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International HS 2.8L Workshop Manual

1. 11 20 IAS E 27 LUDIC SEIN 41 VMS Si MN T 47 14 MN EE o o mmc 63 Pistons and Connecting RodS metub eee us esum ita 68 Sin RIS DRE 76 PUEY 83 ENGGO MII MET _ __ ___ _______ 89 gig 97 ACCOSSONTOS ___ __ ______ acouns 101 Technical 106 SOC CMC ANIONS T UU 113 Additional MNS UNC 119 amp 6 125 Service Manual 8120081 05 02 International HS 2 8L SAFETY PRECAUTIONS Safety Precautions International HS 2 8L gt SAFETY PRECAUTIONS A Warning 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 durin
2. 8120081 05 02 Service Manual Technical Specifications International HS 2 8L NOZZLE HOLDER DSLA140P112 FUEL LIFT PUMP Mechanic of diaphragm Flux pressure static 42 to 55 kN m Gasket thickness to engine block 0 4 mm 0 6 mm FUEL INJECTION PUMP PULLEY No of gear teeth GT 22 56V VNT Actuator valve type VNT 112 aT L ENGINES Service Manual 8120081 05 02 International HS 2 8L TIGHTENING SPECIFICATIONS Tightening Specifications International HS 2 8L gt TIGHTENING SPECIFICATIONS GROUP ILLUSTRATION Rocker Arm Shaft Camshaft Fan and Camshaft Pulley Piston and Connecting Rods Belt and Tensor Oil Pan Intake Exhaust Manifold Fuel Injection Pump Water Pump Fuel Lift Pump Fuel Filter Power Steering Pump Belt Tensor O Injection Piping and Nozzles NO NO Flywheel and Gear Ring gt Engine Brackets UJ CD JJ m D 7 gt lt 2 Q 0 D 3 O D 2 gt 2 2 o 0 2 2 dp gt D 0 D o I 2 O D gt T c T D lar D TI e o 2 f 5 2 L U enum 8 5 5 e 2 D m 2 D x D Service Manual 8120081 05 02 International a
3. 3 5 60 1209 14 20 Nm eee ep qe p 22 28 Nm 14 17 Nm Dri Loc 215 26 28 Nm a 80 Nm 125 CNTERNATONAL ns 8120081 05 02 Service Manual Tightening Specifications International HS 2 8L M8x117mm 60 1209 20 1409 8 i M12x100 mm 60 Nm 120 7 40 50 Nm Loctite 271 13 17 Nm Loctite 567 e 22 28 Nm 9 13 Nm Loctite 242 ne Eo ences Service Manual 8120081 05 02 Tightening Specifications 22 28 Nm P 8 11 Nm 1 2 Loctite 271 8 11 5 40 50 a mo i7 Nm 40 50 MM Loctite 271 40 50 Nm 40 50 Nm Loctite 242 36 42 Nm DC Loctite 242 22 28 Nm Loctite 242 da 9 i 7 26 34 Nm ERES w 44 22 28 Nm 40 50 Nm NEN GV 8 11 Nm 45 55 Nm a 8 11 Nm 26 34 Nm 26 34 Nm i 8120081 05 02 Service Manual Tightening Specifications International HS 2 8L 26 34 Nm E Loctite 271 ge T D j N 2 3 ERU 2 3 T N Re 2 N 3 T E E 4 L Li 8 11 Nm 40 50 Nm Loctite 271 8 11 Nm fs 2228 Nm e 60 30 e 80 90
4. SERVICE MANUAL Nub BUT Eoo li gt International HS 2 8L M NTERNATIONAL Engines A ee Se eee _ M a EAAZAZZMA cmm mg __ _ MN ee COEUR _ CCC 2 L m a sss ee a CcC XX 7 HD wuhiu CONSER ORNARE z MEWS x 7 8 C __ CONEEENLANLIIUS S 2 _ m lt lt _____ __________ ____________ _________ 2 ERR _ _ cU O IMG 5 1 International HS 2 8L Presentation PRESENTATION This Service Manua
5. Assembly new seal spring washers springs and spring seats Lubricate parts in the assembly sequence Compress springs and assembly locks Assembly valves covers International HS 2 81 INTERNATIONAL EN GINES Service Manual 8120081 05 02 International HS 2 8L Cylinder Head Seals and springs replacement with cylinder head installed 1 Setthe 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 3 Remove locks spring seats springs spring washers and seal Do not turn the crankshaft before the end of to replacement operation for that the valve does not fall inside of cylinder 4 Install a new seal on the valve rod fitting it in its housing Assembly spring washers springs and seat 5 Compress valve springs and install locks 6 Assembly valves cover 7 Correctly position rocker arm and adjust the adjustment screw to get the correct clearance see VALVES CLEARANCE ADJUSTMENT VALVE GUIDES Inspection 1 Remove valves see VALVES Disassembly 2 Remove carbons from combustion chambers and valve guides wash them with solvent Check guide hole diameter with an inner diameters measurer in three positions C ERNATIONAL ENGINES ES 59 8120081 05 02 Service Manual Cylinder Head Guide replacement 1 Use tool nr 8130631 and a press
6. Cooling System 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 Always using additives diluted in clean water keeping the mix proportion 1 3 of addictive 2 3 of water In regions of more intense cold use 1 2 of addictive and 1 2 of clean water free of residues 7 Press radiator upper hose to help the air elimination and fill the system until only coolant water leaks free from bubbles through the thermostat housing hole Recommended additives Radiex Qu mica Ltda Fluid for radiator Radiex Mobil Oil do Brasil Ind e Com Ltda Mobil Permazone Promax Products M ximos S A Bardhal Rad Cool Shell Brasil S A Fluid for radiators Warning Carefully read the instructions on the product packing before using it Do not add soluble oil to the cooling circuit water because it attacks and damages the rubber hoses The above mentioned additives usage is very important to guarantee the cooling system efficiency being the engine operating at low or high temperatures International HS 2 81 Service Manual 8120081 05 02 International HS 2 8L n Cooling System 8 Manually reinstall thermostat housing disaeration plug just to seal the liquid outlet h
7. 8120081 05 02 Service Manual Special Tools International HS 2 8L TOOLS NUMBER APLICATION Gyankehat tront seal assembler oil Crankshaft pulley fixation tool Camshaft oil seal fixation tool Camshaft oil seal extractor Compression tester adapter 72 eo 8130643 Fixation device for viscous clutch Service Manual 8120081 05 02 International HS 2 8L Special Tools TOOLS NUMBER APLICATION 8130644 Guide for connecting rods assembly 8130646 Spacer for valves guide 8130647 Ribbon for pistons assembly in cylinders Standard 8130648 Rear crankshaft seal assembly device 8130649 Engine belt tensioning device CT 12 8120081 05 02 Service Manual
8. After storage tank filling it is necessary to let fuel resting during 24 h so that there will be water and impurities sedimentation 2 Before transferring fuel from storage tank to any other tank it is necessary to drain accumulated water and sediments 3 Bottles funnels etc used to transfer fuel from a tank to another must be clean Tow or clothes that loose threads cannot be used to clean these utensils 4 Funnel used for fuel transfer must have a metallic fabric of mesh 80 thread of 0 10 mm and mesh opening of 0 25 mm 122 Service Manual 8120081 05 02 International HS 2 8L F Warning install fuel storage tanks the 10 11 following checks must be followed Location dimension and safety of the area where it is installed The local must be flat preferently far from houses animal shelters electric installations places where there are welding equipments boilers or others that may generate sparks blames or excessive heat Tank must be cylindrical made of steel plates electrically welded Internally the surface of the tank and all fuel piping must be clean and free of any impurities which can contaminate fuel it cannot be zinced because fuel chemically reacts with zinc producing a viscous substance that obstruct filters and damage fuel injection system functioning Externally fuel tank and all components of its piping must be painted with anti corrosive paint Tank mu
9. arms Installation 1 C ERNATIONAL ENGINES Lubricate the lower edge of the push rods making sure that there is a correct fitting in the tappets If the rocker arms support shaft fixation prisoners in the cylinder head have been removed assembly and tighten them according to specification Assembly rocker arms shaft set using new sealing rings Tighten fixation nuts in three steps from the center to the ends according to specification 8120081 05 02 Service Manual Cylinder Head 57 Cylinder Head VALVES Disassembly 1 Remove cylinder head see CYLINDER HEAD Removal With tool nr 8130001 compress springs and remove valves locks Remove springs seats springs springs washers seals and valves While removing or replacing valves mark with electric pencil the corresponding number of each cylinder Cleaning and inspection 1 4 Remove carbon from combustion chamber valve guides and valves Wash all parts with solvent Check valve rod diameters with micrometer in three positions If the clearance between the rod valve outer diameter and guide inner diameter is over than specified replace guide by another see VALVE GUIDES Check springs Assembly 1 58 In the assembly seals must be replaced and assembled very carefully Use a compound of Bisulphet of Molybdenum mixed with engine oil Apply a little coat in valve rod Install valve in its corresponding guide
10. making sure if the pipe turns freely 6 Remove turbocharger outlet eloow from exhaust pipe 7 Position an appropriate recipient under the engine and remove banjo bolt from turbocharger lubrication pipe and disconnect turbocharger oil return pipe from cylinder block p ii Li 8 Loosen turbocharger fixation prisoners nuts from exhaust manifold removing it carefully Reinstallation 1 Reinstall in inverse order of removal INTAKE MANIFOLD Removal 1 Loosen clamp and disconnect turbocharger inlet pipe from intake manifold 2 Remove valve fixation bolts and vacuum derivation and remove the set 3 Remove bolt that fix intake manifold to intake elbow from turbocharger 4 Remove boost pipe control banjo bolt 54 INTERNATIONAL GINES Service Manual 8120081 05 02 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 Reinstallation 1 Clean intake manifold contact surface and reinstall it with a new gasket in the inverse order of the removal tightening bolt within 22 to 28 Nm EXHAUST MANIFOLD Removal 1 Remove turbocharger see TURBOCHARGER Removal 2 Remove exhaust manifold fixation nuts removing
11. Nm Service Manual 8120081 05 02 International HS 2 8L ADDITIONAL INSTRUCTIONS Additional Instructions gt 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 2 10 11 Clean correctly the outer parts of the engine Run engine up to the normal operation temperature Next stop and drain oil from oil pan Remove oil pan clean oil suction pipe and replace lubricant oil filter cartridge Clean breather pipe After to reinstall filter fill oil pan up to the maximum level marked on lubricant oil dipstick with SHELL ENSIS ENGINE MOTOR oil Drain fuel tank and fill it with SHELL CALIBRATION FLUID B oil Run engine until that it reaches normal operation temperature Drain cooling water from engine and radiator Remove air filter or any extension of the intake piping and seal air intake with adhesive tape Remove exhaust pipe and seal exhaust manifold as well as intake manifold Disconnect battery and remove it for storage A Warning t contains acid protect eyes 12 13 120 and hands Remove fan belt Complete battery level with distillated water Clean terminals lubricate with grease and complete charge Do not use quick charge Stock in a fresh dry and free of dust place Complete charge once a mon
12. first lower central nut Remove gasket 4 Clean contact surfaces C ERNATIONAL ENGINES E 55 8120081 05 02 Service Manual 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 Loosen rocker arm shaft set fixation nuts from the edges to the center in 3 steps 2 Remove the set 3 Remove camshaft push rods marking them to reinstall in the same position later 56 INTERNATIONAL GINES Service Manual 8120081 05 02 International HS 2 8L 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 Check rocker arms bushing If its clearance with the upper shaft is over than specified bushing must be replaced see clearance in TECHNICAL SPECIFICATIONS Check waste in the ends and warping of the push rods Assembly 1 Assembly a new plug in the ends of the removed shaft Assembly bushing in rocker arm making sure that the lubrication holes are aligned Machine the inner diameter of the bushing Assembly the connection in rocker arms shaft Assembly springs brackets and rocker
13. head 5 Remove nozzle holders and discard copper washers 6 Protect fuel passages and nozzle pulverization holes Reinstallation 1 Check nozzles In case it is noticed any irregularity seek a Distributor or an Authorized Service of the injection system manufacturer to the nozzle holder set replacement 2 Internally clean all fuel piping with compressed air Externally check pipes conditions and structure replacing them if necessary 3 Make sure that the nozzle holder set and its seat in the cylinder head are clean 4 Grease slightly a new copper washer and position it in the nozzle holder set TERNATIONAL enames 8120081 05 02 Service Manual Fuel System International HS 2 8L 5 Install nozzle holder set with the return outlet turned outside 6 Fixit with the plate and nut tightening according to specification The fixation plates are slightly curved and must be installed with the convex side upwards 7 Install return pipe with only one copper washer under the head of the banjo bolt and two copper washers between the nozzle holder set and the banjo Tighten the banjo bolt according to specification 8 Install high pressure pipe tightening the union nuts according to specification TIMING 1 Externally clean the engine Remove valves cover its gasket and breather pipe 2 Remove high pressure pipes set from nozzle holders to fuel injection pump 3 Remove fuel inje
14. in the inverse order of the removal tightening bolts according to specification C ERNATIONAL ENGINES 8120081 05 02 Service Manual Accessories 105 Eo International HS 2 8L TECHNICAL SPECIFICATIONS qo DONDE ice Manual 8120081 05 02 Service International HS 2 8L _ Technical Specifications gt 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 Rugosity after burnished CLA 0 45 um 0 70 um Burnishing angle 38 42 Shell housing diameter 67 704 67 721 Camshaft bushing housing diameter 49 99 50 01 Tappet housing diameter 34 925 34 950 MAIN BEARING SHELLS MILIMETERS Outer diameter 67 704 67 721 Inner diameter after assembly Oversize 0 25 Main bearings shells width nr 1 2 3 and 4 Main bearing shell width nr 5 rear Thickness Clearance between shell and main journal diametrical 0 080 0 080 CAMSHAFT GEAR MILIMETERS Number of teeth Gear housing diameter 38 030 38 075 CAMSHAFT PULLEY MILIMETERS Seal ring diameter 56 975 57 025 INTERNATIONAL ENGINES 107 8120081 05 02 Service Manual Technical Specifications CRANCKSHAFT Main journals diameter standard Undersize 0 25 mm Main journal length nr 1 standard Main journal length nr 2 standard Main journal length nr 3 standard Main journal le
15. pin of the timing tool nr 8130632 in the flywheel housing hole with the pin fitted in the flywheel hole 2 Make sure that marks are aligned Ref A and B and that injection timing tool pin nr 8130633 is correctly introduced in injection pump pulley Ref C 8120081 05 02 Service Manual 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 Make sure if tensor movement is free that is to say bolt slightly loosen allowing free movement but without side clearance 6 Install in the square among idle and tensor pulleys special tool nr 8130649 which is adjusted to attend a torque equivalent from 9 to 10 Nm 7 Tighten tensor bolt within 40 to 50 Nm 8 Tighten the 3 three fixation bolts of fuel injection pump pulley within 22 to 28 Nm 9 Remove special tool fuel injection pump and flywheel locking device 10 Manually turn engine 2 turns to distribute belt tension 11 Check engine timing Note After the torque application it is recommended to check belt tension by the device pitch within 130 to 160 Hz 88 INTERNATIONAL GINES Service Manual 8120081 05 02 International HS 2 8L ENGINE TIMING INTERNATIONAL ENGINES 1 8120081 05 02 Serv
16. see OIL PAN Removal 2 Remove pipe support fixation bolts 3 Remove pipe flange bolt and oil pump connection 4 Remove oil suction pipe 5 Close oil inlet duct in the timing housing avoiding dirt penetration Reinstallation 1 Reinstall oil suction pipe installing a new sealing ring in pump connection 2 Apply Loctite 242 in the two bearing cap bolts Tighten them according to specification 3 Install bolts in pipe flanges and tighten them according to specification 4 Reinstall oil pan see OIL PAN Installation C ERNATIONAL ENGINES 45 8120081 05 02 Service Manual Lubrication System 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 Ifit is necessary to replace oil pump it is recommended to replace the whole timing housing see TIMING HOUSING Recommended Lubricant Oils Multi viscous SAE 15W 40 CCMC 0 5 ACEA AND 3 Multi viscous oil Keep its features even with high temperatures variations Use obligatory in International HS 2 8L Engines 46 INTERNATIONAL GINES Service Manual 8120081 05 02 International HS 2 8L Cylinder Head CYLINDER HEAD 8120081 05 02 Service Manual Cylinder Head gt CYLINDER HEAD Removal Warning Loosen radiator low
17. 05 02 Service Manual Operation and Maintenance Recommendations International HS 2 8L During running in follow these recommen dations DONOT OPERATE THE ENGINE AT OVER THAN 85 OF THE MAXIMUM SPECIFIED SPEED 3800 rpm see TECHNICAL SPECIFICATIONS e WHEN INA TRIP VARY THE ROTATION TO AVOID CONSTANT SPEEDS DURING LONG PERIODS DO NOT BRUSQUELY ACCELERATE THE ENGINE During useful life of the engine Before starting check lubricant oil cooling system water and fuel levels Donot 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 without need Keepthe engine operation temperature between 86 and 102 187 and 216 engine 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 REVISION PROGRAMS 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 instr
18. 0635 and tool nr 8130636 C ERNATIONAL ENGINES ES 65 8120081 05 02 Service Manual 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 4 Assembly camshaft rear seal applying Loctite 601 CYLINDER Verification 1 Check cylinder inner diameter and out of roundness If dimensions found are higher than specified replace the engine block Maximum bore allowed for service 66 INTERNATIONAL GINES Service Manual 8120081 05 02 International HS 2 8L 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 First step must be made with burnishing batons of granulation 80 to 100 mash In finishing for final bore it has to be used batons of granulation 320 mash In the two steps the grain quality of all the batons must be CG carbide of green silicon hardness N During burnishing use oil Honilo 407 Castrol Finishing must be uniform on all cylinder extension All mandrill marks must be removed The cylinder surface must not be polished The rugosity must be within the specified values Cleaning and inspection 1 Remov
19. 3 5 bar Temperature 4640 rpm 800 rpm 20 Power NBR5454 135 hp 99 kW at 3800 rpm 133 hp 97 kW at 3800 rpm Torque NBR5454 38 2 kgfm 375 at 1400 rpm 36 2 kgfm 355 at 1600 rpm Weight basi INTERNATIONAL ENGINES M 9 8120081 05 02 Service Manual Technical Features International HS 2 8L LOCATION AND IDENTIFICATION OF THE ENGINE NUMBER Location Identification B61 WG B60 VNT 936265 SERIAL NUMBER PARTS LIST NUMBER e For engines manufactured in Brazil nr 000001 to 499999 For engines manufactured in Argentina nr from 500000 on PS WG Wastegate Version VNT Variable Nozzle Turbocharger Version Left side view Service Manual 8120081 05 02 International HS 2 8L OPERATION AND MAINTENANCE RECOMMENDATIONS Operation and Maintenance Recommendati 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 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 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 Ke
20. 8 Nm WATER PUMP Removal 1 Drain cooling system 2 Remove radiator upper hose from the thermostat 3 Loosen fixation bolts of the power steering pump pulley 4 Loosen fixation bolts of the water pump pulley 5 Remove belt tensor 6 Remove accessories belt see ACCESSORIES BELTS Removal 7 Remove water pump pulley 8 Remove power steering pump pulley 9 Remove the 8 fixation bolts of the water pump marking the position of the 3 passing bolts in the engine block 10 Remove pump and gasket and clean the contact surfaces Service Manual 8120081 05 02 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 3 Apply Loctite 242 and tighten the bolts with the specified torque See TIGHTENING SPECIFICATIONS THERMOSTAT Removal 1 Partially drain cooling system until the level of the coolant water is below the thermostat housing 2 Disconnect hose from thermostat housing 3 Disconnect electric connections of the water temperature switch 4 Remove outlet elbow 5 Remove thermostat 6 Pay attention that the initial scale for the thermostat operation evaluation test is 88 190 F Install the thermostat in a recipient with water Heat the water up and check the temperature
21. CE ADJUSTMENT 1 Remove breather valve and hose 2 Remove valves cover 3 Loosen lock nut and adjust clearance turning adjustment screw C ERNATIONAL ENGINES ES 8120081 05 02 Service Manual Cylinder Head 61 International HS 2 81 Cylinder Head Clearances Adjustment Intake conditions valve Procedure Balance valves of Adjust valve of cylinder nr cylinder nr 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 The piston nr 1 is the closest to the timing housing 3 Assembly valves cover correctly positioning its sealing gasket with cylinder head Tighten fixation nuts within 8 to 11 Nm 62 INTERNATIONAL ENGINES Service Manual 8120081 05 02 International HS 2 8L ENGINE BLOCK INTERNATIONAL ENGINES s 8120081 05 02 Service Manual Engine Block International HS 2 8L gt ENGINE BLOCK Removal Warning lubricant oil Warning Remove tank cap and loosen water hoses from radiator A Warning Remove drain plug and drain cooling system 1 Loosen electric cables from starter motor lubricant oil pressure and engine temperature gauges Disassembly 1 Disconnect inlet pipes and fuel return 2 Remove engine from equipment eo Install support on the engine and install it in the engine stand Remove fan Remove crankshaft
22. Camshaft and injetion pump pulleys are the same but they are assembled in inverse Way 3 Reinstall pulley positioning it so that the timing mark stay turned forward tighten bolt according to specification Service Manual 8120081 05 02 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 3 Remove pump limiter and retighten bolt to lock the pump 4 Remove tool nr 8130633 pin from pulley 5 Remove the three bolts and then remove plate and pulley is important to assure that once locked fuel injection pump any attempt to turn pump cannot be made Take care to do not allow crankshaft to be turned Reinstallation Camshaft and injetion pump pulleys are the same even so they are assembled in inverse way Install pulley positioning it in way that timing mark keep turned backwards Install plate and fix it with three bolts Install tool nr 8130633 pin in fuel injection pump pulley and fit it in the pump flange 4 Reinstall limiter to unlock pump 5 Install distribution belt see DISTRIBUTION BELT INSTALLATION 8120081 05 02 Service Manual Engine Timing TIMING HOUSING Removal 1 Remove distribution belt and toothed pulleys
23. National Council of the Environment Warning 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 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 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 Plastic and Metallic Components Packing This type of component must be sent to a Scrap Trade where the parts will be sold and re melted Lubricant Oil 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 8120081 05 02 Service Manual Eo International HS 2 8L TECHNICAL FEATURES s INTERNATIONAL ENGINES ice Manual 8120081 05 02 Service International HS 2 8L Technical Features gt TECHNICAL FEATURES ENGINE TYPE INTERNATIONAL HS 2 8L Turbocharger Variable Nozzle VNT With Wastegate Arrangement Firing Order 1 3 4 2 86 90 C 86 102 C Opening Beginning Operation Temperature Lubricant oil Pressure at Maximum Specified Speed With the Engine at Normal Operation
24. a distributor and or authorized service Lubricant oil and filter replacement If the engine operates in regions with high dust concentration or other harmful conditions to the good operation it will be necessary to reduce the replacement periods filter and lubricant oil After the first oil and filter change at 15 000 km 9 300 mi or 6 months prevailing which one occurs first lubricant oil must be replaced together with filter Warning During drainage lubricant oil is hot and may cause burnings 42 INTERNATIONAL EN GINES Service Manual 8120081 05 02 International HS 2 8L Lubrication System 1 Runthe 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 necessary remove and clean tt 4 Remove lubricant oil filter see OIL FILTER Removal 5 Assembly a new filter see OIL FILTER Assembly 6 Assembly oil pan plug with a new washer 7 Refill and assembly the filling inlet cover Only use recommended lubricant oils Multi viscous SAE 15W 40 CCMC D 5 ACEA AND 3 API CG 4 OIL PAN CAPACITY Minimum 6 liters without filter Maximum 6 5 liters with filter 8 Start the engine 9 Stop the engine check level and eventual leakages existence OIL FILTER Removal 1 Position a recipient under the filter 2 Loosen filter co
25. ability it is necessary drain it before the initial start according to the Periodic Maintenance table 1 Open filter drainage lateral plug 2 Open filter upper plug As soon as the fuel flows clean through the side plug close the drain plug 4 Close upper plug 5 Check for leakages 8120081 05 02 Service Manual 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 4 Remove filter 5 Disconnect water in fuel sensor 6 Discard filter Installation 1 Manually assembly water in fuel sensor until rubber ring touches the new filter 2 urn sensor 1 3 turn clockwise 3 Position filter in the clamp and install water in fuel sensor electric connection 1 and 4 4 Support filter in the support and if necessary adjust filter to allow better a position of the pipes 5 Install fuel inlet and outlet pipes 6 Tighten clamp nut until the clamp touches the support to avoid strangle The upper edge of the filter must be pushed against the aluminum support in order to provide negative according detail below In case of non existence of contact between the edge of the filter and the support the sensor will loose action and will not indicate the water presence in the veh
26. ain journals eccentricity 8 Check main journals and crankpins fillets with caliper 9 To balance remove material from crankshaft arm sides In case of part stock apply antioxidant oil immersion 10 Before assembly wash crankshaft with water at 80 C 176 F in agitation immersion bathing and dry with air Assembly 1 Clean shells housing on the block and bearings caps Check if engine block lubrication galleries are not obstructed 2 Assembly upper and lower shells on engine block and bearing caps correctly positioning locks 8120081 05 02 Service Manual Crankshaft 3 10 Lubricate upper shells and crankshaft main journals and crankpins Lubricate the two upper thrust washers positioning lubrication channels to crankshaft and slip them in their block housing Assembly crankshaft Do not turn crankshaft before bearing caps fixation Lubricate lower shells Assembly bearing caps correctly positioning them After 5th cap assembly apply Loctite 5900 on bearing side grooves Fix bearings from the ends to the center and tighten bolts according to specification Manually turn crankshaft after final tightening of each bearing cap see TIGHTENING SPECIFICATIONS Check crankshaft axial clearance using a dial indicator gauge If clearance checked is over than specified replace thrust washers Rear seal Assembly 1 80 Carefully clean engine block surface and crankshaf
27. and fill it up to correct level 12 Remove adhesive tape from tank or from filling pipe breather IN 8120 081 05 02 Service Manual Additional Instructions 121 Additional Instructions 13 Drain fuel from tank and fill it with new oil 14 Replace fuel filter cartridge 15 Bleed fuel system International HS 2 8L 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 Clean fuel free of water impurities and strange materials are important factors to assure the good engine operation for a long time and without failures Water dirt and sulfur contained in fuel are responsible for dregs formation in oil pan deposit in compression rings housing cylinders walls nozzles and exhaust valves besides interfacing in the good operation of the fuel injection pump The use of recommended lubricants contributes efficiently to neutralize to avoid or to reduce the harmful effects of these products during engine operation The function of the engine fuel filtering system is to avoid dirt and impurities existents in fuel damage fuel injection system high precision parts Lack of care during filling overcharges engine fuel filtering system damaging its purpose These problems are easily eliminated taking the following cares 1
28. 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 15 000 km 9 300 mi 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 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 196 lubricant oil change intervals must be at each 7 500 km 16 INTERNATIONA L ENGINES Service Manual 8120081 05 02 and Maintenance Recommendations International 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 Exhaust Turbine rotor These gases having energy in pressure temperature and speed form cause the rotation of the turbine rotor and consequently of the compressor rotor Exhaust 3 gases from the engine 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 t
29. bolts and remove the complete pump with assembly support 10 In case of a new pump assembly remove assembly support and pump hoses connectors and install them on the new pump 102 INTERNATIONAL GINES Service Manual 8120081 05 02 International HS 2 8L 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 4 Check again fluid level complete if necessary and check for leakages Warning Bleeding according to the manual of the vehicle ALTERNATOR WITH VACUUM PUMP Removal 1 Remove moving belt 2 Disconnect cables from the rear part of the alternator Remove vacuum pump piping 4 Remove alternator base fixation bolt 5 Loosen long passing by upper fixation bolt and remove alternator Reinstallation 1 Reinstall alternator in the inverse order of the removal tighten bolts according to specification ALTERNATOR Removal 1 Remove moving belt 2 Disconnect cables from the rear part of the alternator 3 Remove alternator base fixation bolt 4 Loosen long passing by upper fixation bolt and remove alternator Reinstallation 1 Reinstall alternator in the inverse order of the removal tighten bolts according to specification C ERNATIONAL ENGINES 8120081 05 02 Serv
30. ction pump inspection cover from timing housing cover complete with gasket 4 Install tool nr 8130632 in flywheel housing Service Manual 8120081 05 02 International HS 2 8L B 5 Turn crankshaft to the valves of the cylinder nr 4 to be swinging 1st cylinder piston at 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 8 f with the pin of timing nr 8130632 introduced in the flywheel the timing tool pin nr 8130633 can not be easily introduced in the fuel injection pump proceed as following a Make sure that the timing pin of the flywheel are not introduced in the hole b Turn slightly crankshaft enough to allow the timing pin fitting in the pump c Remove retention plate and lock pump d Loosen the three fixation bolts of the pump gear e Turn crankshaft to TDC until cylinder nr 1 in compression f Check if the timing pin can be easily introduced in the pump and in the flywheel g Tighten fixation bolts of pump gear according to specification h Unlock pump install retention plate and tighten screw i Remove pump and flywheel timing pins 9 Using an adequate anti adherent compound install the flywheel housing plug and tighten it according to specification 10 Install inspection cover with gasket in the timing housing cover and tighten bolts according to
31. d within the correct intervals it may present failures causing serious damages to the engine Follow strictly the specifications of belt tensor tightening guaranteeing its useful life according the recommendation 8120081 05 02 Service Manual Eo International HS 2 8L COOLING SYSTEM Eao Service Manual 8120081 05 02 International HS 2 8L Cooling System gt COOLING SYSTEM Circuit drainage If itis necessary to totally drain the coolant water follow the instructions below Warning not drain cooling water while the engine is still hot and the System pressurized 1 Remove lower and upper radiator hoses 2 Remove engine block drainage plug M14 right side of the engine front view Make sure that the drainage hole is not obstructed 3 Remove radiator hoses from the engine and fan 4 Drain all the coolant water from the block 5 Check hoses condition and replace them if they are damaged or deformed System filling 1 Install plug in the block and tighten it within 13 to 17 Nm 2 Install all cooling system hoses in the inverse order of the removal according to the vehicle Owner s Manual 3 Checkin the Owner s Manual the level capacity of the cooling system engine radiator expansion reservoir if existent Warning Never check the water level immediately after the engine stop This may cause burnings 8120081 05 02 Service Manual
32. e housing Cmm ER 85 8120081 05 02 Service Manual Crankshaft Pulley International HS 2 81 6 Install tool nr 8130633 pin in the fuel injection pump pulley and fit it in pump flange If camshaft teeth pulley has to be removed during these operations its fixation bolts must be loosen before the distribution belt removal 7 Loosen belt tensor bolt 8 Remove distribution belt With the use the belt wears in the rotation sense Note If the original belt will be reused it must be assembled keeping the original rotation sense 9 Mark belt rotation sense to reinstall in the same sense later 86 INTERNATIONAL GINES Service Manual 8120081 05 02 International HS 2 8L 2 Crankshaft Pulley 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 Belt tensor The belt tensor only needs to be removed if it is being replaced or to have access to remove the timing housing 1 Remove fixation bolt idling pulley and inner tensor Distribution belt installation and tensioning Note It is important that belt tensioning is carefully and safely made The following procedure evolves the belt tensioning to assure that it keeps tensioned between each pulley 1 Lockengine at TDC positioning the
33. e incrustated particulate in the inner surface of cylinder after the burnishing 2 Check cylinder bore and out of roundness C ERNATIONAL ENGINES ES 8120081 05 02 Service Manual Engine Block O International HS 2 8L PISTONS AND CONNECTING RODS 68 INTERNATIONAL GINES Service Manual 812008 1 05 02 International HS 2 8L Pistons and Connecting Rods gt 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 Horizontally position cylinders and cylinder piston to be cleaned at BDC Fill with a cloth the space above of the top of the piston Remove carbon with a brush or sandpaper and clean the area with a cloth 4 Remove pistons Disassembly 1 Remove the piston rings 2 Remove snap rings and manually remove piston pin If it is difficult to remove pin heat the piston in water or oil up to 80 C 176 F 3 Remove connecting rod bushing C ERNATIONAL ENGINES ES 69 8120081 05 02 Service Manual Cleaning and inspection 1 Pistons and Connecting Rods International HS 2 8L Check if the pistons have risks or damages in lateral and upper faces Carefully remove carbon residues from the grooves Assembly a new ring and check its clearance in the groove If it is o
34. 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 carbide fluor 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 Service Manual 8120081 05 02 International HS 2 8L Environment ENVIRONMENTAL POLLUTION CONTROL INTERNATIONAL ENGINES SOUTH AMERICA LTDA through its Environmental Administration oystem has improved more and more its engines contributing to pollution reduction Program of Air Pollution Control for Auto Motorized Vehicles PROCONVE and attending in this way to the resolutions of CONAMA
35. equirements and never should be used a lubricant oil that does not attend to API ACEA specification Sth class multi viscous ACCESSORIES BELTS 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 individual adjustment 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 Service Manual 8120081 05 02 International 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 replace
36. er 36 650 36 675 Inner diameter after finish 32 020 32 035 Clearance between pin and bushing 0 020 0 041 PISTON MILIMETERS Type Aluminum alloy with combustion camera in the convex head Side covering with graphite 0 500 0 800 Height in relation to engine block surface PISTON PIN MILIMETERS 31 994 32 000 CAMSHAFT PULLEY MILIMETERS Number of teeth Pulley hole bore 30 000 30 035 INTERNATIONAL ENGINES 8120081 05 02 Service Manual Technical Specifications International HS 2 8L INTAKE VALVE SEAT MILIMETERS Outer diameter 40 490 40 505 EXHAUST VALVE SEAT MILIMETERS Outer diameter 38 080 38 100 INTAKE VALVE GUIDE MILIMETERS Inner diameter after assembly 8 000 8 015 Outer diameter 14 050 14 060 EXHAUST VALVE GUIDE MILIMETERS Inner diameter after assembly 8 000 8 015 Outer diameter 14 050 14 060 110 INTERNATION L ENGINES Service Manual 8120081 05 02 International Technical Specifications ROCKER ARM SHAFT MILIMETERS 17973 17984 Total length 469 850 470 150 TIMING HOUSING COVER MILIMETERS Seal housing diameter 74 000 74 046 Seal housing width 10 7 LUBRICANT OIL FILTER Valve opening pressure 117 21 kN m 20 7 kN m THERMOSTAT Opening temperature 86 1 90 C 187 to 194 Valve minimum course at maximum opening temperature Maximum opening temperature 102 216 Fuel injection pump International Nr INTERNATIONAL E NES 111
37. er and upper hoses Remove reservoir cover and loosen water outlet hose from thermostat housing Drain Cooiant water Warning Loosen exhaust duct from the 11 48 manifold Remove outlet elbow and thermostat Loosen intake duct from manifold Loosen nozzle holder return pipe from fuel injection pump Remove all fuel system pipes Remove nozzle holders and washers Remove air filter and or intake manifold hose Remove turbocharger hoses Remove intake and exhaust manifolds Remove valves cover breather lateral hose Loosen the breather valve fixation bolt remo ve valve together with valve pipe from intake manifold remove and discard o ring Remove valves cover and gasket International HS 2 8L INTERNATIONAL EN GINES Service Manual 8120081 05 02 International HS 2 8L dd 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 16 Remove rear lift handle 17 Uniformly loosen cylinder head fixation bolts from engine block following the inverse of the tightening sequence removing them next 18 Raise cylinder head and remove gasket Cylinder Head Cleaning Inspection and Resurfacing 1 After the complete disas
38. g 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 the health 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 pres
39. g locks Lubricate shell and crankshaft crankpin Assembly cap on connecting rod corresponding to the cylinder watching blue mark on cap bolt and connecting rod and tighten according specified Manually turn crankshaft when assembling each connecting rod If it is difficult to turn check all tightening applied in connecting rods fixation Check axial clearance 0 15 to 0 35 mm between assembled connecting rod and crankpin with dial indicator gauge International HS 2 81 INTERNATIONAL GINES Service Manual 8120081 05 02 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 C ERNATIONAL ENGINES ES 75 8120081 05 02 Service Manual Eo International HS 2 8L CRANKSHAFT enn Service Manual 8120081 05 02 International HS 2 8L Crankshaft gt CRANKSHAFT Removal 1 oO e P Remove engine Remove cylinder head and push rods Remove accessories support Remove oil pan Remove timing housing and camshatt Remove flywheel housing and flywheel Remove pistons and connecting rods Disassembly 1 3 To disassembly position engine topside down Remove rear oil seal housing and gasket Hemove connecting rod caps a
40. he bottom of the tank can be suctioned damaging the filter Filling 1 Clean filling inlet duct cover whenever necessary 2 Every end of working day fill the tank in order to avoid the condensation of the air humidity Warning After tank filling keep it very well closed Never improvise If the cap presents any problem replace it to a genuine spare part Warning Bleed the system every time the engine stops due of a fuel lack Warning not smoke or get close type of exposed blame or sparks while filling the tank because diesel fuel is very inflammable M International HS 2 8L Service Manual 8120081 05 02 International HS 2 8L Fuel System In periods of intense cold under 0 C 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 Only use aviation kerosene in situations when the ambient temperature is under zero 0 32 F Fuel Filter The filter has the function to retain the impurities to make that the system receives a clean fuel avoiding this way damages in the engine fuel injection pump and the nozzles Use only genuine filter element Filter drainage Daily in order to avoid the premature obstruction of the filter and to guarantee the fuel injection pump and nozzles dur
41. hildren must keep out of playing near fuel tank facilities In strategic points around tank must be fixed warning plates like this Warning not smoke in this local on 18 124 near watch out inflammable Keep out The area must be protected with fire extinguishers properly signalized i ammo cones International HS 2 8L anal hs 5 n at ORE I MB EH a m e 183181 Service Manual 8120081 05 02 International HS 2 8L SPECIAL TOOLS INTERNATIONAL ENGINES ____ 8120081 05 02 Service Manual Special Tools International HS 2 8L TOOLS NUMBER APLICATION 8130001 Valves assembly disassembly device with disassembled cylinder head Valves assembler extractor with assembled cylinder head Standard 8130004 Base for height and depth check with dial indicator gauge Standard 8130005 Expander pliers for piston rings Standard 8130625 Torque angle device Standard 8130628 Extractor for crankshaft gear removal Service Manual 8120081 05 02 International HS 2 8L Special Tools TOOLS NUMBER APLICATION 8130631 Valve guides extractor pin 8130632 Flywheel timing adjustment tool 8130633 Fuel injection pump gear fixation a device 8130634 Valve guides assembler pin 8130635 Camshaft bushing extractor 8130636 Flange for camshaft bushing extraction use with 8130635 INTERNATIONAL ENGINES 127
42. ice Manual Accessories 103 Accessories 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 itis necessary to repair vacuum pump it is recommended to send the complete set alternator and vacuum pump to Bosch Network A Warning not execution this procedure the warranty will be canceled Installation 1 Install in the inverse order of the removal tighten bolts according to specification Air conditioning compressor Removal 1 Remove compressor pulley belt tensor see ACCESSORIES MOVING BELTS Removal 2 Disconnect cables from the rear part of the compressor 3 Remove piping from the rear part of the compressor 4 Remove upper support bolts 5 Remove compressor fixation bolts to housing support Reinstallation 1 Reinstall in the inverse order of the removal tighten bolts according to specification 104 INTERNATIONAL GINES Service Manual 8120081 05 02 International HS 2 8L Accessories support Removal 1 Remove water pump and power steering pump pulleys bolts 2 Remove accessories moving belt tensor see ACCESSORIES MOVING BELT Removal Remove water pump hoses 4 Remove power steering pump see POWER STEERING PUMP Removal 5 Remove alternator and vacuum pump see ALTERNATOR Removal Reinstallation 1 Reinstall
43. ice Manual Engine Timing International HS 2 8L gt ENGINE TIMING Camshaft pulley and timing housing Crankshaft pulley and timing housing gib upwards Fuel injection pump pulley and synchronizer pin U U gt Loosen pulley bolts to accommodate belt Service Manual 8120081 05 02 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 Remove ring 4 f necessary remove oil seal from timing housing Installation 1 Lubricate the new crankshaft oil seal with clean engine oil 2 With lip side forward parallel install oil seal using tool nr 8130637 3 Lubricate a new sealing o ring with Vaseline and position it on shaft taking care to do not damage it with the gibs 4 Install crankshaft gear until the total touch making sure o ring stay correctly seated Use tool nr 8130637 8120081 05 02 Service Manual 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 2 With the lip side forward parallel install oil seal using special tool nr 8130639
44. icle panel 7 Start engine wait to speed stabilization in idle speed for 10 seconds 8 Check for leakages Manual bleed is unnecessary Service Manual 8120081 05 02 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 4 Close plug and tighten the high pressure pipe nuts 5 Start and wait for 10 seconds to engine stabilization 6 Ifthe engine doesn t start repeat the procedure starting from the item 2 15 recommended to change the fuel filter Avoid the lack of fuel because it causes serious damages to the fuel injection System LIFT PUMP Fuel lift pump has the function of transferring fuel from fuel tank to fuel injection pump passing through the fuel filter Removal 1 Disconnect fuel lift pump inlet and outlet pipes Note Close pipes ends and connections to avoid dust penetration 2 Loosen fixation bolts and remove pump and gasket 8120081 05 02 Service Manual 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 specificatio
45. if gear ring teeth are worn To replace see GEAR RING REPLACEMENT 3 Useamale M14 in crankshaft bolts holes to remove the residues of Loctite Reinstallation To avoid flywheel excessive eccentricity make sure if flywheel and crankshaft contact surfaces are perfectly clean 1 Install flywheel on crankshaft and fix it with thrust plate and new bolts tightening according to specification 2 Check flywheel eccentricity assembling a dial indicator gauge so that its point touches at 114 mm from the center of the flywheel 98 INTERNATIONAL GINES Service Manual 8120081 05 02 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 5 Reinstall in the inverse order of the removal install the fixation bolts using Scotch Grip and tighten with 60 Nm 30 Flywheel housing Removal 1 Remove flywheel see FLYWHEEL Removal 2 Remove the flywheel housing support four bolts 3 Loosen the six central bolts and remove flywheel housing Reinstallation 1 Clean engine block and remove the excess of liquid gasket Loctite 5900 from the block 2 Applya4 mm fillet of Loctite 5900 on flywheel housing 3 Install housing on engine bloc
46. in which the thermostat begins to open The thermostat will be satisfactory if it opens between 86 and 90 187 and 194 Reinstallation 1 Putthe thermostat with the breathe guide hole pin totally upwards 12 o clock position 2 Install the outlet elbow and a new sealing washer Tighten bolts within 22 to 28 Nm Invert the removal operations 4 Tighten bolts within 22 to 28 Nm 5 Check for coolant water leakages around all the connections and gaskets _ INTERNATIONAL ENGINES 25 8120081 05 02 Service Manual Cooling System B 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 2 Service Manual 8120081 05 02 International HS 2 8L FUEL SYSTEM INTERNATIONAL ENGINES ___________ 8120081 05 02 Service Manual Fuel System 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 During the engine operation be aware to the fuel indicator Fill the tank before the volume reaches the minimum because sedimented impurities in t
47. ing shells housing correctly position connecting rod cap tightening according specification C ERNATIONAL ENGINES 71 8120081 05 02 Service Manual 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 See the correct clearance between ends below Clearance between ends ist groove 0 400 0 600 compression ring 2nd groove 3rd groove 0 300 0 550 oil ring Assembly 1 To assembly all parts must be cleaned Assembly bushing in connecting rod making sure that lubrication holes are aligned Machine bushing inner diameter 2 Assembly piston in connecting rod with combustion chamber turned to the same side of the shell lock Manually install pin and snap rings If it is difficult to assembly the pin heat the piston in water or oil at 80 C 176 F The piston must be carefully handled because any damage on its surfaces may cause bad engine operation Assembly connecting rod and piston in the same cylinder whether they have not been replaced 72 INTERNATIONAL GINES Service Manual 8120081 05 02 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 1s
48. k and fix it with bolts according removed and tighten according to specification see TECHNICAL SPECIFICATIONS C ERNATIONAL ENGINES E 99 8120081 05 02 Service Manual Flywheel International HS 2 8L RING GEAR REPLACEMENT Warning Following operations evolve heat and may cause burinings Disassembly 1 Putflywheel in a recipient with clean water and support ring gear on four metal blocks so ring gear stays approximately 6 5 mm Flywheel Water 1 4 above the level of water Gearring gt 6 5 mm 2 Heatring gear on all its extension so that flywheel loosen Assembly 1 assembly ring gear on flywheel heat it up to approximately 246 475 in a stove 100 INTERNATIONAL GINES Service Manual 8120081 05 02 International HS 2 8L ACCESSORIES INTERNATIONAL ENGINES 8120081 05 02 Service Manual 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 6 Disconnect hydraulic oil inlet pipe low pressure lower pipe and drain fluid in an appropriate recipient 7 Disconnect outlet pipe pipe with union and drain fluid 8 Cover the pump and hoses extremity 9 Loosen pump assembly support fixation
49. kwise Remove belt from pulley Free tensor Finish belt removal gt XQ xc e Loosen fixation bolt of air conditioning compressor moving belt tensor 7 Remove belt from pulley handling it over the fan 8120081 05 02 Service Manual Engine Timing E International HS 2 8L Reinstallation 1 Reinstall moving belts in the inverse order of removal 2 Fixtensor bolt according to specification Camshaft Removal 1 Remove timing housing see TIMING HOUSING Removal 2 Remove cylinder head 3 Remove tappets and tappets rolls 4 Loosen bolts and remove camshaft fixation plate 5 Remove camshaft Installation 1 Reinstall in inverse order of removal tightening bolts according to specification 96 Service Manual 8120081 05 02 International HS 2 8L FLYWHEEL INTERNATIONAL ENGINES NENNEN or 8120081 05 02 Service Manual Flywheel International HS 2 8L gt FLYWHEEL 1 Remove gearbox Remove starter motor Remove clutch qe a 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 and fix it with four bolts to immobilize crankshaft during flywheel fixation bolts removal 6 Loosen flywheel fixation bolts and remove it Cleaning and inspection 1 Wash all parts with biodegradable chemical detergent 2 Check
50. l has technical specifications necessary to a correct maintenance and repairing of the International HS 2 8L engines As a strictly technical literature it has been avoided the inclusion of theory concepts and basic definitions due to this publication purpose 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 5 do Campo SP Brazil ZIP 09840 000 Post Office Box 951 Phone 55 11 4358 8522 Fax 11 4358 5710 site www nav international com br Publication Nr 8120081 05 02 8120081 05 02 Service Manual Index ii International HS 2 8L gt INDEX VC iUe E 3 ig COTM 5 m mt 8 Operation and Maintenance Recommendations
51. m 137 137 mm from 0 50 to 0 60 Cylinder head gasket corresponds to piston height in relation with cylinder head surface C ERNATIONAL ENGINES ES 51 8120081 05 02 Service Manual Cylinder Head International HS 2 8L 5 Install gasket with the identification holes turned back and with mark upwards 6 Clean engine block contact surface 7 Lower cylinder head on the engine block making sure of the correct guide pins position 8 Check bolts deformation with a flat ruler checking their lengthening 1 diameter reduction 2 and whether there is visible waste in the threads 3 If one of the last 3 parameters is out of their project features they must be replaced 9 Apply some lubricant oil on bolts threads and install them in the indicated position 10 Tighten bolts until their heads touches the cylinder head 11 Follow the instructions according the table below to the correct application of tightening Positions Dimensions Torque Nm 1 2 7 8 9 10 15 16 17 and 18 M12 x 140 60 Nm 150 3 5 12 and 13 M8 x 117 mm 20 140 4 6 11 and 14 M12 x 100 mm 60 Nm 120 52 INTERNATIONAL GINES Service Manual 8120081 05 02 International HS 2 8L Cylinder Head Use special tool nr 8130625 Goniometry 12 Install valve caps rods 13 Install camshaft rods on their original positions 14 Install rocker arm shaf
52. n 21 Install inspection cover with a new gasket on timing housing cover and tighten bolts according to specification 22 Reinstall nozzle holders pipes 23 Assembly accelerator cables at fuel injection pump Note Remove special tool 24 Bleed fuel system see FUEL SYSTEM Bleeding 25 Start engine and check system for leakages IDLE SPEED ADJUSTMENT Check and adjust accelerator cable 2 Start engine and let it work until reach normal operation temperature always varying its speed 3 Using an appropriate tachometer check idle speed value 4 Loosen counter nut in fuel injection pump if adjustment is necessary 5 Turn adjustment screw clockwise to increase engine speed or counter clockwise to decrease it Operate engine at a higher speed during a few seconds and check idle speed again 6 Once correct speed is get tighten screw and counter nut The idle speed is the only adjustment allowed in service Any other additional adjustment must be made by a Bosch authorized representative Service Manual 8120081 05 02 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 4 Remove fixation plate nuts from nozzle holders in cylinder
53. n 4 Connect fuel lift pump inlet and outlet pipes BLEEDING Position contact key in start After each one of the operations described next crank the engine until the fuel to leave without air bubbles Next close the bleeding point indicated 1 Open fuel filter upper plug 1 and loosen the 4 nozzle nuts 2 Crank engine until fuel drain through the filter upper plug and nozzles nut approximately 10 seconds 3 Close plug and tighten high pressure pipe nuts 4 Start and wait for 10 seconds to engine stabilization FUEL INJECTION PUMP Removal 1 Remove fuel injection pump inlet and outlet pipes 2 Remove boost control pipe 3 Remove high pressure pipes set from the fuel injection pump to the nozzle holders set 4 Remove valves cover 5 Turn crankshaft clockwise until that the valves of the cylinder nr 4 swings cylinder nr 1 piston at TDC in compression stroke Service Manual 8120081 05 02 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 10 Remove fuel injection pump inspection cover from timing housing cover complete with the gasket 11 Install the pin of the tool nr 8130633 in the fuel injection pump pulle
54. nd shells Remove main bearing caps and shells 8120081 05 02 Service Manual Crankshaft International HS 2 81 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 3 With micrometer measure main journals and crankpins diameter and out of roundness in 4 places 4 Check crankshaft main journals maximum eccentricity with dial indicator gauge Main journals nr 1 and 5 Supported 5 Check for cracks with Magnaflux Demagnetize crankshaft in case of cracks the part must be replaced Machining and inspection 1 Machine main journals and crankpins to the immediately lower undersize than the obtained measure Check main journals rugosity and fillets Main journals crankpins rugosity see TECHNICAL SPECIFICATIONS 2 Remove sharp chamfers from lubrication holes 3 After the machining wash crankshaft with chemical solvent in immersion bathing Dry with compressed air Service Manual 8120081 05 02 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 m
55. ngth nr 4 standard Main journal length nr 5 standard Undersize 0 25 mm Crankpins length standard Main journals fillets roller crankpins Main journals crankpins maximum out of roundness Main journals crankpins rugosity CLA Filets rugosity CLA Rear flange diameter Rear flange width Maximum eccentricity Main journals nr 1 and 5 International HS 2 8L MILIMETERS 63 471 63 491 63 217 63 237 31 090 31 850 34 393 34 645 33 275 33 325 34 393 34 645 44 704 44 958 58 725 58 745 58 471 58 491 33 249 33 401 33 3 7 0 007 0 25 um 0 8 um 99 495 99 517 21 122 22 176 supported Maximum eccentricity Main journal nr 3 0 025 Axial clearance 0 006 0 15 up to 45 in the remaining direction of the ray in direction to the mirror rugosity must be 1 6 mm CONNECTING ROD MILIMETERS Shell housing diameter 62 433 62 446 Bushing housing diameter 36 650 36 675 Distance between centers shell housing connecting rod bushing housing 175 388 175 438 Maximum radial clearance 0 029 Crankshaft axial clearance 0 15 0 35 Service Manual 8120081 05 02 International CONNECTING ROD SHELLS Outer diameter assembled Inner diameter after assembly Thickness Oversize 0 25 mm Shells width Technical Specifications Clearance between shell and main journal diametrical 0 025 0 076 CONNECTING ROD BUSHING MILIMETERS Outer diamet
56. o 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 In turbocharged International HS 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 8120081 05 02 Service Manual Operation and Maintenance Recommendations International HS 2 8L 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 r
57. ole 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 D Stop engine and tighten the disaeration plug within 13 to 17 Nm E Runengine at 2000 rpm approximately medium acceleration for five minutes F Increase speed up to 3500 rpm approximately 3 4 of the maximum acceleration for four minutes more G Slow down engine speed again to 2000 rpm for three minutes more H Check coolant water level in the expansion reservoir if necessary complete to the maximum level FAN Removal 1 Remove radiator shield 2 Using tool nr 8130632 to lock flywheel use tool nr 8130643 to viscous clutch Warning remove the viscous clutch and fan is necessary to rotate the fixation nut clockwise Reinstallation 1 Reinstall in inverse order of removal 2 Using tool nr 8130632 to lock flywheel fix viscous clutch and fan with the tool nr 8130643 counter clockwise tighten nut 8120081 05 02 Service Manual 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 2
58. p to timing housing with nuts tightening within 22 to 28 Nm clockwise and finishing the tightening in the lower nut Tighten the support fixation bolts to the block and pump bolts to the support and tighten within 22 to 28 Nm Connect return and fuel pipes with new washers and fix them with banjo bolts tightening according to specification Connect boost control pipe and fix it with banjo bolt tightening it according to specification Connect stop control solenoid wiring Connect accelerator cable Remove tool nr 8130633 Install gear lock plate Install the tool pin nr 8130633 Fix pulley with bolts Install retention plate in fuel injection pump Remove the pins of the special tools nr 8130632 and 8130633 Turn crankshaft two complete turns check if the pin of the tool nr 8130633 can be totally and easily introduced in the pump Check at the same time that the tool pin nr 8130632 also can to be introduced in the hole of the flywheel with the timing pin nr 8130632 introduced on the flywheel the timing pin of the tool nr 8130633 is not able to be easily introduced in the fuel injection pump make the timing procedures see TIMING INTERNATIONAL ENGINES 8120081 05 02 Service Manual Fuel System 35 Fuel System International HS 2 8L 20 Using adequate anti adherent compound install the flywheel housing plug and tighten it according to specificatio
59. pulley Remove water pump Remove accessories Remove cylinder head SS Remove fuel lift pump 10 Remove lubricant oil filter and cooler 11 Remove distribution cover pulleys and housing 12 Remove fuel injection pump 13 Remove camshaft 14 Remove flywheel and flywheel housing 15 Remove oil pan 16 Remove timing housing 17 Remove alternator with vacuum pump and power steering pump 64 INTERNATIONAL EN GINES Service Manual 8120081 05 02 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 3 Flush block with water at 80 176 under pressure and a chemical grease remover Keep block in an immersion bathing with a solution of the same type for 12 hours and dry with compressed air 4 Clean block galleries flush again with hot water under pressure and dry with compressed air Make sure that the passages of water and lubricant oil are unobstructed 5 Check for cracks or other damages in the block Measure cylinders bore see CYLINDER 6 Assembly water gallery plugs applying Loctite 601 Fix aluminum washer and oil lubricating rear plug applying Loctite 271 CAMSHAFT BUSHING AND BEARING Removal 1 Quit camshaft bearings bushing using tool nr 813
60. 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 Remove oil suction pipe 5 6 Remove timing housing fixation bolts 7 Remove timing housing with gasket 8 Remove all gasket material from contact surfaces Reinstallation 1 Install guide prisoners to position gasket 2 Install a new gasket on guide prisoners in engine block 3 Align oil pump grooves with crankshaft grooves 4 Install timing housing on the block taking care to do not damage oil seal 5 Fix bolts with correct length in the positions where guide prisoners were not installed 6 Remove guide prisoners installing on its places bolts with correct size 7 Tighten all bolts according to specification 8 Install oil suction pipe 9 Install oil pan see ENGINE OIL PAN Installation 10 Reinstall fuel injection pump see FUEL INJECTION PUMP Reinstallation 11 Reinstall teeth pulleys crankshaft gear and belt International HS 2 8L Service Manual 8120081 05 02 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 2 Slowly release pulley tension on belt counter cloc
61. sembly flush cylinder head with chemical biodegradable greasing remover and water at 80 176 under pressure eliminating all presence of carbon Remove existent incrustations in the water galleries Dry with air 2 Check for cracks or damages in the cylinder head Check cylinder head height 4 Check cylinder head distortion with a sheet and a ruler of steel C ERNATIONAL ENGINES ES 49 8120081 05 02 Service Manual Cylinder Head International HS 2 8L 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 Assembly of sealing washers cannot compensate nozzle projection 7 Check valve guides see VALVES 8 Check seats see SEATS AND HOUSING 50 INTERNATIONAL GINES Service Manual 8120081 05 02 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 4 Select a new gasket with the correct Holes Gasket Piston Height thickness thickness m
62. specification 11 Reinstall nozzle holders pipes 8120081 05 02 Service Manual Fuel System 39 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 15 Start engine and check system for leakages 1o ones Service Manual 8120081 05 02 International HS 2 8L LUBRICATION SYSTEM 8120081 05 02 Service Manual Lubrication System International HS 2 8L gt 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 Level Check oil level with the engine on a flat ground and stopped 1 Wait from 10 to 15 minutes to allow the oil return from the upper part of the engine 2 Remove oil dipstick and clean it with a clean cloth introduce it until the edge remove it again and check level twice to make sure of the check Complete the oil level only if the oil mark is below the dipstick lower mark the difference between the volume of the maximum mark and the minimum mark is 1 liter Always use oil of the same specification A Warning lfoillevel is frequently low seek
63. st have a ventilation system with inlet protected with metallic mesh It is also possible to install an air filter Outlet fuel piping must have after register filtering and sedimentation system If itis necessary to install an electric net to power pump that equipment must be special armored type If itis necessary to install a hydraulic pump for fuel manipulation this must be protected when not in use from direct contact with fuel by aretention valve and register Hydraulic pump and control panels must be assembled on bases of concrete Tank must have a storage register of sedimented water and impurities Tank must be installed on appropriated supports so that its frontal part where it is fuel outlet stays higher than rear where it is located drainage register INTERNATIONAL ENGINES E 8120081 05 02 Service Manual Additional Instructions 123 Additional Instructions 12 13 14 15 16 17 Inclination in relation to ground level must be from 20 to 50 mm to each meter of length If gallons are used these must not be internally galvanized Gallons must be protected from sun rain and dust and must be lay down on supports that keep faucets approximately 75 mm higher than the bottom This will make easier water and impurities sedimentation Place where fuel tank is installed must be kept clean Floor under tank even at 1 meter of distance must be covered with thick gravel C
64. sure penetrates the skin Service Manual 8120081 05 02 International HS 2 8L ENVIRONMENT INTERNATIONAL ENGINES LLL LL 8120081 05 02 Service Manual Environment International HS 2 8L ENVIRONMENT ENVIRONMENTAL POLICY 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
65. t see ACCESSORIES MOVING BELT Removal 5 Install tool nr 8130638 in crankshaft pulley and fix it with 4 bolts 6 Remove crankshaft pulley fixation bolt using a lever of an appropriate length 7 Remove pulley necessary use extractor nr 8130628 Reinstallation 1 Reinstall in inverse order tightening fixation bolt with 80 Nm 125 TIMING HOUSING COVER Removal 1 Remove crankshaft pulley see CRANKSHAFT PULLEY REMOVAL 2 Remove 14 fixation bolts from timing housing cover 3 Remove cover with gasket Seal replacement 1 Remove used cover seal and clean housing 2 Support cover and install a new seal open side turned to the housing using tool nr 8130637 84 INTERNATIONAL EN GINES Service Manual 8120081 05 02 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 2 Turn engine until cylinder nr 1 to be at TDC 4th cylinder swinging 3 Remove flywheel housing plug and install timing tool nr 8130632 4 Fitthe timing tool nr 8130632 pin in the hole of the flywheel 5 Check the correct alignment of the timing mark on the camshaft toothed pulley and if crankshaft gib is aligned with the arrow engraved in th
66. t see ROCKER ARM SHAFT Installation 15 Adjust valves clearance see VALVES CLEARANCE ADJUSTMENT 16 Install valves cover making sure that the gasket is good for the continuous use Valves cover gasket can be reused twice at maximum 17 Fix valves cover with special sealing washers and nuts tightened according to specification 18 Lubricate o ring with engine oil and install it in the breather valve Install valve and fix it with the bolt tightening according to specification 19 Reinstall the remaining items inverting the operations tightening bolts according to specification whenever applicable Inspection after assembly 1 Start the engine Check the correct lubricant oil pressure and all engine parts for leakages 2 Warm the engine up to normal operation temperature see TECHNICAL SPECIFICATIONS varying its speed 3 Stopthe engine 4 If necessary adjust valves clearance again see VALVES CLEARANCE ADJUSTMENT Note It is not necessary to retighten cylinder head during the revisions 8120081 05 02 Service Manual 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 5 Loosen lower exhaust pipe in the silencer flange nuts
67. t flange and remove all existent residues Apply a fillet of Loctite 5900 in all rear seal housing edge International HS 2 8L Service Manual 8120081 05 02 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 5 Install tool nr 8130648 and turn the two rods clockwise fix in holes located in crankshaft flange 8120081 05 02 Service Manual 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 8 Carefully remove tool nr 8130648 and check the perfect accommodation of the seal lip In case of seal lip bite install a new seal repeating previous procedures Service Manual 8120081 05 02 International HS 2 8L CRANKSHAFT PULLEY INTERNATIONAL ENGINES 8120081 05 02 Service Manual Crankshaft Pulley International HS 2 8L gt CRANKSHAFT PULLEY Removal 1 Drain coolant water 2 Remove radiator upper hose 3 Remove fan see FAN Removal 4 Remove moving bel
68. t rings with TOP mark or inner chamfer upwards Note that 2nd and 1st grooves rings have different thickness 4 Clearances between rings ends must not be aligned in the same direction of piston pin or skirt Position rings according the illustration 5 Assembly new shells on connecting rod body correctly positioning locks Installation 1 Set engine block in horizontal position Lubricate grooves inside liners connecting rod shells and crankshaft crankpin 2 When assembling piston make sure that the arrow is aiming the engine front side Install connecting rod with the tool nr 8130646 avoiding scratching the liner 3 Assembly piston in cylinder using tool nr 8130647 and a rod of wood to push the piston 4 In turbocharged engines there is one injector of lubricant oil for each engine cylinder During piston assembly in the cylinder check the position of the connecting rod in relation to the injector avoiding breaking its injection pipe 5 The positioning of the oil injector inside the engine block is checked with the engine viewed from the top without cylinder head C ERNATIONAL ENGINES ES 8120081 05 02 Service Manual Position As Spring 3rd ring C 2nd ring D 1st ring 73 74 Pistons and Connecting Rods 6 Complete lubricant oil injector for cylinder inside and piston pin lubrication is shown below 7 Assembly new shell in connecting rod cap correctly positionin
69. th International HS 2 81 Service Manual 8120081 05 02 International HS 2 8L N 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 Before starting an engine which was being inactive for a long time back to operation take the following cares 1 Clean perfectly all the outer parts 2 Close all block and radiator drain plugs and fill cooling system with clean water Check for leakages 3 Turn water pump pulley with the hand to assure if the water pump seals are free 4 Install fan belt and adjust its tension 5 Remove valves cover lubricate rocker arms with engine oil and assembly it again 6 Clean and assembly air filter and filling inlet remove the sealing adhesive tape from intake and exhaust manifolds 7 Assembly exhaust pipe 8 Pressurize with new engine oil engine galleries 50 60 Ibf pol and turn crankshaft with the hands so it displaces the shells Depressurize system and remove pressurization tank 9 Connect battery ies Warning In terminals fixation do not invert cables position in relation to battery contacts First connect positive terminal 10 Remove the excess of grease from alternator and starter motor terminals Check if all the connections are ok 11 Drain oil from oil pan
70. to quit guide 2 Press the guide with the tool nr 8130634 and the spacer nr 8130644 3 Checkclearance specification between valve and guide see TECHNICAL SPECIFICATIONS SEAT AND HOUSING Seat disassembly and machining 1 60 Seats replacement operations be made only after valve guides replacement see VALVE GUIDES Machine seat removing it In housing machining operation cylinder head surface must be flat and perpendicular to the valve guides see cylinder head Cleaning Inspection and Resurfacing Machine seat housing using valve guide reference Proceed according the specifications See TECHNICAL SPECIFICATIONS table VALVE SEATS Try to work the closest possible of the minimum value for later adjustment International HS 2 81 INTERNATIONAL EN GINES Service Manual 8120081 05 02 International HS 2 8L Assembly 1 Inthe 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 3 Press intake and exhaust valve seats Use valve guides for assembly reference Inspection 1 Check valve seat on its seat The seat must not present an eccentricity over than 0 08 mm in relation to valve guide 2 Check valves depth from cylinder head surface Use a micro dial indicator gauge together with the tool nr 8130004 See TECHNICAL SPECIFICATIONS VALVES CLEARAN
71. uctions 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 Service Manual 8120081 05 02 Operation and Maintenance Recommendations International INSTALLATION REVISION ITEM CHECK Water and lubricant oil Level complete if necessary General performance Operation temperature and speed at maximum load Intake system Intake air temperature and restriction extreme heat areas and leakages occurrences 8120081 05 02 Service Manual Operation and Maintenance Recommendations International HS 2 8L PERIODIC MAINTENANCE PERIODS CHECK Check engine oil level complete if necessary Check water reservoir level complete if necessary sedimentation filter Check teeth belt conditions through the inspection lateral plug Check external belts conditions Cooling system check anti freezing replace at each 2 years Check oil fuel cooling piping conditions Replace external belts Replace toothed belt e Evaluate starter alternator and turbocharger 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
72. unter clockwise using a belt or a universal ribbon C ERNATIONAL ENGINES 43 8120081 05 02 Service Manual 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 1 2 turn more without tightening excessively OIL COOLER Removal 1 Drain cooling system 2 Remove water inlet and outlet hoses from the cooler 4 Disconnect pressure switch Loosen fixation bolts and remove lubricant oil filter head complete with the gasket Installation 1 Clean contact surfaces 2 Reinstall it with a new gasket 3 Fix with bolts tightening them according to specification 4 Reinstall pipes and reconnect pressure switch LUBRICANT OIL PAN Removal 1 Drain engine oil 2 Loosen oil pan fixation bolts and use a sharp knife break the adhesive around oil pan flange 3 Remove bolts in the inverse of the tightening sequence and remove oil pan 44 INTERNATIONAL GINES Service Manual 8120081 05 02 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 OIL SUCTION PIPE Removal 1 Remove oil pan
73. ver than indicated next piston must be replaced Lateral clearance Milimeters Ring of the 1st groove 0 050 0 090 compression Ring of the 2nd groove Ring of the 3rd groove 0 030 0 065 compression Measure piston pin outer diameter with micrometer Measure piston pin housing with bore gauge The measurements must be taken in the horizontal vertical and diagonal direction in relation to the hole that houses the pin Check connecting rod warping and alignment 70 INTERNATIONAL EN GINES Service Manual 8120081 05 02 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 7 Connecting rod and cap have serial number on one of its side When assembling cap check if its serial number corresponds to the connecting rod number 8 Onone ofthe sides connecting rod has the code of weight that goes from approximately 1259 to 1322 grams and it is identified only by the two last weight digits by an ink mark on the body of the connecting rod Note In the four kits assembly piston connecting rod and rings the variation of the set can be of at maximum 5 5 g 9 Measure bushing and shell housings in the horizontal vertical and diagonal positions When measur
74. y 12 Remove limiter bolt tightening it to lock the pump 13 Remove from the motor pulley the fixation bolts of pump hub and plate 14 Remove pump pulley pin 15 Install tool nr 8130633 with an 8 mm washer and 1 5 to 2 mm thickness under each bolt head beyond existent washer 8120081 05 02 Service Manual Fuel System 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 20 Loosen the pump support bolts in the block 1 enough to move the support 21 Loosen pump fixation nuts in the flange and remove pump and gasket 22 Install plugs in pipes connections 23 Reinstall limiter if a new pump is being installed Reinstallation 1 Remove pump plugs 2 Only for a new pump Install the tool pin nr 8130633 in the fuel injection pump turning the pump the necessary to introduce the pin Remove the limiter and tighten the bolt to lock the pump International HS 2 81 Service Manual 8120081 05 02 International HS 2 8L i Hemove special tool pin from the pump Clean pump and timing housing contact surfaces Install pump in timing housing with a new gasket and fix it with nuts tightening according to specification Fix pum
75. y Positions 1 Off 2 Contact 3 Start 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 Service Manual 8120081 05 02 International Operation and Maintenance Recommendations 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 or Authorized Services 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 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 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 enone T 8120081

International HS 2.8L Workshop Manual

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