engine ISUZU TF SERIES 2004 Workshop Manual

6A-74 ENGINE MECHANICAL (C24SE)

RTW46JSH000101









Air Cleaner Filter
NOTE:
The air cleaner filter is not damaged with the edge of the air
cleaner housing.

Removal
(2.4L)
1. Remove air cleaner cover and air cleaner element.
2. Remove air intake nose.
3. Remove lower air cleaner.
4. Remove mud guard.
5. Remove front fender cover.
6. Remove outside air intake duct.


Inspection
Check the air cleaner filter for damage or dust clogging.
Replace if it is damaged, or clean if it is clogged.


130RW002




Cleaning Method
Tap the air cleaner filter gently so as not to damage the paper
filter, or clean the element by blowing with compressed air of
about 490 kPa (71 psi) from the clean side if it is extremely
dirty.

Installation
(2.4L)
1. Install outside air intake duct.
2. Install front fender cover.
3. Install mud guard.
4. Install lower air cleaner.
5. Install air intake hose.
6. Install air cleaner element and air cleaner cover.

ENGINE MECHANICAL (C24SE) 6A-75









Spark Plug Thread
Recondition
Ream thread and recut using commercially available spark
plug thread drill (observe manufacturer's instructions).

Removal
Remove thread bush on spark plug. (dimensions (A) =
17mm/0.67in.)

Tighten (Torque)
Spark plug with thread bush into cylinder head - 25N

m (2.5
kgf
m) - use.

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

ENGINE MECHANICAL (C24SE) 6A-77

Cooling System
Radiator

Type: Cross-flow

Radiator core surface in cm
2: 2000

Cooling system capacity (in litres): 7.2



Anti-freeze Mixture
Anti-freeze Mixture

Required
Quantity Up to-10




C
Quantity in litres Up to-20




C
Quantity in litres Up to-30




C
Quantity in litres Up to-40




C
Quantity of litres
(in litres) Water
(80%) Anti-
Freeze
(20%) Water
(66%) Anti-
Freeze
(34%) Water
(56%) Anti-
Freeze
(44%) Water
(48%) Anti-
Freeze
(52%)
7.2 5.7 1.5 4.7 2.5 4.0 3.2 3.4 3.8



Cooling System (continued)
Fan

Type Visco Clutch Fan
Number of blades 5
Distribution of blades asymmetric
Diameter mm



Radiator cap

Boiling point 123
C
Opening pressure kPa (bar) 120 to 135 (1.20 to 1.35)



Thermostat

Start of opening 92
C
Fully opened 107
C
Type Bypassed



Idle Speeds, CO Content, Ignition
Adjustment

Applicable System Idle speed in min-1 (rpm)
Manual CO content
in vol. % Ignition timing in CA BTDC (adjustment
ensues at able speed,
ignition marks must align) with TDC
sensor measuring instrument:
Closed Loop System 825 *<0.4 *** 8 to 12
Open Loop System 825
**1.0+0.2
-0.5 *** 8 to 12
Note) * CO content adjustment not applicable.
** CO content adjustment refer to Section 6E1 (W/O catalytic converter system)
*** Ignition timing adjustment not possible.

6A-78 ENGINE MECHANICAL (C24SE)

Adjustment Values/Checking Values

Valve clearance
Inlet Hydraulic valve lash adjustment
Outlet No adjustment necessary

Spark plugs - electrode gap 1.0  1.1mm

Compression The difference in compression
between the individual cylinders
in the engine must not exceed
100 kPa (1 bar).

Pressure loss The pressure loss of an engine
in perfect condition per cylinder
is not more than max. 25%
























Cylinder Head
Cylinder Head Gasket
Thickness - installed mm 1.2

Valve seat width at cylinder head
inlet mm 1.0 to 1.5
outlet mm 1.7 to 2.2

Valve stem play inlet mm 0.018 to 0.052
outlet mm 0.038 to 0.072

Permissible valve stem to cone runout
inlet mm 0.03
outlet mm 0.33

Overall height of cylinder head
(Sealing surface to sealing surface) mm 95.5  0.25

Installation height
inlet and
outlet valves mm 17.85 to 18.25
dimension "A" Distance Gauge
5-8840-2596-0

Installation height valve guide mm 83.50 to 83.80

Sealing surface peak-to-valley height mm max. 0.025

ENGINE MECHANICAL (C24SE) 6A-79
Cylinder Head (continued)
Valve System

Valve lifter valve play compensator
(hydraulic)

Valve rotators
(inlet or outlet) outlet

Valve play
(warm or cold) inlet mm 0
outlet mm 0

Cylinder head height mm 280.30.075
Cylinder head bottom, face parallelism mm 0.05
Valve Dimensions
C24SE
A in mm B in
mm C(diameter in mm) and identification mark D
1) 2) Normal K Oversize K1
0.075 Oversize K2
0.150 Oversize A
0.250
Inlet valve 104.2 103.8 41.8 7.012
6.998 7.087
7.073 7.162
7.148 7.262
7.248 44

Outlet valve 104.0 103.6 36.5 6.992
6.978 7.087
7.053 7.142
7.128 7.242
7.228 44

Valve stem
bore - 7.050
7.030 7.125
7.105 7.200
7.180 7.300
7.280 -
1) Production
2) Customer service
The P and A department only supplies valves with a length of 103.8mm (inlet valve) and 103.6mm (outlet valve)
only



Camshaft
2.4L
Identification letter K

Colour code Normal size -
0.1mm undersize violet

Radial runout mm 0.03

End play mm 0.09 to 0.21

Cam lift Inlet and outlet valve mm 6.67

6A-80 ENGINE MECHANICAL (C24SE)
Grinding Dimension for Camshaft Bearing Position
Bearing Bearing journal
diameter in mm Diameter
in housing
normal -0.1mm normal -0.1mm
1 42.470
42.455 42.370
42.355 42.525
42.425 42.500
42.400

2 42.720
42.705 42.620
42.605 42.775
42.750 42.675
42.650

3 42.970
42.955 42.870
42.855 43.025
43.000 42.925
42.900

4 43.220
43.205 43.120
43.105 43.275
43.250 43.175
43.150

5 43.470
43.455 43.370
43.355 43.525
43.500 43.425
43.400

ENGINE MECHANICAL (C24SE) 6A-81
Crankshaft, Cylinder Block

Cylinder Grinding and Piston Dimensions
Size Cylinder bore dia. in mm Cylinder to Related piston dia. in mm Piston head
Crankshaft co- efficient
housing
co-efficient
over to over to
Production
(2.4L) 1 87.48
87.49 87.49
87.50 99
00 87.46
87.47 87.47
87.48 99
00
Customer
service
(2.4L) - 87.99 88.00 0+0.5 87.97 87.98 7+0.5
Piston diameter must be measured at the position "D".
*inclusive


Cylinder Bore
Rebore cylinder Permissible oversize to 0.5mm (see parts
microfiche)

After reboring, invalidate original crankcase
housing coefficient and drive in new oversize
coefficient

Permissible out-of-round: 0.013mm
Permissible taper: 0.013mm
Measure out-of-round in bore at 4 different
heights
Piston projection above upper edge of cylinder block
0.40mm

Piston
Type Recessed pistons

Clearance For short-blocks and cylinder blocks with
complete pistons, the clearance is 0.02 to
0.04mm

For replacement (oversize), depending on
available pistons, a clearance of 0.02 to
0.04mm is permissible

6A-82 ENGINE MECHANICAL (C24SE)
Crankshaft, Cylinder Block (continued)
Piston Rings
2.4L
Square ring Height mm 1.2

Tapered ring Height mm 1.5

Oil scraper Height mm 2.5

Ring gap offset 180


Note that the upper steel band ring gap is offset 25 to 50mm to
the left and the lower 25 to 50mm to the right opposite the
intermediate ring gap.

Piston Pin

Length mm 61.5
Diameter mm 21
Type Shrunk into con-rod
Play mm 2.4L
in piston 0.010-0.015
in con-rod none
Installation When installing piston pins,
heat con-rods to approx.
280
C in oil bath. This
temperature should under no
circumstances be exceeded.


Crankshaft, Cylinder Block (continued)
The permissible weight variation of con-rods without piston and
bearing shell inside an engine is 8 g.
As the con-rods do not have balancing studs, reworking is not
possible.
Con-rods can only be replaced in sets.

ENGINE MECHANICAL (C24SE) 6A-83
Crankshaft, Cylinder Block (continued)

Crankshaft
jounal
I, II, IV, V Guide
bearing
III Con-rod journal
1 to 4 Con-rod width
Diameter
mm Widtht
mm Diameter
mm Width
mm
mm
Normal size
Bearing journal and colour code from 57.9820 green
to 57.9885
> 57.9885 brown
to 57.9950
25.900
25.850
48.988
48.970
26.580
26.460
26.390
26.338

Bearing shell identification mark
Colour code and embossed Crankshaft bearing
I, II, IV, V Guide bearing
III Con-rod bearing
1 to 4
Identification mark brown-662N
green-663N brown-655N
green-658N

Crankshaft
jounal
I, II, IV, V Guide
bearing
III Con-rod journal
1 to 4 Con-rod width
Diameter
mm Widtht
mm Diameter
mm Width
mm
mm
0.25mm Undersize for Production and Customer Service
Bearing journal and colour code from 57.7320 green/
to 57.7385 blue
> 57.7385 brown/
to 57.7450 blue
26.100
26.050
48.738
48.720
26.580
26.460

Bearing shell identification mark
Colour code and embossed Crankshaft bearing
I, II, IV, V Guide bearing
III Con-rod bearing
1 to 4
Identification mark brown/blue-664 A
green/blue-655 A brown/blue-657 A
green/blue-658 A

Crankshaft
jounal
I, II, IV, V Guide
bearing
III Con-rod journal
1 to 4 Con-rod width
Diameter
mm Widtht
mm Diameter
mm Width
mm
mm
0.50mm Undersize Customer Service
Bearing journal and colour code from 57.4820 green/
to 57.4885 blue
> 57.4885 brown/
to 57.4950 blue
26.300
26.250
48.488
48.470
26.580
26.460

Bearing shell identification mark
Colour code and embossed Crankshaft bearing
I, II, IV, V Guide bearing
III Con-rod bearing
1 to 4
Identification mark brown/white-666 B
green/white-667 B brown/blue-659 B
green/blue-660 B