oil ISUZU TF SERIES 2004 Workshop Manual

6A – 120 ENGINE MECHANICAL









4. Water Inlet Pipe
1) Tighten the water inlet pipe bolts to the specified
torque.
Suction Pipe Bolt Torque N·m(kg·m/Ib ft)
19 (1.9/14)





5. Generator and Adjusting Plate
1) Install the generator to the bracket (1).
2) Temporarily tighten the generator bolt (2) and
adjusting plate bolts (3).
The bolts will be finally tightened after installation of
the cooling fan drive belt.



3) Connect the vacuum pump rubber hose (4) to the
vacuum pump (5), and the oil pan (6).
6. Vacuum Pump Oil Return Hose
Connect the vacuum oil pipe (7) to the vacuum pump, and
the cylinder body

052R300001
7. Compressor Bracket
1) Install the compressor bracket to the cylinder head.
2) Tighten the bracket bolts to the specified torque.
Bracket Bolt Torque N·m(kg·m/Ib ft)
M8
1.25
19 (1.9/14)
M10
1.25
40 (4.1/30)











066RY00002 032R300001
042RY00003

ENGINE MECHANICAL 6A – 121
















8. Turbocharger
1) Install the turbocharger and the gasket.
2) Temporarily tighten the turbocharger nuts at this time.
They will be fully tightened after the installation of the
turbocharger oil pipe.
Always install new nuts and new gasket.











3) Install the oil return pipe with gasket to the
turbocharger.
4) Tighten the turbocharger oil return pipe to the
specified torque.
Bracket Bolt Torque N·m(kg·m/Ib ft)
8 (0.8/6)




5) Before installing the oil feed pipe, supply 10 - 20 cc of
clean engine oil to the turbocharger center housing
through the oil feed opening.
6) Turn the rotating assembly with your hand to
thoroughly lubricate the internal parts.
7) Tighten the oil feed pipe to the specified torque.
Turbocharger Oil Feed Pipe Joint
Bolt Torque N·m(kg·m/Ib ft)
M10
1.5
22 (2.25/16)
M14
1.5
54 (5.5/40)

RTW46ASH001501

















8) Tighten the turbocharger nut to the specified torque.
Turbocharger Nut Torque N·m(kg·m/Ib ft)
27 (2.7/20)




036R100001
027R100005027R100002

6A – 122 ENGINE MECHANICAL

















RTW46ASH001601































9) Install the water feed adapter (1) with the gaskets to
turbocharger and tighten to the specified torque.
Adapter Torque N·m(kg·m/Ib ft)
39 (4.0/29)

10) Install the water feed pipe with the gaskets and tighten
to the specified torque.
Water Return Pipe Torque N·m(kg·m/Ib ft)
39 (4.0/29)

11) Install the water return pipe with the gaskets and
tighten to the specified torque.
Water Return Torque N·m(kg·m/Ib ft)
39 (4.0/29)

12) Clamp the water feed pipe to the oil return pipe of the
turbocharger.
Fixing Bolt (3) Torque N·m(kg·m/Ib ft)
8 (0.8/6)

13) Install the hoses for the water feed and return.






















9. Catalytic Converter
Install the catalytic converter with gasket and tighten the
nut to the specified torque.
Catalytic converter Nut Torque N·m(kg·m/Ib ft)
27 (2.7/20)

Do not install the catalytic converter, if drop down it.
10. Heat Protector
Install the heat protector and tighten the bolt to the
specified torque.
Heat Protector Bolt Torque N·m(kg·m/Ib ft)
9 (0.9/6.5 Ib in)

033R300002











11. Cooling Fan Pulley
1) Install the cooling fan pulley to the water pump.
2) Tighten the cooling fan pulley nuts to the specified
torque.
Pulley Nut Torque N·m(kg·m/Ib ft)
8 (0.8/6)

12. Oil Cooler Water Pipe
13. Fuel Leak Off Pipe
14. Oil Pressure Warning Switch
027R100007

6A – 124 ENGINE MECHANICAL
20. Power Steering Oil Pump Bracket
Oil Pump Braket Nut and Bolt Torque N·m(kg·m/Ib ft)
1M10
1.25
37 (3.8/28)
2
3M8
1.25
18 (1.8/13) (Bolt ID:8)






040R300005























21. Fuel Injection Pipe with Clip
1) Temporarily tighten the injection pipe sleeve nut.
2) Set the clip in the illustrated position.
Note:
Make absolutely sure that the clip is correctly
positioned.
An improperly positioned clip will result in injection
pipe breakage and fuel pulsing noise.
3) Tighten the injection pipe sleeve nut to the specified
torque.
Torque
Injection Pump Side (4JA1TC/4JH1TC) N·m(kg·m/Ib ft)
40 (4.1/30)

Injection Pipe Sleeve Nuts N·m(kg·m/Ib ft)
29 (3.0/22)

Injection Pipe Clip Nuts N·m(kg·m/Ib ft)
8 (0.8/6)




















22. Fuel Filter Bracket (Except EURO III model)
Install the fuel filter bracket and tighten fixing bolts to the
specified torque.
Fuel Filter Bracket Bolt Torque N·m(kg·m/Ib ft)
21 (2.1/15)

23. Fuel Filter Assembly (Except EURO III model)
Install the fuel filter assembly and tighten fixing bolts to the
specified torque.
Fuel Filter Assembly Bolt Torque N·m(kg·m/Ib ft)
21 (2.1/15)








24. Oil Level Gauge
Install the oil level gauge and tighten fixing bolts to the
specified torque.
Oil Level Gauge Bolt Torque N·m(kg·m/Ib ft)

M8 19 (1.9/14)
M6 8 (0.8/6)

431RY00013

6A – 126 ENGINE MECHANICAL


LUBRICATION SYSTEM
LUBRICATING OIL FLOW









1. Oil Pump Relief Valve Operating Pressure: 6.2 - 7.8kg/cm 2 (608 - 764Kpa)
2. Regulating Valve Operating Pressure: 5.7 - 6.3kg/cm 2 (558.6 - 617.4Kpa)
3. Oil Cooler Relief Valve Opening Pressure: 2.8 - 3.4kg/cm 2 (270 - 330Kpa)
4. Oil Filter Relief Valve Opening Pressure: 0.8 - 1.2kg/cm 2 (78.4 - 117.6Kpa)
5. Oil Pressure Switch Operating Pressure: 0.3 - 0.5kg/cm 2 (29.4 - 49.0Kpa)
6. Regulating Valve: 1.8 - 2.2kg/cm 2 (176 - 216Kpa)

The 4J series engine has a full flow type lubricating system.
Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil cooler and the oil filter. It is
then delivered to the vital parts of the engine from the cylinder body oil gallery.
Oiling jets installed on the cylinder body spray engine oil to the piston backside faces to achieve maximum piston
cooling effect.

ENGINE MECHANICAL 6A – 127

OIL PUMP AND OIL FILTER




RTW46ALF001501

The 4J series engine is equipped with a gear type oil pump.
The oil filter and the water cooled oil cooler integrated a single unit to increase the cooling effect.

6A – 128 ENGINE MECHANICAL
OIL PUMP
DISASSEMBLY



















Disassembly Steps
1.
Oil pipe 5.
Driven gear
2.
Strainer 6. Relief valve assembly
3. Pump cover 7. Pinion gear
4. Driven gear with bushing 8. Oil pump body
Disassembly procedure is shown in the illustration above numerical order.
051R100005

ENGINE MECHANICAL 6A – 129

INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
Gear Teeth and Body Inner Wall Clearance
Use a feeler gauge to measure the clearance between the
gear teeth and the body inner wall.
If the clearance between the gear teeth and the body inner
wall exceeds the specified limit, either the gear or the body
must be replaced.
Gear Teeth and Body Inner Wall Clearance mm (in)
Standard Limit
051RY00001 0.14 (0.0055) 0.20 (0.0079)

Gear and Body Clearance
Use a feeler gauge to measure the clearance between the
body and the gear.
If the clearance between the gear and the body exceeds
the specified limit, the body must be replaced.
Gear and Body Clearance mm (in)
Standard Limit




RTW46ASH002701
0.06 (0.024) 0.15 (0.0059)

Drive Shaft and Oil Pump Body Clearance
Use a micrometer to measure the drive shaft outside
diameter.
Use an inside dial indicator to measure the pump body
inside diameter.
If the clearance between the drive shaft and the oil pump
body exceeds the specified limit, the oil pump assembly
must be replaced.
Drive Shaft and Oil Pump Body Clearance mm (in)
Standard Limit
0.04 (0.0016) 0.20 (0.0079)
051RY00003

6A – 130 ENGINE MECHANICAL

REASSEMBLY

























Reassembly Steps
1.
Oil pump body 5.
Pinion gear
2.
Drive gear 6. Strainer
3. Driven gear 7. Relief valve assembly
4. Pump cover 8.
Oil pipe
Reassembly procedure is shown in the illustration above numerical order.
Pump cover fixing bolts torque: 16 N·m (1.6 kg·m/12 lb ft)
051R100006

ENGINE MECHANICAL 6A – 131

OIL FILTER AND OIL COOLER
DISASSEMBLY






























Disassembly Steps
1.
Oil filter cartridge 5.
Body
2.
Bolt 6. Oil cooler relief valve
3. Gasket 7. Regulating valve
4. Oil cooler
Disassembly procedure is shown in the illustration above numerical order.
050R300004