lock ISUZU TF SERIES 2004 Workshop Manual

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

ENGINE MECHANICAL 6A – 113




RTW31BSH000401

8) Insert the bolts of the special tool into the rear gear
setting hole. Rotate the rear gear to mesh the teeth
of main gear and rear gear.
9) Insert a lock bolt (M6  1 L=30) into scissors gea
r
fixing hole to prevent the scissors gear from turning.
10) Place the main gear in a vise with copper plate so
that the front side of the main gear facing up.
11) Repeat steps 4 to 8 to install the front gear.
12) Lock the front gear, the main gear, and the rear gea
r
with lock bolt (inserted at Step 8).

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

6B – 16 ENGINE COOLING

P1010064
Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug to drain EC.
3. Disconnect oil cooler hose on automatic transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose from the engine.





PTW46BSH000101
5. Remove fan guide(1), clips(2) on both sides and the bottom
lock, then remove lower fan guide(3) with fan shroud(4).
6. Disconnect the reserve tank hose(6) from radiator.





RTW36BMH000101
7. Remove bracket(5).

8. Lift up and remove the radiator assembly with hose, taking
care not to damage the radiator core with a fan blade.

6C – 12 FUEL SYSTEM
FUEL GAUGE UNIT
Fuel Gauge Unit and Associated Parts


RTW46CLF000501

Legend

1. Fuel Feed Port
2. Fuel Return Port

3. Fuel Emission Port

4. Fuel Gauge Unit and Sender Assembly

5. Connector; Fuel Gauge Unit


6. Fuel Tube/Quick Connector
7. Retainer Ring (Fuel Gauge Unit Lock)
8. Seal; Fuel Gauge Unit
9. Fuel Tank Assembly
10. Evapo Tube/Quick Connector

FUEL SYSTEM 6C – 13

Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system for
loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission".
1. Remove fuel tank assembly (9). Refer to “Fuel Tank
Removal" in this section.
2. Disconnect the quick connector (6) of the fuel tube from fuel
gauge unit.
3. Disconnect the quick connector (10) of the evapo tube from
fuel gauge unit.


140R100035

3. Remove the retainer ring (7) from the fuel tank with the
removal tool 5-8840-2602-0.
4.
Remove slowly the fuel gauge unit (4) from the fuel tank as
no bend float arm.
NOTE: Cover opening for the fuel gauge unit on fuel tank to
prevent any dust entering.
5.
Discard fuel gauge unit seal (8) because it cannot be
reusable.


Installation
1. Clean the seal surface of the fuel tank and the fuel gauge
unit.
NOTE: If there is dust on the seal surface, it becomes cause o
f
fuel leak.
2. Install the new fuel gauge unit seal (8) to opening of the fuel
tank as along the groove.
3. Install slowly the fuel gauge unit (4) into the fuel tank as no
bend float arm.
4.
Set flange of the fuel gauge unit on fuel gauge unit seal as
mating convexity of the fuel gauge unit and reentrant of the
fuel tank.
5.
Lock slowly the retainer ring (7) to the fuel tank with the
remover tool 5-8840-2602-0.
6. Connect the quick connector (10) of the evapo tube from
fuel gauge unit.
7.
Connect the quick connector (6) of the fuel tube to to gauge
unit.
NOTE: Pull off the left ckecker of the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.

6C – 16 FUEL SYSTEM


140R100037

2. For removal of the quick connector, hold the quick
connector in one hand, and pull out the connector with the
other hand while pressing the square relieve button of the
connector, as illustrated.
NOTE: Do not use tools of any kind. Only use bare hands
when disconnecting the connector. Use a lubricant (light oil)
and/or push and pull the connector until the pipe is
disconnected.




140R100028

Cover the connectors that was removed with a plastic bag,
to prevent dust or rain water from entering.




140R100036
Reuse of Quick–Connector


Replace the port and connector if scratch, dent or crack is
found.

Remove any dirt build up on the port when installing the
connector. Replace the connector, if there is any forms o
f
rust, dent, scratch.


After cleaning the port, insert it straight into the connector
until it clicks. After it clicks, try pulling at 49N (5kgf) it out to
make sure that it is not drawn and is securely locked.


Assembling Advice
By applying engine oil or light oil to the pipe, port makes pipe
assembly easier. The pipe assembly should take place
immediately after applying oil (to prevent dust from sticking to
the pipe surface – which may decrease sealing ability).
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Start the engine and observe the engine idle speed. The
presence of dirt in the fuel system may affect the fuel
injection system.
3. Check for fuel leakage from the connector.

FUEL SYSTEM 6C – 21


020L200017


RTW46CSH000201
18. Timing Check Hole Cover
1) Remove the timing check hole cover.
2) For ease in reinstalling the injection pump, align the
timing mark on the timing gear case cover by turning
the crankshaft using wrench.
And bring the piston in the No.1 cylinder to TDC on the
compression stroke by turning the crankshaft until the
crankshaft pulley TDC line aligned with the timing
mark.
Note:
If the check hole cover is reinstalled with the lock bolt
still in place, the crank pulley will not turn.


6C-7
3) Insert the lock bolt (M6 x 30) into the scissors gear idle
gear “B” fixing hole to prevent the scissors gear from
turning.


29. Injection Pump Bracket
20. Injection Pump

6C – 22 FUEL SYSTEM


RTW46CSH000201
Installation


1. Injection Pump
1) Install the injection pump gear (When gear is
removed).
Injection Pump Gear Nut N
m (kg
m/lb ft)
64 (6.5 / 47)
2) Bring the piston in the No.1 cylinder to TDC on the
compression stroke by turning the crankshaft until the
crankshaft pulley TDC line aligned with the timing
mark.


020L200017






3) Install the injection pump to the timing gear case with
align the timing mark on the pump gear to the arrow
mark on the timing gear case cover.
4) Check that the setting marks of the injection pump
gear and the idler gear B are aligned.
5) Remove the lock bolt (M6 
30) from the idle gear “B”.

6C-7




6) Tighten the injection pump fixing bolts to the specified
torque.
Injection Pump Bolts Torque N·m (kg·m/lb ft)
19 (1.9 / 14)