engine mechanical 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.

6A-28 ENGINE MECHANICAL (C24SE)


2. Install cable to temperature sensor.
3. Install upper bolts of rear toothed belt rear cover.
4. Install camshaft timing gear then check timing according
to the corresponding operation.
5. Install camshaft housing cover.
6. Install toothed belt and front cover.
7. Fill up and bleed cooling system according to the
corresponding operation.


Tighten (Torque)
Thermostat housing to cylinder head - 15 N
m/1.5 kgf
m.




Seal Ring - Front Camshaft Housing, Replace
Removal
Mark running direction of toothed belt.
Remove toothed belt-see operation “Toothed Belt, Replace”.

Camshaft housing cover, camshaft pulley-counterhold on hex
of camshaft.


Removal
Screw self-tapping screw into seal ring.

Edge out seal ring.

Installation
Lightly coat sealing lip of seal ring with protective grease.

Install seal ring with 5-8840-0451-0 into camshaft housing-use
screw and washer of camshaft pulley.

ENGINE MECHANICAL (C24SE) 6A-29









Installation
Camshaft pulley-counterhold at hex head of camshaft,
camshaft housing cover.

Toothed belt-see operation “Toothed Belt, Replace”.
Note operating erection of toothed belt.

Tighten (Torque)
Camshaft pulley to cammshaft-45 N

m (3.7 kgf

m)


Tighten (Torque)
Camshaft housing cover to cover to housing-8 N

m (0.8 kgf

m)

6A-30 ENGINE MECHANICAL (C24SE)

Toothed Belt Rear Cover
(Engine with toothed belt tension
roller)

Removal
1. Mark operating direction of toothed belt.
2. Remove toothed belt according to the operation "Toothed
Belt".
3. Remove toothed belt tension roller according to the
operation "Toothed Belt Tension Roller ".



4. Remove fastening bolt while counterholding with 5-8840-
2598-0 (Holding wrench).


5. Remove toothed belt drive gear while counterholding with
5-8840-2598-0 (Holding wrench).
6. Remove camshaft housing cover.
7. Remove camshaft pulley while counterholding at hex
head of camshaft.


8. Remove toothed belt rear cover (arrows) from oil pump
and camshaft housing.

ENGINE MECHANICAL (C24SE) 6A-31







Installation
1. Install toothed belt rear cover.
2. Install camshaft pulley while counterholding at camshaft
hex head.
3. Install camshaft housing cover.

Tighten (Torque)
Toothed belt rear cover to oil pump and camshaft housing - 6
N

m/4 lbf ft.
Camshaft housing cover to housing - 6 N

m (0.6 kgf

m).
Camshaft pulley to camshaft - 45 N

m (4.6 kgf

m).



4. Install toothed belt drive gear to crankshaft - 130 N

m
(13.3 kgf

m).
5. Install toothed belt according to the operation "Toothed
Belt".



Toothed Belt Tension Roller
Removal
1. Mark operating direction of toothed belt.
2. Remove toothed belt according to the operation "Toothed
Belt”.
3. Remove toothed belt tension roller (1) from oil pump.










Installation
1. Install toothed belt tension roller and make sure that the
locking lever (1) engages in the guide lugs (arrowed) on
the oil pump housing.
2. Install toothed belt according to the operation "Toothed
Belt" with paying attention to the operating direction of
toothed belt.

Tighten (Torque)
Toothed belt tension roller to oil pump - 25 N
m (2.5 kgf
m)

6A-32 ENGINE MECHANICAL (C24SE)
COMPONENT PARTS
CYLINDER HEAD
(A)

1. Camshaft Housing Cover
2. Camshaft Housing
3. Camshaft
4. Cylinder Head
(A) Valve Drive

ENGINE MECHANICAL (C24SE) 6A-33
HYDRAULIC VALVE LIFTER

1. Hydraulic Valve Lifter
1. Oil reservoir
2. Piston with ball head (moving)
3. Pressure cylinder (fixed)
4. Check ball
5. Pressure chamber
6. Oil feed

6A-34 ENGINE MECHANICAL (C24SE)
OPERATIONS ON CYLINDER HEAD AND CAMSHAFT
HOUSING
Camshaft



Removal
1. Remove cylinder head according to the corresponding
operation.
2. Remove camshaft housing from cylinder head and lay
housing on base provided
3. Remove rear sealing gasket and plate camshaft housing
with taking care not to damage housing.
4. Remove thrust plate.





5. Remove camshaft.
6. Remove front sealing gasket and plate from camshaft
housing with taking care not to damage housing.

Inspection
All parts.







Installation
1. Install camshaft.
2. Coat sliding surfaces with molybdenum disulphate paste.

Tighten (Torque)
Thrust plate for camshaft housing - 8 N

m (0.8 kgf

m)

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.

6A-36 ENGINE MECHANICAL (C24SE)



















Clean
All sealing surfaces, drill holes in cylinder head bolts.

Check cylinder block and cylinder head for plane surface
according to the corresponding operations.

Installation
1. Install cylinder head sealing with marking "OBEN/TOP"
facing upwards and to right side of engine.
2. Install cylinder head on cylinder block.
3. Install hydraulic valve lash adjuster, pressure parts and
rocker arm - molybdenum disulphate paste.
4. Install camshaft housing-Sealing Compound TB-1207C
or equivalent.

Important!
Use new cylinder head bolts.
Screw in bolts until they rest on cover.



Torque - Angle Method
Cylinder head to cylinder block - 25 N

m (2.5 kgf

m)
Further turn angle 90
+90
+ 90
.
Tighten cylinder head bolts from inside outwards. In four
stages in a spiral pattern.









5. Install rear toothed belt cover onto camshaft housing.
6. Install toothed belt and apply tension according to the
corresponding operation.

Tighten (Torque)
Camshaft timing gear to camshaft - 45 N

m (4.6 kgf

m)




7. Install camshaft housing cover and front toothed belt
cover.
8. Install cable connections, all hoses and lines onto
cylinder head.
9. Adjust accelerator cable for free of play.
10. Install V-belt according to the corresponding operation.
11. Install air intake hose.
12. Install front exhaust pipe.
13. Install ground cable onto battery.
14. Fill up cooling system and bleed according to the
corresponding operation.