oil ISUZU TF SERIES 2004 Workshop Manual

6A – 106 ENGINE MECHANICAL


7. Camshaft
1. Apply a coat of engine oil to the camshaft and the
camshaft bearings.
2. Install the camshaft to the cylinder body.
Take care not to damage the camshaft bearings.











8. Timing Gear Case
Tighten the timing gear case with timing gear case gasket
to the specified torque.


Timing Gear Case Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)











9. Camshaft Thrust Plate
Install the thrust plate to the cylinder body and tighten the
thrust plate bolts to the specified torque.


Thrust Plate Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)




RTW36ASH000901









10. Camshaft Timing Gear
1. Install the camshaft timing gear to the camshaft. The
timing gear mark must be facing outward.
2. Tighten the timing gear to the specified torque.


Timing Gear Bolt Torque N·m(kg·m/lbft)
110 (11.2/82)
014RY00019
020R300003
020RY00032

ENGINE MECHANICAL 6A – 107


RTW36ASH002001




11. Piston and Connecting Rod with Upper Bearing
12. Connecting Rod Bearing Cap with Lower Bearing
1. Apply a coat of engine oil to the circumference of each
piston ring and piston.
2. Position the piston ring gaps as shown in the
illustration.
1. Oil ring
2. 2nd compression ring
3. 1st compression ring










3. Apply a coat of molybdenum disulfide grease to the two
piston skirts.
This will facilitate smooth break-in when the engine is
first started after reassembly.
4. Apply a coat of engine oil to the upper bearing
surfaces.
5. Apply a coat of engine oil to the cylinder wall.














6. Position the piston head front mark so that it is facing
the front of the engine.
7. Use the piston ring compressor to compress the piston
rings.
Piston Ring Compressor: 5-8840-9018-0
8. Use a hammer grip to push the piston in until the
connecting rod makes contact with the crankpin.
At the same time, rotate the crankshaft until the
crankpin is at BDC.



9. Align the bearing cap cylinder number marks and the
connecting rod cylinder number marks.
The cylinder number marks must be turned toward the
exhaust manifold.



015LX096
015R100007015R100006

6A – 108 ENGINE MECHANICAL











10. Apply a coat of engine oil to the threads and setting
faces of each connecting rod cap bolt.
11. Tighten the connecting rod caps to the two step of
anglar tigthen method.


Connecting Rod Bearing Cap Bolt Torque N·m (kg·m/Ib ft)
4JA1T (L),
4JA1TC 78-88 (8.0/57 – 9.0/65)
1st step ; 29.0–29.2 (3.00/22.0–3.01/22.2)4JH1TC
2nd step ; 45
-60







13. Piston Cooling Oil Jet
1. Install the piston cooling oil jet to the cylinder body.
2. Tighten the oil jet bolts and relief valve to the specified
torque.


Oil Jet Bolt Torque N·m(kg·m/lbft)
M8  1.25 19 (1.9/14)
M6  1.00 8 (0.8/6)


Relief Valve Torque N·m(kg·m/lbft)
29 (3.0/22)

NOTE:
Check that there is no interference between the piston
and the oiling jet by slowly rotating the crankshaft.












14. Oil Pump with Oil Pipe
Install the oil pump with the oil pipe and tighten the bolts to
the specified torque.


Oil Pump Bolt Torque N·m(kg·m/lbft)
19 (19/14)

NOTE:
Take care not to damage the O-rings when tightening
the oil pipe bolts.







15. Crankshaft Rear Oil Seal
Use a oil seal install to install the crankshaft rear oil seal.
Oil Seal Installer : 5-8840-2359-0


015LX130
015LX112 052LX010
051R100004

ENGINE MECHANICAL 6A – 109



16. Crank Case
1. Apply the recommended liquid gasket (Three bond
1207B) or its equivalent to arch gasket fitting surface
as shown in the illustration.
2. Install the crankcase front gasket (1) to the timing gear
case arches.
The gasket projection (2) must be facing forward.
NOTE:
ThreeBond 1207B is a fast-drying liquid gasket.
Install the arch packing to the crankcase immediately
aftter applying the gasket.










3. Install the rear arch gasket (2) to the No. 5 bearing
cap. Use your fingers to push the arch gasket into the
bearing cap groove.Take care not to scratch the arch
gasket outer surface.
Also apply the recommended liquid gasket (1207C) or
its equivalent to arch gasket fitting area as indicated in
the illustration.






4. Apply the recommended liquid gasket or its equivalent
to groove of the crankcase fitting surface as shown in
the illustration.

NOTE:
Be sure that the crank case fitting surface is
completely free of oil and dust before applying the
liquid gasket.












5. Install the crank case to the cylinder body.
6. Tighten the crank case bolts to the specified torque a
little at a time in the sequence shown in the illustration.


Crank Case Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)

013LV003 013RW012
013RW011
013R100001

6A – 110 ENGINE MECHANICAL









17. Cylinder Body Rear Plate
1. Align the rear plate with the cylinder body knock pins.
2. Tighten the rear plate to the specified torque.


Rear Plate Torque N·m(kg·m/lbft)
82 (8.4/61)














18. Flywheel
1. Apply a coat of engine oil to the threads of the flywheel
bolts.
2. Align the flywheel with the crankshaft dowel pin.
3. Tighten the flywheel bolts in the numerical order shown
in the illustration.
Gear stoper: 5-8840-0214-0


Flywheel Bolt Torque N·m(kg·m/lbft)
118 (12/87)











19. Crankshaft Timing Gear
Use the crankshaft timing gear installer (1) to install the
crankshaft timing gear (2).
The crankshaft timing gear setting mark must be facing
outward.
Crankshaft Timing Gear Installer: 9-8522-0020-0


















20. Idler Gear Shaft
21. Idler Gear "A"
1. Turn the crankshaft clockwise to set the DTC of the
No.1 piston.
2. Apply engine oil to the idler gear and the idler gear
shaft.
The idler gear shaft oil hole (A) must be facing up.
3. Position the idler gear setting marks so that they are
facing the front of the engine.


015LX113 020R100001
020RY00034
020RY00035

ENGINE MECHANICAL 6A – 111
























4. Align the idler gear setting mark with the crankshaft
timing gear (1) setting mark.
5. Align the idler gear setting mark with the camshaft
timing gear (2) setting mark.
6. Install the thrust collar and bolts to the cylinder body
through the shaft.
The thrust collar oil hole must be facing up, and the
thrust collar chamfered must be outward.
7. Tighten the idler gear bolt to the specified torque.


Idler Gear "A" Bolt Torque N·m(kg·m/lbft)
30 (3.1/22)

020R300006











22. Idler Gear "B" and Shaft
1. Apply engine oil to the idler gear and the idler gear shaft.
2.
Align the idler gear "B" (3) setting mark with the idler
gear "A" (4) setting mark.
3. Tighten the idler gear bolt to the specified torque.
4. Be sure to remove the lock bolt (5) from idle gear “B”.


Idler Gear "B" Bolt Torque N·m(kg·m/lbft)
76 (7.7/56)




020L200019

5. If the idle gear "B" is disassembled, reassemble in the
following procedure.
1) Drive pins into the main gear, the front gear, and the
rear gear.





020L200007

2) Install the main gear bearing from the front side of
the main gear (the side with the groove).
3) Place the main gear in a vise with copper plate so
that the rear side of the main gear facing up.
020RY00036

6A – 116 ENGINE MECHANICAL


27. Cylinder Head Gasket
The cylinder head gasket "TOP" mark must be facing up.

NOTE:
Before the gasket installation, measure the piston
head projection and select the appropriate head
gasket.
Refer to "INSPECTION AND REPAIR", "Cylinder Head
Gasket Selection".









28. Cylinder Head
1. Align the cylinder body dowels and the cylinder head
dowel holes.
Carefully place the cylinder head on the cylinder head
gasket.
2. Apply a coat of engine oil to the cylinder head bolt
threads and setting faces.















3. Tighten the cylinder head bolts in three steps of anglar
tightening methed.
Follow the numerical sequence shown in the
illustration.


Cylinder Head Bolt Torque N·m(kg·m/lbft)
1st step 49 (5.0/36)
2nd step
60
- 75

3rd step
60
- 75













30. Rocker Arm Shaft and Rocker Arm
Tighten the rocker arm shaft bracket bolts in the numerical
order shown in the illustration.


Rocker Arm Shaft Braket Bolt Torque N·m(kg·m/lbft)
54 (5.5/40)











31. Thermostat Housing
1. Install the thermostat housing.
2. Tighten the thermostat housing bolts to the specified
torque.


Thermostat Housing Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)

014LX083 011LX073
031R300002

ENGINE MECHANICAL 6A – 117


RTW46ASH001201
33. Injection Nozzle Holder
1. Install the injection nozzle gasket and the O-ring to the
injection nozzle holder.
Be sure that the O-ring fits snugly in the injection
nozzle groove.
2. Install the nozzle holder toghther with the nozzle holder
bracket to the cylinder head.










3. Tighten the nozzle holder bracket bolt to the specified
torque.


Injection Nozzle Holder Bracket Bolt
Torque N·m(kg·m/lbft)
37 (3.8/28)













Note on Valve Clearance Adjustment
Valve clearances must be adjusted before the cylinder
head cover is reinstalled.Refer to "Valve Clearance
Adjustment" in the "Servicing" Section of this manual.


Valve Clearance (At Cold) mm(in)
0.4 (0.0157)


RTW46ASH001101















34. Cylinder Head Cover
1. Apply engine oil to the rocker arm and the valve spring.
2. Install the cylinder head cover gasket to the head
cover. Check to see that the head cover gasket has no
loose areas.
3. Tighten the cylinder head cover nuts in the numerical
order shown in the illustration.


Cylinder Head Cover Bolt Torque N·m(kg·m/lbft)
13 (1.3/9.4)
4. Connect the positive crankcase ventilation (PCV) hose
to the cylinder head cover.




014RY00015

6A – 118 ENGINE MECHANICAL

INSTALLATION
EXTERNAL PARTS





RTW36AMF000701
Installation Steps
1.
Exhaust Manifold 18. Engine Mounting Bracket and
2.
Oil Cooler with Oil Filter Foot
3. Generator Bracket 19. Intake Manifold
4. Water Inlet Pipe 20. Power Steering Oil Pump
5.
Generator and Adjusting Plate Bracket
6.
Vacuum Pump Oil Return Hose 21. Fuel Injection Pipe with Clip
7.
Compressor Bracket 22. Fuel Filter Bracket (Except
EURO III)
8. Turbocharger 23. Fuel Filter Assembly (Except
EURO III)
9. Catalytic Converter 24. Oil Level Gauge
10. Heat Protector 25. EGR Valve
11. Cooling Fan Pulley 26-1. EGR Pipe
12. Oil Cooler Water Pipe 26-2. EGR Cooler (EURO III model
only)
13. Fuel Leak Off Pipe 27. Intake Pipe and Throttle Body
(4JA1TC/4JH1TC only)
14. Oil Pressure Warning Switch 28. Clutch Assembly or Flex Plate
15. Starter Motor
16. Injection Pump
17. Injection Pump Cover

ENGINE MECHANICAL 6A – 119












Installation
1. Exhaust Manifold
1) Install the exhaust manifold to the cylinder head with
the manifold gasket.
2) Tighten the exhaust manifold bolts and nuts to the
specified torque a little at a time.
Exhaust Manifold Bolt and Nuts
Torque N·m(kg·m/Ib ft)
27 (2.7/20)




3) Install the exhaust manifold bracket to the manifold
and the cylinder body.
Manifold Bracket Bolt Torque N·m(kg·m/Ib ft)
19 (1.9/14)






RTW46ASH001301









2. Oil Cooler with Oil Filter
1) Install the O-ring to the oil filter body flange groove.
2) Install the oil filter body to cylinder block and tighten to
the specified torque.
Oil Filter Body Bolt and Nut
Torque N·m(kg·m/Ib ft)
BOLT 19 (1.9/14)
NUT 24 (2.4/17)









3. Generator Bracket
Install the generator bracket to the cylinder body and
tighten the bracket bolts to the specified torque.
Bracket Bolt Torque N·m(kg·m/Ib ft)
40 (4.1/30)




027R100003
027R100004
066RY00001