service ISUZU TF SERIES 2004 Workshop Manual

ENGINE MECHANICAL (C24SE) 6A-3
PAGE
ENGINE EXTERNAL PARTS ............................................................................................ 6A-65
Radiator ....................................................................................................................... 6A-65
Thermostat................................................................................................................... 6A-66
Water Pump ................................................................................................................. 6A-66
Coating sealing surfaces with Silicone Grease ....................................................... 6A-67
Alternator ..................................................................................................................... 6A-67
Starter .......................................................................................................................... 6A-67
V-belt Tension of Alternator ....................................................................................... 6A-68
FUEL INJECTION SYSTEM.............................................................................................. 6A-69
Map Sensor.................................................................................................................. 6A-69
Pressure Regulator ..................................................................................................... 6A-69
ECM (Engine Control Module).................................................................................... 6A-69
ECT ............................................................................................................................... 6A-70
Idle Air Control(IAC) Valve.......................................................................................... 6A-70
Ignition Coil ................................................................................................................. 6A-70
Crank Position Sensor................................................................................................ 6A-71
FUEL INJECTOR .............................................................................................................. 6A-72
Knock Sensor .............................................................................................................. 6A-72
Oxygen Sensor ............................................................................................................ 6A-73
Throttle Valve Position Sensor .................................................................................. 6A-73
Acclelerator Pedal and Cable..................................................................................... 6A-73
Air Cleaner Filter ......................................................................................................... 6A-74
Spark Plug Thread ...................................................................................................... 6A-75
TECHNICAL DATA ........................................................................................................... 6A-76
Recommended Troque Values................................................................................... 6A-87
SPECIAL SERVICE TOOL................................................................................................ 6A-88

6A-4 ENGINE MECHANICAL (C24SE)
GENERAL DESCRIPTION

Engine Cleanliness And Care
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances
that are measured in the thousandths of a millimeter (ten thousandths of an inch). Accordingly, when any internal
engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that
proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is
considered standard shop practice even if not specifically stated.

A liberal coating of engine oil should be applied to all friction areas during assembly to protect and lubricate
the surfaces on initial operation.

Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft journal
bearings are removed for service, they should be retained in order.


At the time of installation, they should be installed in the same locations and with the same mating surfaced as
when removed.

Battery cables should be disconnected before any major work is performed on the engine. Failure to
disconnect cables may result in damage to wire harness or other electrical parts.

The four cylinders of this engine are identified by numbers; cylinders 1, 2, 3 and 4, as counted from crankshaft
pulley.
General Information on Engine Service
The following information on engine service should be noted carefully, as it is important in preventing damage and

ENGINE MECHANICAL (C24SE) 6A-13
Valve System C24SE
Actuation Type Direct-acting Inverted Bucked Tappet
Valve Clearance Adjustment Hydraulic
Valve Rotor Type None
Inlet-Valve Material Chromium Alloyed Steel
-Seat Insert Material Sintered Iron
Exhaust-Valve Material Head: Cr-Mn-Ni Alloyed Shaft: Cr-Si Alloyed &Cr plated
-Seat Insert Material Sintered Iron
Valve Spring Material GME 06 100-C1
Valve Guide Material QS 13 MR 00
Valve Seal Type Lip

Water Pump C24SE
Type Centrifugal
Drive-Material &Type HNBR Toothed-belt
Bearing Type Double Row Ball
Shaft Seal Type Mechanical Ceramic

Thermostat-Coolant C24SE
Type Bypass

Oil Pump & Filter C24SE
Type Gear Pump
Location Front of Engine
Drive Direct Crankshaft Driven
Filter Type Full Flow with Bypass for blocked filter

Oil & Oil Reservoir C24SE
Reservoir-Description & Location 1-piece below Engine
Reservoir Material Aluminum Alloy (pressure cast)
Replacement Oil Fill Volume
-With Filter change 4.25liters
-Without Filter change 4.00liters
Recommended Oil-Run-in 10W/30SG
-Service (above-18C) 10W/40SG
-Service (below-18C) 5W/30SG
Oil Classification API&CCMC

Ignition Components C24SE
Spark Plugs Conventional
Type Electronic Spark Control
No. of Coils &Type 2 Solid State
Coil Location Engine-mounted
Ignition Lead Type Inductive (hi-resistance)

6A-44 ENGINE MECHANICAL (C24SE)








Valve, Grind
Valves can be reused once or twice after regrinding-only if
there are no crater-like burns on the valve cone.
Excessive grinding can cause the upper valve head edge to
become too thin.

Important!
Valve stem protection must not exceed dimension “A”-use 5-
8840-2596-0.
Do not regrind valve stem ends.
For all valve reworking note that angle of valve head is 44
and
the valve seat 45
-see also “Technical Data”.











Valve, Grind In
Grind-In the valve to improve valve seating.
Grind-In by rhythmically lifting valves and turning uniformly.
Use commercially available grinding tool.

Important!
Use only fine-grained pastes for grinding.
Lubricate valve stem before grinding in.

Clean
After grinding, carefully clean valve and valve soat.







Valve Guide, Ream
Measure
Diameter of valve guide-dial gauge and internal measuring
instrument.

Important!
Valve oversizes are available ex-works.
Oversize identification, on the valve guide and on the valve
stem end with the following specified identificaton
flgures/letters-see also “Technical Data”.



Identification Mark
Size Production Customer Service Reamer

Normal none K
0.075 mm 1 K1
0.150mm 2 K2

Ream valve guide from the upper side of the cylinder head to
the next oversize (use 5-8840-2599-0).
After reaming, cross out identification mark and stamp in new
identification mark.

6A-58 ENGINE MECHANICAL (C24SE)









Clean
Plastigage from journals.

Lightly coat journals and bearings with engine oil.

Installation
Install bearing cap and shell using new bolts.

Torque - Angle Method
Main bearing cap bolt - 60 N

m (6.1 kgf

m) +40
to 50
.
Con-rod bearing cap bolts - 35 N

m (3.9 kgf

m) +45
.








2.Micrometer and gauge method.
Crankshaft removed.

Installation
1. Install caps and bearing shells to con-rods and cylinder
block.


Measure
Con-rod and main bearing diameters at three points I, II, III
(arrowed).
Divide the sum of the three measurements by three to obtain a
mean diameter.

The top illustration shows con-rod measuring points.
The second illustration shows main bearing measuring points.



Measure
Crankshaft main and con-rod bearing journals at points I and
II. Divide the sum of both measurements to obtain a mean
diameter.

Crankshaft must be replaced if mean diameter of main or con-
rod journals is below specified limit - see "Technical Data".

If crankshaft is serviceable subtract crankshaft mean journal
diameters from corresponding shell bearing mean diameters to
determine bearing clearance.

Permissible main bearing clearance - 0.015 to 0.04mm/0.0006
to 0.002in.
Permissible con-rod bearing clearance - 0.006 to
0.031mm/0.002 to 0.001in.

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

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

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

ENGINE MECHANICAL (C24SE) 6A-85
Con-rod

Permissible, weight variation of con-rods without pistons and bearing shells within an engine 8 g.
As the con-rods have no counterweights, re-working is not possible.
Con-rods must be replaced only as a set.

Crankshaft Grinding Dimensions
Crankshaft
bearing journals
I, II, III, IV, V
Guide bearings
III

Con-Rod bearing journals
1 to 4
Con-rod
diameter in
mm/colour code width
in mm diameter
in mm width
in mm width
in mm
Standard Size for Production and Service

from 57.974
white
to 57.981
over 57.981
green
to 57.988
over 57.988
brown
to 57.995 26.002

25.950
48.988
48.970
26.580
26.450
26.390
26.338





Crankshaft, Cylinder Block (continued)
Crankshaft and con-rod journal Permissible out-of-round:
0.04mm

Out-of-round Permissible variation of
middle crankshaft bearing
journal when seating shaft into
cylinder block: 0.03mm

Permissible end play 0.05 to 0.152mm

Permissible main bearing play Bearing I to V0.015 to
0.04mm

Permissible con-rod play 0.006 to 0.031mm

Permissible con-rod and play 0.07 to 0.24mm

6A-88 ENGINE MECHANICAL (C24SE)
SPECIAL SERVICE TOOLS
ITEM NO. ILLUSTRATION PART NO. PART NAME



5-8840-2634-0



Aligner



5-8840-2593-0


Cutter set



5-8840-2594-0


Spring Compressor



5-8840-0451-0


Installer



5-8840-0452-0


Remover / Installer



5-8840-2596-0


Distance Gauge



5-8840-0455-0


Assembly Sleeves


5-8840-2597-0

Installer



5-8840-0457-0


Remover / Installer



5-8840-0468-0


Remover / Installer