belt ISUZU TF SERIES 2004 Workshop Manual

ENGINE MECHANICAL (C24SE) 6A-17
ENGINE ASSEMBLY & LOOSE PARTS


Loose Parts
1 Alternator
2 P/S Pivot Spacer
3 P/S Adjusting Screw
4 P/S Adjusting Plate
5 P/S Adjusting Nut
6 Alternator & Fan Drive Belt
7 A/C Compressor Drive Belt
8 P/S Pump Drive Belt
9 Tensioner Bolt
10 Tensioner Pulley
11 Pulley Dust Shield Cover
12 Pulley Spacer
13 A/C Compressor Bracket
14 Pulley Bolt
15 Fan Pulley
16 Cooling Fan
Engine Assembly
20 C24SE

6A-18 ENGINE MECHANICAL (C24SE)
OPERATIONS ON ENGINE AGGREGATES
Engine Damping Blocks (Engine Without
Transmission)
Removal
1. Remove bonnet.
2. Remove radiator.
3. Remove air inlet hose.
4. Remove power steering pump drive belt and power
steering pump from engine.


5. Remove all cable connections, hoses and lines from
engine.
6. Remove accelerator cable from inlet pipe.


7. Remove exhaust pipe from manifold.



8. Remove lower nine bolts and transmission from engine
block.
9. Remove clutch slave cylinder and allow to hang free.
10. Remove starter from engine block.

11. Remove upper bolts of left and right engine mounting
from damping blocks.
12. Raise engine slightly.
13. Remove lower bolts of left and right damping blocks.
14. Remove damping blocks.

6A-20 ENGINE MECHANICAL (C24SE)





6. Install power steering pump and V-belt.

Adjust
Adjust power steering pump V-belt tension according to the
corresponding operation.


Installation
7. Install radiator according to the corresponding operation.
8. Install air inlet hose.
9. Install all electrical cable connections, hoses and lines to
engine.
10. Install accelerator cable from inlet pipe.
11. Install bonnet.


Inspection
1. Check engine oil level.
2. Fill up cooling system and bleed according to the
corresponding operation.

ENGINE MECHANICAL (C24SE) 6A-21

Toothed Belt and Timing Check

Removal
1. Remove the belts on the bracket for alternator.
2. Remove the fan.
3. Remove the V-belt for power steering.
4. Remove the V-belt for A/C.
5. Remove the fan belt.
6. Remove the fan shroud.

7. Remove the crankshaft pulley while counterholding on
the fastening bolt of toothed belt drive gear.
8. Remove the toothed belt from cover.

Inspection
1. Turn the crankshaft in the engine rotational direction
mark(2) so that the notch (1) on the camshaft gear aligns
with the mark on toothed belt rear cover.
2. Check the timing belt for worn, cracks or oil adhesion.

3. Check that the cast on the water pump aligns with the
counterpart on cylinder block (arrowed).
4. The tension of a toothed belt is correctly adjusted when
the pointer and the center of the notch are aligned(I).
The tension of a run-in toothed belt (regardless of
mileage covered) is correctly adjusted when the pointer
is positioned approx. 4mm (0.16 in.) to the left of the
center of the notch(II).
Check the condition of the run-in toothed belt for
suitability for reuse. Only toothed belts of the toothed
belt tension rollers must be replaced and the source of oil
contamination must be eliminated.

6A-22 ENGINE MECHANICAL (C24SE)


Installation
1. Install the toothed belt to the cover.
2. Install the crankshaft pulley while counterholding on the
fastening bolt of toothed belt drive gear.
3. Install the fan shroud.


Tighten(Torque)
Crankshaft pulley bolts - 20 N

m (2.1 kgf

m)


4. Install the fan belt
5. Install the V-belt for A/C.
6. Install the V-belt for power steering.
7. Install the fan.
8. Install the belts on the bracket for alternator.

ENGINE MECHANICAL (C24SE) 6A-23
Toothed Belt Tension, Adjust
(Engines with toothed belt tension
roller)
Removal
Refer to 6A-21. Toothed Belt and Timing check and removal
steps.


Adjust
1. Loosen the fastening bolt of the toothed belt tension
roller.
2. Turn the toothed belt tension roller at adjustment
eccentric (1) in the direction of arrow (counterclockwise),
until pointer (2) comes to the right stop.
3. If necessary tighten the fastening bolt of toothed belt
tension roller.


4. Rotate the crankshaft twice (720
) in the engine
rotational direction until marks (2) and (1) align again.


5. Turn the eccentric in the direction of arrow (clockwise)
until pointer (1) and notch (2) are positioned to suit age of
toothed belt.
6. Rotate the crankshaft twice (720
) in the engine
rotational direction again and correct adjustment if
necessary.

Installation
Refer to 6A-21. Toothed Belt and Timing check and installation
steps.

6A-24 ENGINE MECHANICAL (C24SE)
Toothed Belt, Replace
(Engine with toothed belt tension
roller)

Removal
1. Remove the belts on the bracket for alternator.
2. Remove the fan.
3. Remove the V-belt for power steering.
4. Remove the V-belt for A/C.
5. Remove the fan belt.
6. Remove the fan shroud.


7. Remove the crankshaft pulley while counterholding on
the fastening bolt of toothed belt drive gear.
8. Remove the toothed belt from cover.


Adjust
Turn the crankshaft in the engine rotational direction to
mark(2).
Align markings on toothed belt and on toothed belt rear cover.
Simultaneously, notch (1) on camshaft gear must align with the
mark on toothed belt rear cover.
Turn the crankshaft slowly and smoothly.

ENGINE MECHANICAL (C24SE) 6A-25








Adjust
Loosen the fastening bolt of the toothed belt tension roller and
turn the adjustment eccentric in the direction of arrow
(clockwise) until pointer (1) comes to the left stop.
Remove the toothed belt.

Installation
1. Install a new toothed belt while keeping tension side taut.

Adjust
Toothed belt tension - see operation " Toothed Belt Tension".


2. Install the toothed belt to the cover.
3. Install the crankshaft pulley while counterholding on the
fastening bolt of toothed belt drive gear.
4. Install the fan shroud.
5. Install the fan belt.
6. Install the V-belt for A/C.
7. Install the V-belt for power steering.
8. Install the fan.
9. Install the belts to the bracket for alternator.

6A-26 ENGINE MECHANICAL (C24SE)
OPERATIONS ON INSTALLED ENGINE
SEALING OPERATIONS

Gasket, Exhaust Manifold, Cylinder Head
Removal
1. Remove front exhaust pipe from exhaust manifold.
2. Remove exhaust manifold heat shield.
3. Remove exhaust manifold retaining nut.
4. Remove exhaust manifold from cylinder head.




Clean
Sealing surfaces.

Tighten (Torque)
Exhaust manifold to cylinder head - 22 N

m (2.2 kgf

m)
Front exhaust pipe to exhaust manifold - 25 N

m (2.6 kgf

m)


Gasket, Intake Manifold, Cylinder Head
Removal
1. Remove air intake hose.
2. Remove drive belt for alternator.
3. Remove bolt clamping bracket for alternator from intake
manifold.
4. Remove intake manifold from cylinder head.








Clean
Sealing surfaces

Tighten (Torque)
Intake manifold to cylinder head - 22 N

m (2.2 kgf

m)
Clamping bracket for alternator to intake manifold - 25 N

m (2.5
kgf

m)

Installation
1. Install V-belt according to the corresponding operation.
2. Install air intake hose.

ENGINE MECHANICAL (C24SE) 6A-27



Seal Ring, Camshaft Housing, Timing Side
Removal
1. Remove front toothed belt cover toothed belt from
camshaft timing gear according to the corresponding
operation.
2. Remove camshaft housing cover and camshaft timing
gear.
3. Remove sealing ring by making hole in middle of ring,
turning in self-tapping screw and edging out.


Installation
1. Install sealing ring by using 5-8840-0451-0 with camshaft
sprocket bolt and washer.
2. Install coat seal lips of shaft seal ring slightly.



Seal Ring, Thermostat Housing, Cylinder Head
Removal
1. Open radiator drain tap and collect coolant.
2. Remove toothed belt rear cover and toothed belt
according to the corresponding operation.
3. Remove camshaft housing cover.
4. Remove camshaft timing gear by counterholding
camshaft with a flat spanner.
5. Remove cable from temperature sensor.






6. Remove upper inner hex bolts of rear toothed belt cover.
7. Turn rear toothed belt cover to one side.
8. Remove thermostat housing.
9. Remove sealing ring from cylinder head.

Clean
Sealing surfaces in cylinder head and thermostat housing.

Installation
1. Install sealing ring in recess of cylinder head.