maximum durability of the
turbocharger, take care of these items:
To accelerate the engine immediately after
starting damages the turbocharger, because it
gets a high speed without the oil flow need on its
shaft.
To accelerate the engine before stop it, also
damages the turbocharger, because it stops the
lubrication but, on the other hand, the turbo shaft
still has a high speed.
Filtrateair
Exhaust
gases Turbinerotor
Compressedair
Compressorrotor
Exhaust
gasesfrom
theengine

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Operation and Maintenance Recommendations
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The intake of strange objects, even smalls, will
damage the rotor of the compressor, damaging
the operation of the turbocharger, this way,
between the recommended periods check the air
filtering system.
By working at high speeds and temperatures, the
turbo requires a lubricant oil that accomplish to
these requirements, and never should be used a
lubricant oil that does not attend toAPI /ACEA
specification (5th class - multi-viscous).
ACCESSORIESBELTS
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.
Two tensors adjust automatically the belts
tension, eliminating this way the necessity of
individualadjustment.
The belts must be checked at each service and
replaced when necessary.
Off-road use
Belts regular checks are essential if the vehicle is
used off-road. When executing service in the
vehicle, the owner must be contacted to identify
the way in that the vehicle’s mileage has been
get.
After each off-road use, the owner must check
the belts for cuts and damages caused by
stones. If one of the belts gets loose, it must be
repositioned correctly, replacing in the next
service or before, depending on the damage
level.
Belts conditions check
Check belts conditions, replacing them if they
present waste, cracks or contamination with oil.

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CAMSHAFTBELT
The engine timing pulleys are moved by a flexible
rubber belt, which must be replaced in
predetermined intervals depending on the use
conditions severity.
Follow strictly the specifications of belt tensor
tightening, guaranteeing its useful life, according
the recommendation.
Note: If the belt is not replaced within the correct intervals, it may present failures, causing
serious damages to the engine.