International HS 2.8L Workshop Manual ARO

SERVICE MANUAL
International HS 2.8L
Presentation
PRESENTATION
This Service Manual 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.
It is important to learn how to correctly operate, to maintain and to repair these engines, as well to know
the issues that may cancel warranty due to a bad operation, unauthorized adaptations, unoriginal parts
use or any other procedures that affect it way any.
Following the instructions and specifications of this manual, the maintenance and repairing will be made
in the most correct and safety way possible.
INTERNATIONAL ENGINES SOUTH AMERICA LTDA reserves the right of changing the content of this
publication without warning, whenever innovations are necessary to be introduced in its products.
INTERNATIONAL ENGINES SOUTH AMERICA LTDA

Strategic Planning and Control Management
After Sales Department
Estrada dos Casa, 3155
S.B. do Campo - SP - Brazil
ZIP 09840-000 - Post Office Box 951
Phone: 55 (11) 4358-8522 - Fax (11) 4358-5710
site: www.nav-international.com.br
Publication Nr. 8120081 - 05/02.
INTERNATIONAL ENGINES
8120081 - 05/02 - Service Manual
Index
INDEX
Safety Precautions ......................................................................................................................................3
Environment ................................................................................................................................................5
Technical Features ......................................................................................................................................8
Operation and Maintenance Recommendations ....................................................................................... 11
Cooling System .........................................................................................................................................20
Fuel System ..............................................................................................................................................27
Lubrication System ...................................................................................................................................41
Cylinder Head ............................................................................................................................................47
Engine Block .............................................................................................................................................63
Pistons and Connecting Rods ..................................................................................................................68
Crankshaft .................................................................................................................................................76
Crankshaft Pulley ......................................................................................................................................83
Engine Timing............................................................................................................................................89
Flywheel ....................................................................................................................................................97
Accessories ............................................................................................................................................ 101
Technical Specifications .......................................................................................................................... 106
Tightening Specifications ......................................................................................................................... 113
Additional Instructions ............................................................................................................................. 119
Special Tools ........................................................................................................................................... 125
Service Manual - 8120081 - 05/02
SAFETY PRECAUTIONS
Safety Precautions
SAFETY PRECAUTIONS
Warning:
The texts emphasized with the symbol

means direct or indirect personal injuries
risk.
Read carefully this manual and keep it always on hand to clarify any doubts.
Do not try to operate the equipment without knowing all controls and understanding the
operation of the main systems.
Take all precautions of safety indicated next, because they are your protection during
the work.
Do not change the original features of the engine.

Do not smoke while filling fuel tank.
Clean immediately all and any spilled fluid. Put the material used on cleaning in a safe position and
discard according the Local Legislation.
Do not fill, while engine is running, unless it is absolutely necessary.
Never clean, lubricate or adjust an engine in operation.
Do not adjust anything, if you do not know how to do it correctly.
Do not operate the engine in closed rooms, because the exhaust gases are extremely prejudicial to
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 pressure, penetrates the skin.
ENVIRONMENT
Environment
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 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.
Environment
ENVIRONMENTAL POLLUTION CONTROL

INTERNATIONAL ENGINES SOUTH AMERICA LTDA, through its Environmental Administration
System, has improved more and more its engines contributing to pollution reduction (Program of Air
Pollution Control for Auto-Motorized Vehicles - PROCONVE) and attending, in this way, to the resolutions
of CONAMA (National Council of the Environment).
Warning:
The engine adjustment values specified in this manual, must be strictly observed,
because, besides to offer a better performance to the vehicle, also reduce noises and
harmful gases emissions to the atmosphere.
Warning:
Any change in the fuel injection or air intake system, or even the exhaust system, may
affect directly the homologated values.
DESTINATION OF THE USED COMPONENTS OF THE ENGINE

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).
TECHNICAL FEATURES
Technical Features
TECHNICAL FEATURES
ENGINE TYPE
PL number
Turbocharger
INTERNATIONAL HS 2.8L
8B60
8B61
Variable Nozzle (VNT)
With Wastegate
Number and Cylinder

Arrangement
4 in line
Cylinder Nominal Bore
93.0 mm
Stroke
102.50 mm
Cycle
Diesel, 4 stroke
Compression Relation
19.5 : 1
Total Displacement
2,8 Liters
Combustion System
Direct Injection
Rotation Sense (front view)
Clockwise
Firing Order
1-3-4-2
Opening Beginning
86 - 90 C
Operation Temperature
86 -102 C
Lubricant oil Pressure (at

Maximum Specified Speed With
the Engine at Normal Operation
Temperature)
3.5 bar
Maximum Speed Unload
4640 rpm
Idle Speed
800 rpm 20
Static Injection Beginning at TDC
0
Liquid
Engine Cooling
Power (NBR5454)
135 hp (99 kW) at 3800 rpm
133 hp (97 kW) at 3800 rpm
Torque (NBR5454)
38.2 kgfm (375 Nm) at 1400 rpm
36.2 kgfm (355 Nm) at 1600 rpm
Weight (basic unit)
208 kg
205 kg
Technical Features
LOCATION AND IDENTIFICATION OF THE

ENGINE NUMBER
Location
Front
Left side view
Identification
B61 (WG)
B60 (VNT)
536265
SERIAL NUMBER
PARTS LIST NUMBER
For engines manufactured in Brazil nr 000001 to 499999.

For engines manufactured in Argentina nr from 500000 on.
PS: (WG) - Wastegate Version

(VNT) - Variable Nozzle Turbocharger Version
10
OPERATION AND MAINTENANCE

RECOMMENDATIONS
11
Operation and Maintenance Recommendations
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.
Key Positions
If the engine has been stayed inactive for a long

period, bleed the fuel system.
2. Contact
1. Off
3. Start
Start
Warning:
POSITION TRANSMISSION
LEVER TO NEUTRAL.
1. Position key in start position for seven

seconds, at the maximum.
If engine doesnt work, repeat operation after 30
(thirty) seconds.
Note:
Do not keep the key turned too much long, because it will damage the starter.
In turbocharged engines, after to start, do not

accelerate over than 1000 rpm, during the firsts
30 (thirty) seconds. This allows turbocharger
lubrication line pressure equalization avoiding
damages to this equipment.
12
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.
Note:
Do not extremely load the engine, while it is not at the normal operation temperature.
Stop
Warning:
Let the engine in idle speed and

transmission lever in neutral.
In turbocharged engines, in order to do not

damage the turbocharger shaft, the engine must
run during 30 (thirty) seconds under 1000 rpm
before stopped.
Do not accelerate the engine.
Turn key to off position.
RUNNING-IN
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.
13
During running-in follow these recommendations:

DO NOT OPERATE THE ENGINE AT OVER
THAN 85% OF THE MAXIMUM SPECIFIED
SPEED (3800 rpm), see TECHNICAL
SPECIFICATIONS.
WHEN IN A TRIP, VARY THE ROTATION TO
AVOID CONSTANT SPEEDS DURING LONG
PERIODS. DO NOT BRUSQUELY
ACCELERATE THE ENGINE.
During useful life of the engine:
Before starting, check lubricant oil, cooling
system water and fuel levels.
Do not warm the engine up in idle speed but
varying its speed.
To reach the normal operation temperature,
move the vehicle without extremely loading
and without exceeding 3800 rpm.
Do not let the engine running in idle speed
without need.
Keep the engine operation temperature
between 86 and 102 C (187 and 216 F)
engine.
Note:
It is operator responsibility the correct use of the product during the running-in. The not
execution of the recommendations above mentioned will provoke the decrease of the
product useful life, with consequent increase of the lubricant oil consumption to higher
levels than the ones defined by the project.
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 instructions of this
Manual.
Optional equipment installation, not originals from
factory, will cancel warranty and may cause
serious damages to the engine, with consequent
decrease of its useful life.
For a better engine performance, always use
genuine parts.
14
INSTALLATION REVISION
ITEM
CHECK
Alternator belt
Tension
Water and lubricant oil
Level (complete if necessary)
General performance
Operation temperature and speed at

maximum load
Intake system
Intake air temperature and restriction
Fuel system circuit
If the piping is unobstructed and free of vibrations,

extreme heat areas and leakages occurrences
Exhaust system
If there isnt restriction to the exhaust gases
Command system
Accelerator course
Engine fixation
Alignment among engine and transmition
Instrument panel
Indicators, warning lamps and sensors functioning
Cooling system
Radiator, hoses, piping and clamp conditions
15
PERIODIC MAINTENANCE
120,000 km
(74,600 mi)
105,000 km
(65,200 mi)
90,000 km
(55,900 mi)
75,000 km
(46,600 mi)
60,000 km
(37,300 mi)
45,000 km
(27,900 mi)
30,000 km
(18,600 mi)
15,000 km
(9,300 mi)
PERIODS
CHECK
Daily
Check engine oil level (complete if necessary).
Daily
Check water reservoir level (complete if necessary).
Daily
Drain impurities from the fuel filter and

sedimentation filter.
Daily
Check air filter hoses and connections conditions.
Check the terminals and battery level.

Retighten engine rubber pads.
Replace lubricant oil and filter.
Replace fuel filter element.
Adjust valves clearance.
Check idle speed*.
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.
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) at each 6 months, even without reached the limit of 15.000 km (9,300 mi)
(recommended for the fuel filter change).
* Services that have to be made by Distributors / Authorized Services Net.
** Services that have to be made by part manufacturer.
Remark:
16
For vehicles that work predominantly in regions where sulfur index in fuel is over than
1%, lubricant oil change intervals must be at each 7.500 km.
TURBOCHARGER
The turbocharger is compound of a rotary turbine
and a air compressor, located in opposite sides
of a same shaft. The compressor and turbine
rotors are covered by housing denominated
compressor and turbine, which function is to
direct the gases flow through the rotors shovels.
These gases having energy in pressure,
temperature and speed form, cause the rotation
of the turbine rotor and consequently of the
compressor rotor.
With the rotation, the atmospheric air (that must
be properly filtrate) is aspired, and later on,
compressed to the compressor rotor from where
goes to turbocharging (in turbocharged
International HS 2.8L engines) and later on to the
engine cylinders. Having a higher pressure in the
intake, the work done by the cylinders is positive,
in other words, the cylinders spent a smaller
amount of energy in the intake.
Exhaust
gases
Turbine rotor
Compressed air
Filtrate air
Exhaust
gases from
the engine
Compressor rotor
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.
17
The intake of strange objects, even smalls, will

damage the rotor of the compressor, damaging
the operation of the turbocharger, this way,
between the recommended periods check the air
filtering system.
By working at high speeds and temperatures, the
turbo requires a lubricant oil that accomplish to
these requirements, and never should be used a
lubricant oil that does not attend to API / ACEA
specification (5th 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 vehicles 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.
18
CAMSHAFT BELT
The engine timing pulleys are moved by a flexible
rubber belt, which must be replaced in
predetermined intervals depending on the use
conditions severity.
Note:
If the belt is not replaced within the correct intervals, it may present failures, causing
serious damages to the engine.
Follow strictly the specifications of belt tensor

tightening, guaranteeing its useful life, according
the recommendation.
19
COOLING SYSTEM
20
Cooling System
COOLING SYSTEM
Circuit drainage
If it is necessary to totally drain the coolant water,
follow the instructions below:
Warning:
Do not drain cooling water while

the engine is still hot and the
system pressurized.
1. Remove lower and upper radiator hoses.

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
Owners Manual.
3. Check in the Owners 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.
21
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 Qumica Ltda - Fluid for radiator Radiex.
Mobil Oil do Brasil Ind. e Com. Ltda. - Mobil
Permazone.
Promax Products Mximos 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.
22
Cooling System
8. Manually reinstall thermostat housing

disaeration plug, just to seal the liquid outlet
hole.
A. Fill system until reaching the maximum level
of the tank.
B. Tighten expansion reservoir cover and check
for leakages.
C. Run engine at idle speed for 10 seconds and
let the liquid spill through the disaeration plug,
eliminating all air bubbles from the system.
D. Stop engine and tighten the disaeration plug
within 13 to 17 Nm.
E. Run engine 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:
To 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.
23
Cooling System
FAN PULLEY
Removal
1. Remove fan, see FAN - Removal.
2. Loosen pulley fixation bolts.
3. Remove accessories belt, see
ACCESSORIES BELTS.
4. Remove pulley.
Reinstallation
1. Reinstall in the inverse order, tightening bolts
within 22 to 28 Nm.
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.
24
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 C (190 F). Install the thermostat in a
recipient with water. Heat the water up and
check the temperature in which the
thermostat begins to open. The thermostat
will be satisfactory if it opens between
86 and 90 C (187 and 194 F).
Reinstallation
1. Put the 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.
3. Invert the removal operations.
4. Tighten bolts within 22 to 28 Nm.
5. Check for coolant water leakages around all
the connections and gaskets.
25
Cooling System
Note:
26
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).
FUEL SYSTEM
27
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 the
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:
Do not smoke or get close any

type of exposed blame or
sparks while filling the tank,
because diesel fuel is very
inflammable.
28
Fuel System
3. 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.
Note:
Only use aviation kerosene in situations when the ambient temperature is under zero.
(0 C) (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.
Note:
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 durability, 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.
3. As soon as the fuel flows clean, through the
side plug, close the drain plug.
4. Close upper plug.
5. Check for leakages.
29
Fuel System
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. Turn sensor 1/3 turn clockwise.
CORRECT
3. Position filter in the clamp and install waterin-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.
INCORRECT
5. Install fuel inlet and outlet pipes.

6. Tighten clamp nut until the clamp touches the
support (to avoid strangle).
Note:
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 vehicle panel.
7. Start engine, wait to speed stabilization (in

idle speed), for 10 seconds.
8. Check for leakages.
Note:
30
Manual bleed is unnecessary.
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. If the engine doesnt start, repeat the
procedure starting from the item 2.
It is 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.
31
Fuel System
Reinstallation
1. Clean pump and block contact surfaces.
2. Install pump in cylinder block with a new
gasket, ensuring of the correct location of the
lever with the camshaft.
3. Fix with bolts tightening according to
specification.
4. Connect fuel lift pump inlet and outlet pipes.
BLEEDING
Note:
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).
32
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 pulley.
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.
33
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.
34
Fuel System
3. Remove special tool pin from the pump.

4. Clean pump and timing housing contact
surfaces.
5. Install pump in timing housing with a new
gasket and fix it with nuts tightening
according to specification.
6. Fix pump to timing housing with nuts,
tightening within 22 to 28 Nm, clockwise, and
finishing the tightening in the lower nut.
7. Tighten the support fixation bolts to the block
and pump bolts to the support, and tighten
within 22 to 28 Nm.
8. Connect return and fuel pipes with new
washers and fix them with banjo bolts
tightening according to specification.
9. Connect boost control pipe and fix it with
banjo bolt tightening it according to
specification.
10. Connect stop control solenoid wiring.
11. Connect accelerator cable.
12. Remove tool nr. 8130633.
13. Install gear lock plate.
14. Install the tool pin nr. 8130633.
15. Fix pulley with bolts.
16. Install retention plate in fuel injection pump.
17. Remove the pins of the special tools nr.
8130632 and 8130633.
18. 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.
19. If, 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.
35
Fuel System
20. Using adequate anti-adherent compound,

install the flywheel housing plug and tighten it
21. Install inspection cover with a new gasket on
timing housing cover and tighten bolts
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

1. 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.
Note:
36
The idle speed is the only adjustment allowed in service. Any other additional
adjustment must be made by a Bosch authorized representative.
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 nozzleholders in cylinder 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.
37
Fuel System
5. Install nozzle-holder set with the return outlet

turned outside.
6. Fix it with the plate and nut, tightening
Note:
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 nozzleholder 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 injection pump inspection cover
from timing housing cover, complete with
gasket.
4. Install tool nr. 8130632 in flywheel housing.
38
Fuel System
5. Turn crankshaft to the valves of the cylinder

nr. 4 to be swinging (1st cylinder piston at
TDC in compression stroke).
6. Continue turning crankshaft clockwise until fit
the center pin.
7. Install the tool pin nr. 8130633 in the fuel
injection pump pulley.
8. If, 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

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
10. Install inspection cover with gasket in the
timing housing cover and tighten bolts
11. Reinstall nozzle-holders pipes.
39
Fuel System
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.
40
LUBRICATION SYSTEM
41
Lubrication System
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.
Warning:
If oil level is frequently low, seek

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.
Note:
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
Lubrication System
1. Run the engine until reach the ideal operation

temperature.
2. Stop the engine, clean the filling inlet cover
and oil pan plug. Remove and let oil drain
freely.
3. Check if the breather pipe is obstructed. If
necessary, remove and clean it.
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.
Note:
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 counter clockwise, using a belt
or a universal ribbon.
43
Lubrication System
Assembly
1. Lubricate new filter seal with clean engine oil.
2. Screw manually the filter until the sealing ring
touches the surface, manually tighten 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.
5. 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
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, 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 o 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
4. Reinstall oil pan, see OIL PAN - Installation.
45
Lubrication System
LUBRICANT OIL PUMP

Removal
The lubricant oil pump of the Turbocharged
International HS 2.8L Engines is attached to the
timing housing.
1. Remove timing housing, see TIMING
HOUSING - Removal.
2. If it is necessary to replace oil pump, it is
recommended to replace the whole timing
housing, see TIMING HOUSING.
Recommended Lubricant Oils:
46
Note:
Multi-viscous SAE 15W/40: CCMC D-5 / ACEA AND 3 / API CG4.
Note:
Multi-viscous oil: Keep its features even with high temperatures variations.
Use obligatory in International HS 2.8L Engines.
Cylinder Head
CYLINDER HEAD
47
Cylinder Head
CYLINDER HEAD
Removal
1.
Warning:
Loosen radiator lower and

upper hoses. Remove reservoir
cover and loosen water outlet
hose from thermostat housing.
Drain Cooiant water.
Warning:
Loosen exhaust duct from the

manifold.
Remove outlet elbow and thermostat.
2. Loosen intake duct from manifold.

3. Loosen nozzle-holder return pipe from fuel
injection pump.
4. Remove all fuel system pipes.
5. Remove nozzle-holders and washers.
6. Remove air filter and / or intake manifold
hose.
7. Remove turbocharger hoses.
8. Remove intake and exhaust manifolds.
9. Remove valves cover breather lateral hose.
10. Loosen the breather valve fixation bolt, remove valve together with valve pipe from intake
manifold, remove and discard oring.
11. Remove valves cover and gasket.
48
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 disassembly, flush
cylinder head with chemical biodegradable
greasing remover and water at 80 C (176 F)
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.
3. Check cylinder head height.
4. Check cylinder head distortion with a sheet
and a ruler of steel.
49
Cylinder Head
Note:
The maximum allowed distortion is 0.05 mm; over this value, cylinder head must be
replaced.
5. Check nozzle maximum projection:
6. Resurfacing can be made only if the

maximum nozzle projection to the cylinder
head does not surpass the specified
dimension (1.82 - 2.10 mm).
Note:
Assembly of sealing washers cannot compensate nozzle projection.
7. Check valve guides, see VALVES.

8. Check seats, see SEATS AND HOUSING.
50
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

thickness.
Note:
Holes
reference
Gasket
thickness
Piston Height
(mm)
1.37 mm
from 0.50 to 0.60
00
1.48 mm
from 0.61 to 0.70
000
1.59 mm
from 0.71 to 0.80
Cylinder head gasket corresponds to piston height, in relation with cylinder head
surface.
51
Cylinder Head
5. Install gasket with the identification holes

turned back and with TOP mark upwards.
6. Clean engine block contact surface.
7. Lower cylinder head on the engine block,
making sure of the correct guide-pins
position.
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,
M12 x 140 mm 60 Nm + 150
16, 17 and 18
3, 5, 12 and 13 M8 x 117 mm
20 Nm + 140
4, 6, 11 and 14 M12 x 100 mm
60 Nm + 120
52
Note:
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 shaft, 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.
Note:
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. Stop the engine.
4. If necessary adjust valves clearance again,
see VALVES CLEARANCE ADJUSTMENT.
Note:
It is not necessary to retighten cylinder head during the revisions.
53
Cylinder Head
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, making sure if the pipe turns
freely.
6. Remove turbocharger outlet elbow 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.
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
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 first lower central nut.
3. Remove gasket.
4. Clean contact surfaces.
55
Cylinder Head
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
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
Cylinder Head
Disassembly
1. Remove rocker arms, springs, brackets and
spacers.
Cleaning and inspection
1. To clean shaft, remove the plugs of the
edges. Check lubricant, rocker arms and
shaft passage holes, unblocking them if
necessary.
2. Check rocker arms bushing. If its clearance
with the upper shaft is over than specified,
bushing must be replaced, see clearance in
TECHNICAL SPECIFICATIONS.
3. 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.
2. Machine the inner diameter of the bushing.
3. Assembly the connection in rocker arms
shaft.
4. Assembly springs, brackets and rocker
arms.
Installation
1. Lubricate the lower edge of the push rods,
making sure that there is a correct fitting in
the tappets.
2. If the rocker arms support shaft fixation
prisoners in the cylinder head have been
removed, assembly and tighten them
3. Assembly rocker arms shaft set using new
sealing rings. Tighten fixation nuts in three
steps from the center to the ends according
to specification.
57
Cylinder Head
VALVES
Disassembly
1. Remove cylinder head, see CYLINDER
HEAD - Removal.
2. With tool nr. 8130001, compress springs and
remove valves locks.
3. Remove springs seats, springs, springs
washers, seals and valves.
4. While removing or replacing valves, mark
with electric pencil the corresponding number
of each cylinder.
1. Remove carbon from combustion chamber,
valve guides and valves. Wash all parts with
solvent.
2. Check valve rod diameters with micrometer
in three positions.
3. If the clearance between the rod valve outer
diameter and guide inner diameter is over
than specified replace guide by another, see
VALVE GUIDES.
4. Check springs.
Assembly
1. 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.
2. Install valve in its corresponding guide.
3. Assembly new seal, spring washers, springs
and spring seats. Lubricate parts in the
assembly sequence.
4. Compress springs and assembly locks.
5. Assembly valves covers.
58
Cylinder Head
Seals and springs replacement with cylinder

head installed
1. Set the piston of the replacement
corresponding cylinder at TDC.
2. Loosen valve rocker arm adjustment bolt.
Displace rocker arm, allowing the access of
the tool nr. 8130 002 and compress springs.
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.
3. Check guide-hole diameter with an inner
diameters measurer in three positions.
59
Cylinder Head
Guide replacement
1. Use tool nr. 8130631 and a press to quit
guide.
2. Press the guide with the tool nr. 8130634 and

the spacer nr. 8130644.
3. Check clearance specification between valve
and guide, see TECHNICAL SPECIFICATIONS.
SEAT AND HOUSING

Seat disassembly and machining
1. Seats replacement operations can be made
only after valve guides replacement, see
VALVE GUIDES.
2. Machine seat, removing it.
3. In housing machining operation, cylinder
head surface must be flat and perpendicular
to the valve guides, see cylinder head
Cleaning, Inspection and Resurfacing.
4. 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.
60
Cylinder Head
Assembly
1. In the pressing, the seat can be cooled in
liquid nitrogen. Use a press, with 2 to 3 ton
capacity. Do not use hammer or similar to
press.
2. Position seat with its base turned to the
housing.
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 CLEARANCE ADJUSTMENT

1. Remove breather valve and hose.
2. Remove valves cover.
3. Loosen lock nut and adjust clearance turning
adjustment screw.
61
Cylinder Head
Clearances
Procedure
Note:
Adjustment
conditions
Intake
valve
Exhaust
valve
COLD ENGINE
0.20 mm
0.20 mm
Balance valves of
cylinder nr.
Adjust valve of
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
ENGINE BLOCK
63
Engine Block
ENGINE BLOCK
Removal
Warning:
Drain lubricant oil.
Warning:
Remove tank cap and loosen

water hoses from radiator.
Warning:
Remove drain plug and drain

cooling system.
1. Loosen electric cables from starter motor,

lubricant oil pressure and engine temperature
gauges.
Disassembly
1. Disconnect inlet pipes and fuel return.
2. Remove engine from equipment.
3. Install support on the engine and install it in
the engine stand.
4. Remove fan.
5. Remove crankshaft pulley.
6. Remove water pump.
7. Remove accessories.
8. Remove cylinder head.
9. 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
Engine Block
18. Remove accessories support.

19. Remove rear seal and crankshaft.
20. Remove pistons and connecting rods.
1. Remove oil gallery rear plug.
2. Remove all water gallery plugs and lubricant
oil filter support.
3. Flush block with water at 80C (176 F)
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.
8130635 and tool nr. 8130636.
65
Engine Block
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-ofroundness. If dimensions found are higher
than specified, replace the engine block.
Maximum bore allowed for service.
66
Engine Block
CYLINDER FINISHING
Mandrill and burnishing
1. Adjust the machine to operate at 293 rpm
and advance of 0.15 to 0.30 mm / turn. The
final bore must be gotten in only one pass of
the broach.
2. 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).
3. During burnishing, use oil Honilo 407
(Castrol).
4. 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.
1. Remove incrustated particulate in the inner
surface of cylinder after the burnishing.
2. Check cylinder bore and out-of-roundness.
67
PISTONS AND
CONNECTING RODS
68
Pistons and Connecting Rods
PISTONS AND CONNECTING

RODS
Removal
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.
69

1. Check if the pistons have risks or damages
in lateral and upper faces. Carefully remove
carbon residues from the grooves.
2. Assembly a new ring and check its clearance
in the groove. If it is over than indicated next,
piston must be replaced.
Lateral clearance
Millimeters
Ring of the 1st groove,

compression
0.050
0.090
Ring of the 2nd groove,

compression
0.050
0.090
Ring of the 3rd groove,

compression
0.030
0.065
3. Measure piston pin outer diameter with

micrometer.
4. 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.
5. Check connecting rod warping and

alignment.
70
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. On one of the 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 measuring shells housing, correctly
position connecting rod cap, tightening
according specification.
71
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
Millimeters
1st groove,
compression ring
0.400
0.600
2nd groove,
compression ring
0.300
0.550
3rd groove,
oil ring
0.300
0.550
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
3. Assembly ring spring in piston 3rd groove

and next ring, with ends in opposite position
from spring ends. Install 2nd and 1st rings
with TOP mark or inner chamfer upwards.
Note that 2nd and 1st grooves rings have
different thickness.
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.
73
6. Complete lubricant oil injector for cylinder

inside and piston pin lubrication is shown
below.
7. Assembly new shell in connecting rod cap,

correctly positioning locks. Lubricate shell
and crankshaft crankpin.
8. Assembly cap on connecting rod

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.
9. Check axial clearance (0.15 to 0.35 mm)

between assembled connecting rod and
crankpin with dial indicator gauge.
74
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.
75
CRANKSHAFT
76
Crankshaft
CRANKSHAFT
Removal
1. Remove engine.
2. Remove cylinder head and push rods.
3. Remove accessories support.
4. Remove oil pan.
5. Remove timing housing and camshaft.
6. Remove flywheel housing and flywheel.
7. Remove pistons and connecting rods.
Disassembly
1. To disassembly, position engine topside
down. Remove rear oil seal housing and
gasket.
2. Remove connecting rod caps and shells.
3. Remove main bearing caps and shells.
77
Crankshaft
4. Remove crankshaft and shells.

5. Position crankshaft in vertical fitted in the
flywheel in order to avoid warping.

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.
78
Crankshaft
4. Check for cracks and remove crankshaft

magnetization.
5. Clean the lubrication holes.
6. Check with micrometer main journals and
crankpins length, see TECHNICAL
SPECIFICATIONS - Crankshaft.
7. Check again crankshaft main journals

eccentricity.
8. Check main journals and crankpins fillets
with caliper.
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.
79
Crankshaft
3. Lubricate upper shells and crankshaft main

journals and crankpins,
4. Lubricate the two upper thrust washers,
positioning lubrication channels to crankshaft
and slip them in their block housing.
5. Assembly crankshaft. Do not turn crankshaft
before bearing caps fixation.
6. Lubricate lower shells.
7. Assembly bearing caps correctly positioning

them.
8. After 5th cap assembly, apply Loctite 5900 on
bearing side grooves.
9. 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.
10. Check crankshaft axial clearance using a dial
indicator gauge. If clearance checked is over
than specified, replace thrust washers.
Rear seal
Assembly
1. Carefully clean engine block surface and
crankshaft flange and remove all existent
residues.
2. Apply a fillet of Loctite 5900 in all rear seal
housing edge.
80
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.
81
Crankshaft
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.
Note:
82
In case of seal lip bite, install a new seal, repeating previous procedures.
CRANKSHAFT PULLEY
83
Crankshaft Pulley
CRANKSHAFT PULLEY
Removal
1. Drain coolant water.
2. Remove radiator upper hose.
3. Remove fan, see FAN -Removal
4. Remove moving belt, see ACCESSORIES
MOVING BELT - Removal.
5. Install tool nr. 8130638 in crankshaft pulley
and fix it with 4 bolts.
6. Remove crankshaft pulley fixation bolt, using
a lever of an appropriate length.
7. Remove pulley. If 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
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. Fit the 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 the housing.
85
Crankshaft Pulley
6. Install tool nr. 8130633 pin in the fuel injection

pump pulley and fit it in pump flange.
Note:
If camshaft teeth pulley has to be removed during these operations, its fixation bolts
must be loosen before the distribution belt removal.
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
Note:
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
Note:
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. Lock engine, at TDC, positioning the pin of

the timing tool nr. 8130632 in the flywheelhousing 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).
C
A
B
D
87
Crankshaft Pulley
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:
88
After the torque application, it is recommended to check belt tension by the device
pitch within 130 to 160 Hz.
ENGINE TIMING
89
Engine Timing
ENGINE TIMING
Camshaft pulley and timing housing
Crankshaft pulley and timing housing (gib upwards)
Fuel injection pump pulley and synchronizer pin
Loosen pulley bolts, to accommodate belt
90
Engine Timing
CRANKSHAFT GEAR
Removal
1. Remove distribution belt, see DISTRIBUTION
BELT - Removal.
2. Use tool nr. 8130628 if the crankshaft gear
cannot be manually removed.
3. Remove o ring.
4. If necessary remove oil seal from timing

housing.
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.
91
Engine Timing
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.
Note:
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
92
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.
Note:
It 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
Note:
Camshaft and injetion pump pulleys are the same, even so they are assembled in
inverse way.
1. Install pulley, positioning it in way that timing

mark keep turned backwards.
2. Install plate and fix it with three bolts.
3. 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
93
Engine Timing
TIMING HOUSING
Removal
1. Remove distribution belt and toothed pulleys,
see DISTRIBUTION BELT - Removal.
2. Remove fuel injection pump, see FUEL
INJECTION PUMP Removal.
3. Remove crankshaft gear, see CRANKSHAFT
GEAR- Removal.
4. Remove oil pan, see ENGINE OIL PAN
Removal.
5. Remove oil suction pipe.
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.
94
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

clockwise).
3. Remove belt from pulley.

4. Free tensor.
5. Finish belt removal,
6. Loosen fixation bolt of air conditioning
compressor moving belt tensor.
7. Remove belt from pulley handling it over the

fan.
95
Engine Timing
Reinstallation
1. Reinstall moving belts in the inverse order of
removal.
2. Fix tensor bolt according to specification.
Camshaft
Removal
1. Remove timing housing, see TIMING
HOUSING Removal.
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
FLYWHEEL
97
Flywheel
FLYWHEEL
1. Remove gearbox.
2. Remove starter motor.
3. Remove clutch.
4. Install two long bolts of 8 mm in clutch bolt
holes diametrically opposites, to use as
handles when removing flywheel from
crankshaft.
5. Install tool nr. 8130638 in crankshaft pulley
and fix it with four bolts, to immobilize
crankshaft during flywheel fixation bolts
removal.
6. Loosen flywheel fixation bolts and remove it.

1. Wash all parts with biodegradable chemical
detergent.
2. Check if gear ring teeth are worn. To replace,
see GEAR RING REPLACEMENT.
3. Use a male M14 in crankshaft bolts holes, to
remove the residues of Loctite.
Reinstallation
Note:
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
2. Check flywheel eccentricity, assembling a
dial indicator gauge so that its point touches
at 114 mm from the center of the flywheel.
98
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. Apply a 4 mm fillet of Loctite 5900 on flywheel
housing.
3. Install housing on engine block and fix it with

bolts according removed and tighten
according to specification, see TECHNICAL
SPECIFICATIONS.
99
Flywheel
RING GEAR REPLACEMENT
Warning:
Following operations evolve

heat, and may cause burinings.
Disassembly
1. Put flywheel in a recipient, with clean water
and support ring gear on four metal blocks,
so ring gear stays approximately 6,5 mm
(1/4") above the level of water.
Flywheel
6.5 mm
Water
Gear ring
2. Heat ring gear on all its extension so that

flywheel loosen.
Assembly
1. To assembly ring gear on flywheel, heat it up
to approximately 246 C (475 F) in a stove.
100
ACCESSORIES
101
Accessories
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 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
Accessories
Reinstallation
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.
3. 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.
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.
103
Accessories
VACUUM PUMP
Removal
Vacuum pump of turbocharged International
HS 2.8L Engines is attached to the alternator.
1. Remove alternator, see ALTERNATOR,
Removal.
2. If it is necessary to repair vacuum pump, it is
recommended to send the complete set
(alternator and vacuum pump) to Bosch
Network.
Warning:
By not execution this procedure,

the warranty will be canceled.
Installation
1. Install in the inverse order of the removal,
Air conditioning compressor

Removal
1. Remove compressor pulley belt tensor, see
ACCESSORIES MOVING BELTS - Removal
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
104
Accessories
Accessories support
Removal
1. Remove water pump and power steering
pump pulleys bolts.
2. Remove accessories moving belt tensor, see
ACCESSORIES MOVING BELT Removal.
3. Remove water pump hoses.
4. Remove power steering pump, see POWER
STEERING PUMP Removal.
5. Remove alternator and vacuum pump, see
ALTERNATOR Removal.
Reinstallation
1. Reinstall in the inverse order of the removal
tightening bolts according to specification.
105
TECHNICAL SPECIFICATIONS
106
Technical Specifications
TECHNICAL SPECIFICATIONS
COMPONENTS: MEASURES, ADJUSTS AND TOLERANCES
ENGINE BLOCK
MILIMETERS
Total height, between finished surfaces
348.28 - 348.46
Cylinder bore, after burnished
93.000 - 93.013
Rugosity, after burnished (CLA)

Burnishing angle
0.45 m - 0.70 m
38 - 42
Shell housing diameter
67.704 - 67.721
Camshaft bushing housing diameter
49.99
Tappet housing diameter
34.925 - 34.950
MAIN BEARING SHELLS
50.01
MILIMETERS
Outer diameter
67.704 - 67.721
Inner diameter, after assembly
63.535 - 63.536
Oversize (0.25 m)
63.281 - 63.282
Main bearings shells width nr. 1, 2, 3 and 4
24.25
24.50
Main bearing shell width nr. 5 (rear)
34.81
35.06
Thickness
2.083
2.093
Clearance between shell and main journal (diametrical)
0.030
0.080
CAMSHAFT GEAR
Number of teeth
MILIMETERS
24
Gear housing diameter
38.030 - 38.075
CAMSHAFT PULLEY
MILIMETERS
Seal ring diameter
56.975 - 57.025
107
CRANCKSHAFT
MILIMETERS
Main journals diameter, standard
63.471 - 63.491
Undersize (0.25 mm)
63.217 - 63.237
Main journal length nr. 1 - standard
31.090 - 31.850
34.393 - 34.645
33.275 - 33.325
34.393 - 34.645
44.704 - 44.958
Crankpin diameter - standard
58.725 - 58.745
Undersize (0.25 mm)
58.471 - 58.491
Crankpins length - standard
33.249 - 33.401
Main journals fillets / roller crankpins
3.3
Main journals / crankpins maximum out-of-roundness
3.7
0.007
0.25 m
Main journals / crankpins rugosity (CLA)

Fillets rugosity (CLA)
0.8 m (*)
Rear flange diameter
99.495 - 99.517
Rear flange width
21.122 - 22.176
Maximum eccentricity - Main journals nr. 1 and 5
supported
Maximum eccentricity - Main journal nr. 3
0.025
Axial clearance
0.05
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

Crankshaft axial clearance
108
0.029
0.15
0.35
CONNECTING ROD SHELLS
MILIMETERS
Outer diameter (assembled)
62.433 - 62.446
Inner diameter, after assembly
58.779 - 58.780
Thickness
1.827
1.833
Oversize (0.25 mm)
1.952
1.958
Shells width
24.750 - 25.000
Clearance between shell and main journal (diametrical)
0.025
CONNECTING ROD BUSHING
0.076
MILIMETERS
Outer diameter
36.650 - 36.675
Inner diameter after finish
32.020 - 32.035
Clearance between pin and bushing
0.020
PISTON
0.041
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
Diameter
PISTON RING
MILIMETERS
31.994 - 32.000
MILIMETERS
Side clearance in the 1st and 2nd grooves, compression
0.050
0.090
Side clearance in the 3rd groove, oil ring
0.030
0.065
Clearance between ends of the 1st ring, compression
0.400
0.600
Clearance between ends of the 2nd ring, compression
0.300
0.550
Clearance between ends of the 3rd ring, oil ring
0.300
0.550
CAMSHAFT PULLEY
MILIMETERS
Number of teeth
48
Pulley hole bore
30.000 - 30.035
CAMSHAFT
MILIMETERS
Axial clearance
0.100
Bushing diameter
46.812 - 46.825
Camshaft bearing diameter
46.760 - 46.780
0.200
109
CYLINDER HEAD
MILIMETERS
Height
127.87 - 128.13
Valve guides hole diameter: Standard
14.000 - 14.018
Intake valve seat housing diameter: Standard
40.400 - 40.416
Intake valve seat housing depth
11.000
Exhaust valve seat housing diameter: Standard
38.000 - 38.016
Exhaust valve seat housing depth
11.000
INTAKE VALVE SEAT

Outer diameter
EXHAUST VALVE SEAT
Outer diameter
INTAKE VALVE GUIDE
- 11.100
- 11.100
MILIMETERS
40.490 - 40.505
MILIMETERS
38.080 - 38.100
MILIMETERS
Inner diameter after assembly
8.000
Outer diameter
14.050 - 14.060
EXHAUST VALVE GUIDE
8.015
MILIMETERS
Inner diameter after assembly
8.000
8.015
Outer diameter
14.050 - 14.060
INTAKE VALVE
MILIMETERS
Valve rod diameter
7.957
7.977
Clearance of valve in guide
0.023
0.058
Head diameter
Seat surface angle
38.750 - 39.050
60 to 60 30
Valve depth, under cylinder head surface: Standard
0.810
Total length
116.14
- 116.62
EXHAUST VALVE
1.090
MILIMETERS
Valve rod diameter
7.940
7.960
Clearance of valve in guide
0.040
0.075
Head diameter
36.35
36.65
Seat surface angle
44 30 to 45
Valve depth, under cylinder head surface: Standard
0.860
Total length
116.29
- 116.77
110
1.140
VALVE SPRING
MILIMETERS
Spring inner diameter
23.7
Free length
47.1
Minimum length, under load of
304 to 336 N
39.8
652.5 to 707.5 N
32.0
ROCKER ARM
MILIMETERS
Bushing housing diameter
20.310 - 20.340
Bushing outer diameter
20.354 - 20.380
Bushing assembly interference
0.014
Bushing inner diameter
18.034 - 18.049
Clearance of the shaft in the bushing
0.050
ROCKER ARM SHAFT
0.070
0.076
MILIMETERS
Diameter
17.973 - 17.984
Total length
469.850 - 470.150
TIMING HOUSING COVER

Seal housing diameter
MILIMETERS
74.000 - 74.046
Seal housing width
10.7
LUBRICANT OIL FILTER

Valve opening pressure
117.21 kN/m2 20.7 kN/m2
THERMOSTAT
Type
Opening temperature
Valve minimum course at maximum opening temperature
Maximum opening temperature
Wax capsule
86 to 90 C (187 to 194 F)
9 mm
102 C (216 F)
FUEL INJECTION PUMP

Mark
Bosch
Type
VE Rotary
Rotation sense
Clockwise
Pump service code (Bosch)
VE4/12F1900R905-1 (WG)
Pump service code (Bosch)
VE4/12F1900R905-1 (VNT)
Pump piston displacement
1.44 mm
Fuel injection pump International Nr.
77529 N Bosh: 0460424237 (WG)
Fuel injection pump International Nr.
77528 N Bosh: 0460424234 (VNT)
111
NOZZLE HOLDER
Mark
Bosch
Type
DSLA 140P112
Set number
No International: 77530
No Bosh:
1st stage opening pressure
200 bar
2nd stage opening pressure
330 bar
Nozzle height (in relation to cylinder head)
1.82 mm - 2.10 mm
FUEL LIFT PUMP

Type
Mechanic, of
diaphragm
Flux pressure, static
42 to 55 kN/m2
Gasket thickness to engine block
0.4 mm - 0.6 mm
FUEL INJECTION PUMP PULLEY

Number of teeth
48
STARTER
Mark
Prestolite Indiel
Tension
12 v
Power
2.8 cv
No. of gear teeth
z=9
TURBOCHARGER
Mark
GARRETT
Type
GT 20 (52S) WG
GT 22 (56V) VNT
Operation pressure
1.2 Bar
Wastegate type (WG)
Diaphragm
Actuator valve type (VNT)
Diaphragm
112
TIGHTENING SPECIFICATIONS
113
Tightening Specifications
TIGHTENING SPECIFICATIONS
GROUP
ILLUSTRATION
Engine Block
Timing Housing
Rocker Arm Shaft / Camshaft
Rear Seal
Fan and Camshaft Pulley
Oil Cooler / Filter
Piston and Connecting Rods
Cylinder Head
Belt and Tensor
Oil Pan
10
Cylinder Head Cover / Engine Breather
11
Thermostat and Housing
12
Intake / Exhaust Manifold
13
Fuel Injection Pump
14
Gear Box Adaptor Plate
15
Starter / Alternator
16
Water Pump
17
Turbo Installation
18
Fuel Lift Pump / Fuel Filter
19
Power Steering Pump / Belt Tensor
20
Injection Piping and Nozzles
21
Flywheel and Gear Ring
22
Brake System
23
Engine Brackets
24
114
115
116
117
118
ADDITIONAL INSTRUCTIONS
119
Additional Instructions
ADDITIONAL INSTRUCTIONS
INACTIVE ENGINES CONSERVATION
In order to avoid engine corrosion if it stays
inactive during long period, it is necessary to take
the following providences:
1. Clean correctly the outer parts of the engine.
2. Run engine up to the normal operation
temperature. Next, stop and drain oil from oil
pan.
3. Remove oil pan, clean oil suction pipe and
replace lubricant oil filter cartridge.
4. Clean breather pipe.
5. After to reinstall filter, fill oil pan up to the
maximum level, marked on lubricant oil
dipstick with SHELL ENSIS ENGINE MOTOR
oil.
6. Drain fuel tank and fill it with SHELL
CALIBRATION FLUID B oil.
7. Run engine until that it reaches normal
operation temperature.
8. Drain cooling water from engine and radiator.
9. Remove air filter or any extension of the
intake piping and seal air intake with adhesive
tape.
10. Remove exhaust pipe and seal exhaust
manifold, as well as intake manifold.
11. Disconnect battery and remove it for storage.
Warning: It contains acid, protect eyes

and hands.
12. Remove fan belt.

13 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 month.
120
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 lbf/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 and fill it up to correct
level.
12. Remove adhesive tape from tank or from
filling pipe breather.
121
13. Drain fuel from tank and fill it with new oil.
14. Replace fuel filter cartridge.
15. Bleed fuel system.
Notes:
If these instructions are followed the return to work will not damage the engine.
INTERNATIONAL ENGINES SOUTH AMERICA LTDA is not responsible for
damages in the engine, caused by the incorrectly made procedures.
FUEL STORAGE
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. 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
Warning:
To install fuel storage tanks the

following checks must be
followed:
1. Location, dimension and safety of the area

where it is installed.
2. The local must be flat, preferently far from
houses, animal shelters, electric installations,
places where there are welding equipments,
boilers, or others that may generate sparks,
blames or excessive heat.
3. 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.
4. Externally, fuel tank and all components of its
piping must be painted with anti-corrosive paint.
5. Tank must have a ventilation system with inlet
protected with metallic mesh. It is also
possible to install an air filter.
6. Outlet fuel piping must have, after register,
filtering and sedimentation system.
7. If it is necessary to install an electric net to
power pump, that equipment must be
special, armored type.
8. If it is necessary to install a hydraulic pump
for fuel manipulation, this must be protected,
when not in use, from direct contact with fuel,
by a retention valve and register.
9. Hydraulic pump and control panels must be
assembled on bases of concrete.
10. Tank must have a storage register of
sedimented water and impurities.
11. 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.
123
12. Inclination in relation to ground level must be

from 20 to 50 mm to each meter of length.
13. If gallons are used, these must not be
internally galvanized.
14. Gallons must be protected from sun, rain and

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.
15. 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.
16. Children must keep out of playing near fuel

tank facilities.
17. In strategic points, around tank, must be fixed
warning plates like this:
Warning:
Do not smoke in this local on

near watch out inflammable!
Keep out
18. The area must be protected with fire

extinguishers properly signalized.
124
SPECIAL TOOLS
125
Special Tools
TOOLS
NUMBER
APLICATION
8130001
Valves assembly / disassembly device

with disassembled cylinder head.
8130002
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
126
Extractor for crankshaft gear removal
TOOLS
Special Tools
NUMBER
APLICATION
8130631
Valve guides extractor pin
8130632
Flywheel timing adjustment tool
8130633
Fuel injection pump gear fixation

device
8130634
Valve guides assembler pin
8130635
Camshaft bushing extractor
8130636
Flange for camshaft bushing extraction

(use with 8130635)
127
Special Tools
TOOLS
128
NUMBER
APLICATION
8130637
Crankshaft front seal assembler / oil

seal fixation part assembler
8130638
Crankshaft pulley fixation tool
8130639
Camshaft oil seal fixation tool
8130640
Camshaft oil seal extractor
8130641
Compression tester adapter
8130643
Fixation device for viscous clutch
TOOLS
Special Tools
NUMBER
8130644
APLICATION
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
129

International HS 2.8L Workshop Manual ARO

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What is the purpose of this manual?

What is the purpose of this manual?

What safety precautions are outlined for fuel storage?

What safety precautions are outlined for fuel storage?

SERVICE MANUAL

INTERNATIONAL ENGINES SOUTH AMERICA LTDA

The texts emphasized with the symbol

Do not change the original features of the engine.

ENVIRONMENTAL POLLUTION CONTROL

DESTINATION OF THE USED COMPONENTS OF THE ENGINE

Plastic and Metallic Components / Packing

Variable Nozzle (VNT)

Number and Cylinder

Cylinder Nominal Bore

Rotation Sense (front view)

Lubricant oil Pressure (at

Maximum Speed Unload

Static Injection Beginning at TDC

135 hp (99 kW) at 3800 rpm

133 hp (97 kW) at 3800 rpm

38.2 kgfm (375 Nm) at 1400 rpm

36.2 kgfm (355 Nm) at 1600 rpm

Weight (basic unit)

LOCATION AND IDENTIFICATION OF THE

Left side view

For engines manufactured in Brazil nr 000001 to 499999.

PS: (WG) - Wastegate Version

OPERATION AND MAINTENANCE

Operation and Maintenance Recommendations

OPERATION AND MAINTENANCE

If the engine has been stayed inactive for a long

1. Position key in start position for seven

In turbocharged engines, after to start, do not

Operation and Maintenance Recommendations

2. Check the panel instruments, engine noise

Let the engine in idle speed and

In turbocharged engines, in order to do not

Operation and Maintenance Recommendations

During running-in follow these recommendations:

Operation and Maintenance Recommendations

Water and lubricant oil

Level (complete if necessary)

Operation temperature and speed at

Intake air temperature and restriction

Fuel system circuit

If the piping is unobstructed and free of vibrations,

If there isnt restriction to the exhaust gases

Alignment among engine and transmition

Indicators, warning lamps and sensors functioning

Radiator, hoses, piping and clamp conditions

Operation and Maintenance Recommendations

Check engine oil level (complete if necessary).

Check water reservoir level (complete if necessary).

Drain impurities from the fuel filter and

Check air filter hoses and connections conditions.

Check the terminals and battery level.

Operation and Maintenance Recommendations

In turbocharged International HS 2.8L engine, the

Operation and Maintenance Recommendations