Cummins ISF 2.8 engine for Gazelle Next: repair manual

Diesel engines have become more and more popular lately. And not only due to the reliability and unpretentiousness of these units.

Rising fuel prices are encouraging more and more businesses to switch to fuel-efficient cars. This is especially true for truck fleet owners. And diesel is usually more economical, not to mention that diesel fuel is cheaper than gasoline.

Among the wide variety of types and models of diesel cargo engines, the development of the American international automobile concern Cummins deserves special attention.

General information on Cummins ISF 2.8 diesel engines.

Cummins introduces its latest series of ISF diesel engines that are ideal for use in small business vehicles.

The key feature of this series is high performance combined with low operating costs. In addition, they are characterized by traditional Cummins reliability. From an environmental point of view, this engine has low noise and low emissions.

Although the Cummins lineup is very diverse, the ISF series was designed as a lightweight, high-performance engine for use in light commercial trucks and vans. This means that, despite the compactness of the motor, it is able to provide sufficient torque and power.

A modern turbocharger is an air pump that supplies pressurized air into the combustion chamber of a diesel engine. Air is taken from the environment and compressed before entering the intake manifold.

Repairing the fuel pump is possible, but all components except the housing are replaced. Therefore, it turns out to be very expensive, almost equal in price to a new product. Read more about pump malfunctions and repairs here.

Also, the installation of this unit on small trucks allows an improved heat removal system, which allows the engine to operate at elevated temperatures, saving space due to an additional cooling system and thereby reducing the minimum size and cost of the vehicle. At the same time, the modular architecture of the motor makes its subsequent modernization possible. This will make the engine even more environmentally friendly and adapt it to ever-tightening environmental safety requirements.

Among the competitive parameters of the Cummins ISF 2.8 diesel engine, we can note it:

• small dimensions and weight;
• compliance with international environmental safety requirements;
• high reliability and performance.

Thanks to this approach to the manufacture of its products, Cummins is far ahead of its competitors and continues to occupy a leading position in the market for medium and heavy-duty diesel engines.

Technical characteristics of the Cummins ISF 2.8 model

The Cummins ISF 2.8 diesel engine, equipped with turbocharging and intercooler, has 4 cylinders with a displacement of 2.8 liters and is capable of developing a power of 120 hp.

Traction force and excellent acceleration dynamics are provided by the engine torque, which in this case is 270 Nm. It should be noted that it is precisely due to its high torque that this engine is significantly ahead of similar engines from both domestic and foreign manufacturers.

The resource of the unit has been increased to 500 thousand kilometers, which, of course, indicates the reliability of the unit.

The installation location and type of piston rings depend on their application profile. The set of rings for a solid piston will differ from the set of a composite piston, since the latter includes an intermediate second ring.

The Cummins ISF 2.8 starter in our country is installed on GAZelle cars, and the ISF 3.8 starter is installed on Valdai cars. The 2.8 liter engine guarantees high torque and good cross-country ability, while it has six power settings. Read more about starters in this article.

Microprocessor ignition system. It is the use of processors and electronics that makes it possible to achieve high parameters in this propulsion system.

The ISF 2.8 cylinder block is cast from gray cast iron, which ensures high strength. The cylinder liners are repairable and can also be replaced as needed. By the way, the valves are equipped with reinforced springs.

The cylinder valves are made of heat-resistant steel and equipped with chrome-plated shutters. This prevents scoring on the valves. Although all valves are of identical design, they are not interchangeable. To avoid mistakes with their installation, each valve has a special engraving.

The cylinder head is resistant to corrosion due to the fact that it is made of aluminum rather than steel. The same factor allows you to reduce the total weight of the motor.

An important parameter: the fuel consumption of this engine is 8.7/10.1 liters. diesel fuel per 100 km at a speed of 60 km/h. The design of the motor is distinguished by its simplicity. It is designed to be universal, so it can be installed on most modern mid-size trucks.

After installation, such a motor is very easy to maintain, since it provides quick access to all components that require periodic inspection and repair.

Power and speed characteristics of the Kamens 2.8 engine

Main parameters:

• The rated power declared by the manufacturer is 88.3 kW, which is approximately 120 horses.
• The maximum torque developed at the engine crankshaft is 297 Nm.
• The specific power of the power plant is 0.41 kW/kg, while the specific torque of the motor is almost 1.39 Nm/kg.

The maximum engine speed is 3600 rpm, while at idle the speed of this isf is only 750-800 rpm.

When the engine is operating at maximum power, the crankshaft speed is approximately 3200 rpm, and max. the torque developed by the power plant is achieved between 1600 and 2700 rpm.

As follows from the power and speed characteristics, the cummins isf 2.8 combines good power and rotational speed indicators for a diesel engine, as well as a fairly high torque value.

Cummins ISF 2.8 design

One of the most important advantages that distinguishes the Kamens 2.8 diesel engine from its competitors is its improved architecture and design. The engine crankcase is highly durable while being lightweight.

Durable composite materials were used in the manufacture of the pan, valve cover and gears, which reduced noise and vibration of the unit during operation. And the modular architecture makes it easier to repair engine parts and components, simplifying access to them.

The diesel Cummins ISF 2.8 has increased the maximum permissible temperature. Therefore, using this equipment you can avoid wasting space and money on installing a complex cooling system. All this reduces vehicle operating costs.

Maintaining optimal engine operation is possible thanks to an integrated electronic sensor system that transmits status information from all engine components and assemblies to the electronic control unit. This unit processes the received information and ensures an optimal balance between load, performance and harmful emissions.

The improvements did not bypass the fuel system, which was equipped with the “High Pressure Common Rail system” technology, or high-pressure direct injection. This system provides precise control of the combustion process by injecting fuel under high pressure.

Due to this, the injection speed increases, the efficiency of the engine increases, and the noise level decreases, which is important for a diesel engine. After all, it is the noise of a diesel engine, along with its smokiness, that are considered the main disadvantages of these engines.

Another highlight from Cummins is the Wastegated Turbocharger technology, a turbocharger that provides high performance throughout the entire engine speed range. The entire fuel system is protected by a superior fuel filtration system.

Our works

We are often asked how much will it cost to overhaul a Cummins ISF2.8? It is difficult to indicate the exact amount for such a question, but an approximate calculation can be made.

For repairs, you need to remove the engine from the car. The cost of removing/installing an engine from a Gazelle Business and Gazelle Next car is 15,000 rubles.

Next, it is necessary to disassemble the engine and discard faulty parts. Most often, engine repair requires:

1. Piston - 4 pcs
2. Piston rings - 4 sets
3. Main bearings - 1 set
4. Connecting rod bearings - 1 set
5. Gaskets and seals - 1 set
6. Valves - 1 set
7. Engine oil, oil filter
8. Consumables
9. Repair inserts for motor lining

The cost of these spare parts will be about 55,000 rubles. The cylinder block liner costs 15,000 rubles.

Next, the engine is assembled, run-in on the stand, and the engine is installed on the car. The cost of a major engine overhaul is 26,000 rubles. A major overhaul includes: complete disassembly of the engine, washing of components and parts, rejection of faulty parts, engine assembly, straightening of seats and lapping of valves, “cold” running-in, “hot” running-in. Now you can calculate the total cost of repairing the Cummins ISF2.8 engine, and it will be 111,000 rubles.

In some cases, it is necessary to replace the crankshaft, cylinder block, turbine, camshaft, or carry out any additional work. And the cost of repairs will be greater by the amount of these spare parts or labor. In rare cases, it is possible to save on valves, pistons, and liners.

Advantages and ease of use of Cummins ISF 2.8

Since it was said in a negative way about the lack of environmental friendliness of diesel engines, it should be noted that this does not apply to the Cummins ISF 2.8 diesel engine. As already noted, ISF models comply with the international environmental standard Euro 4. This efficiency was achieved thanks to selective catalytic exhaust neutralization integrated into Cummins engine systems.

The simultaneous use of all cleaning systems adds advantages to this unit: an electronic control system for air treatment and fuel combustion, an exhaust filtration system and exhaust aftertreatment. Also, if necessary, the engine design allows you to quickly switch to the Euro-5 standard without significant design changes.

While Cummins is confident in the quality of its products, there are more than 5,500 Cummins service and service centers around the world. This allows you to quickly respond to the needs of all users of the company's products, no matter where they live.

From all of the above, we can conclude that the Cummins engineers did a good job, producing not only a worthy analogue of diesel engines of other well-known brands, but also eliminating the shortcomings that were blamed on diesel engines when comparing them with gasoline ones. The Cummins ISF 2.8 engine is an excellent engine for medium-sized businesses.

Stages and timing of repairs for Cummins 2.8 Gazelle Business Next

• Acceptance of the vehicle for repair. Having made an appointment by phone in advance, the customer comes for repairs.
• Preliminary inspection and diagnostics of the engine. Possible causes of failure are determined.
• Removing the engine from the car.
• Engine disassembly. All removed parts are washed, inspected, and measurements are taken. Rejection of parts unsuitable for further use.
• Calculation. The cost and timing of repairs are determined.
• Coordination with the customer. Making changes to the calculation as desired.
• Preparing for engine assembly. At this stage, coordinated work is carried out, such as block liner, cylinder head repair, and crankshaft polishing.
• Engine assembly with replacement of spare parts according to calculations. Carrying out control measurements, tightening threaded connections with a certain force.
• Running in the engine. During break-in, engine operating parameters are measured mechanically, computer diagnostics, and various adjustments are made.
• Installing the engine on a car. After installation, repeat computer diagnostics.

The warranty for our Cummins ISF2.8 engine repairs is 1 year or 50,000 km, whichever comes first.

The timing of repairs depends on many factors. On average, engine repair with removal, installation, and block sleeve takes 5 working days.