coolant temperature ISUZU TF SERIES 2004 Workshop Manual

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.

ENGINE MECHANICAL (C24SE) 6A-35
Camshaft Housing, Removal and
Installation

Cylinder Head
Important!
Remove cylinder head only from cold engine (room
temperature).



Removal
1. Remove ground cable from battery.
2. Open radiator drain tap and collect coolant.
3. Remove air intake hose.
4. Remove all cable connections, hoses and lines to the
cylinder head.
5. Remove accelerator cable on the throttle valve.
6. Remove V-belt for alternator.



7. Remove front toothed belt cover according to the
corresponding operation.
8. Bring piston of 1st cylinder to TDC and mark the position.
9. Remove camshaft housing cover.
10. Remove camshaft timing gear after releasing tension on
toothed belt.


11. Remove upper bolts of rear toothed belt cover.
12. Remove exhaust pipe from exhaust manifold.
13. Remove cylinder head after loosening bolts from outside
inwards (at first quarter turn then half turn) in a spiral
pattern.
14. Remove camshaft housing from cylinder head.
15. Remove rocker arm, pressure parts and hydraulic valve
lifter adjuster.

ENGINE MECHANICAL (C24SE) 6A-63
OPERATIONS ON COOLING SYSTEM
Caution!
Before working with the cooling system, be sure to confirm that
the temperature of the engine is cooled down.
Failure to observe this may cause burn.








Cooling System, Check for Leaks
Installation
1. Install commercially available coolant checking
instrument onto compensation tank (Refer to section 6B;
Engine cooling).
2. Check coolant level.

Inspection
Use 5-8840-0277-0 tester & 5-8840-2603-0 adaptor.




Cooling System, Fill Up and Bleed
Important!
Radiator and heater core are made from alminium.
To avoid corrosion, use only anti-freeze with corrosion
protection.


Replace Coolant
1. Confirm the engine is cold enough.
2. Open the radiator cap, pour coolant to the filler neck level
and close the cap.
3. Pour coolant into the reservoir until MAX line is reached.
4. Start the engine, run 2 
3 minutes at idling speed and
switch off the engine.
5. Refill coolant if the coolant level is lowered.

6A-64 ENGINE MECHANICAL (C24SE)
Important!
Do not loosen or open the radiator cap when coolant is hot.
Doing so may cause hot water or steam to splash out, resulting
in burn. When opening the radiator cap, be sure to confirm the
coolant is cold. Cover a thick cloth over the cap and loosen it
slowly to reduce pressure, then open the cap.
6. Close the radiator cap firmly and run the engine at
approx. 2000 rpm. In addition, set the heater temperature
adjuster to the max position to circulate coolant in the
heater conduit system.
7. Confirm that the temperature gauge reads half or more
of full scale and that the thermostat is activated.
Then continue idling 5 minutes more and switch off the
engine, and allow it to cool.
8. After the engine cools down, check the coolant level and
refill it if necessary. When the level is lowered extremely,
check the coolant conduit system and reservoir hose for
leak.
9. Pour coolant into the reservoir to MAX level.







Refill Coolant
Important!
After closing the cooling system, let engine run warm until
thermostat opens (coolant approx. 92C/197.6F)

Inspection
Coolant level
Allow engine to cool. If necessary, refill coolant.

Check that cooling system self-bleeds during engine warming-
up phase.


Ignition Timing, Check
No Adjustment

6A-70 ENGINE MECHANICAL (C24SE)
Installation

(2.4L)
1. Install the ECM to the ECM bracket on engine.
2. Tighten the four screws to the bracket.
3. Connect the connector.









ECT
Removal
1. Remove wiring harness plug and coolant temperature
sensor.

Tighten (Torque)
Temperature sensor to intake pipe - 10 N

m (1.0 kgf

m)
Wiring harness plug to temperature sensor

Inspection
Coolant level







Idle Air Control (IAC) Valve
Removal
1. Remove wiring harness plug, hose clamps and idle
speed adjuster.

Installation
1. Install idle speed adjuster, hose clamps and wiring
harness plug.






Ignition Coil
Removal
1. Remove 2 bolts, plug and ignition coil.

Installation
1. Install ignition coil, plug and bolts.

6A-76 ENGINE MECHANICAL (C24SE)
TECHNICAL DATA
SOHC Gasoline Engine C24SE

Engine Oil Viscosity
The following engine oils can be used:
A = single-grade oils
B = multigrade oils
C = easy run oils
depending on the outside temperature.

Engine Oil Quality
It is important that the following API and CCMC classes are
used:


Engines Single and multigrade oils Easy run oils
Petrol API-SF/CC, SF/CD, SG/CC,
SG/CD, CCMC/G4 API-SF/CC, SF/CD, SG/CD
CCMC-G5/PD2




Important!
CD engine oils designed by manufacturers specially for diesel
engines are not suitable for petrol engines, unless a sufficient
performance class for petrol engines (e.g. API-SF/CCMC-G4)
is also indicated.

Disposal.
Observe the relevant national regulations when disposing of
used oil.


Engine Oil Filling Quantities

Engine Model Initial filling
(litres) Filling quantity
with filter change*
(litres) MIN to MAX
(litres)
2.4L 4.80 4.25 1.00
*Up to mark "MAX" on oil dipstick




Oil Pump
Backlash 0.1 to 0.2mm
Gaps in gears opposite housing 0.03 to 0.1mm
Oil pressure at idle speed Engine at operating
temperature (>70
C oil and
approx. 80
C coolant)
450 - 500 kpa
Oil drain plug M14  1.5

6B-4 ENGINE COOLING

Antifreeze Solution

Calculating mixing ratio
Mixing ratio

= Antifreeze solution (Lit/gal.)
Antifreeze solution (Lit/gal.) + Water (Lit/gal.)

NOTE: Antifreeze solution + Water = Total cooling system
capacity.

Total Cooling System Capacity
5.7Lit




Mixing ratio
Check the specific gravity of engine coolant in the cooling
system temperature ranges from 0C to 50C using a
suction type hydrometer, then determine the density of the
engine coolant by referring to the table.

NOTE: The LLC is 50% at all environment in order to prevent
the corrosion of cooling system parts.

ENGINE COOLING 6B-5
Diagnosis
Engine Cooling Trouble
Condition Possible cause Correction
Engine overheating Low Engine Coolant level Replenish
Thermo mater unit faulty Replace
Faulty thermostat Replace
Faulty Engine Coolant temperature
sensor Repair or replace
Clogged radiator Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of
improper engine oil Replenish or change oil
Clogged exhaust system Clean exhaust system or replace
faulty parts
Faulty Throttle Position sensor Replace throttle valve assembly
Open or shorted Throttle Position
sensor circuit Repair or replace
Damaged cylinder head gasket Replace
Loosen V-belt tension Adjust belt tension or replace.
Collapsed hoses Replace
Faulty Fan clutch Replace
Engine overcooling Faulty thermostat Replace
Engine slow to warm-up Faulty thermostat Replace
Thermo unit faulty Replace

ENGINE COOLING 6B-9
Thermostat





























Removal
1. Disconnect battery ground cable.
2. Drain engine coolant from the radiator and engine.
3. Disconnect radiator hose from the inlet pipe.
4. Remove thermostat housing.
5. Remove thermostat from thermostat housing.
Inspection
Suspend the thermostat in a water-filled container using thin
wire. Place a thermometer next to the thermostat.
Do not directly heat the thermostat.
Gradually increase the water temperature. Stir the water so
that the entire water is same temperature.
Confirm the temperature when the valve first begins to open.
Valve opening temperature 92
 C (197.6
 F)
Confirm the temperature when the valve is fully opened.
Valve full open temperature 107
 C(224.6
 F)
Make necessary repair and parts replacement if extreme wear
or damage is found during inspection.
Installation
1. Before installing thermostat, coat sealing surface with
silicon grease.
2. Install O-ring.
3. Install thermostat housing and tighten bolts to the specified
torque.
Torque: 15 N




m (1.5 kgf




m)
4. Installation rubber hose.
5. Replenish engine coolant (EC).
6. Start engine and check for EC leakage.













Fan Clutch with Cooling Fan
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage or any other abnormal condition are found through
inspection.

Visually inspect for damage, leak (silicon grease) or other
abnormal conditions.
1. Inspection (on-vehicle)
1) Turn the fan clutch by hand when in a low temperature
condition before starting the engine, and confirm that it
can be turned readily.
2) Start the engine to warm it up until the temperature at the
fan clutch portion gets to around 80C. Then stop the
engine and confirm that the fan clutch can be turned with
considerable effort (clutch torque) when turned by hand.

ENGINE COOLING 6B-13

Installation
1. Install radiator assembly, taking care not to damage the
radiator core.
2. Install the radiator assembly.
3. Connect reserve tank hose.
4. Connect radiator inlet hose and outlet hose.
5. Pour engine coolant up to filler neck of radiator, and up to
MAX mark of reserve tank.
Important operation (in case of 100% engine coolan
t
change) procedure for filling with engine coolant.

Remove radiator cap.

Fill with engine coolant (EC) to the radiator filler neck.

Fill with EC to the "MAX" line on the reservoir tank.

Start the engine with the radiator cap removed and bring to
operating temperature by running engine at 2,500 - 3,000
rpm for 30 minutes.

By EC temperature gauge reading make sure that the
thermostat is open.

If air bubbles come up to the radiator filler neck, replenish
with EC. Repeat until the EC level does not drop any further.
Install the radiator cap and stop the engine.

Replenish EC to the "MAX" line on the reservoir tank and
leave as it is until the engine gets cool.


After the engine gets cool, start the engine and make sure
there is no water running noise heard from the heater core
while the engine runs at 3000 rpm.

Should water running noise be heard, repeat the same
procedure from the beginning.


Main Data and Specifications
General Specifications
Cooling system Engine Coolant forced circulation
Radiator Tube type corrugated (2 tube in row)
Heat radiation capacity 66.3 kcal/h
Heat radiation area 7.08 m2
Radiator front area 028 m2
Radiator dry (weight) 3.1 kg
Radiator cap valve opening pressure 93.3 – 122.7 kpa
Engine coolant capacity 2.0L
Engine coolant pump Centrifugal type
Thermostat Bypass type
Engine coolant total capacity 5.7lit