engine oil ISUZU TF SERIES 2004 Workshop Manual

ENGINE MECHANICAL (C24SE) 6A-61
OPERATIONS ON OIL CIRCULATION

Cylinder Head Safety Valve
Removal
1. Remove cylinder head according to the corresponding
operation.
2. Make hole in core plugs with pointed drift, turn in self
tapping screw and edge out.

Important!
Cover oil duct in cylinder head with piece of cloth.

3. Pull out valve retainer, using commercially available tool.
4. Remove ball and spring.


5. Cut three threads in the ball seating with M 10 tap (3rd
stage).
6. Coat tap with grease.



7. Remove ball seating from cylinder head with
commercially available tool.
Do not damage cylinder head.

6A-70 ENGINE MECHANICAL (C24SE)
Installation

(2.4L)
1. Install the ECM to the ECM bracket on engine.
2. Tighten the four screws to the bracket.
3. Connect the connector.









ECT
Removal
1. Remove wiring harness plug and coolant temperature
sensor.

Tighten (Torque)
Temperature sensor to intake pipe - 10 N

m (1.0 kgf

m)
Wiring harness plug to temperature sensor

Inspection
Coolant level







Idle Air Control (IAC) Valve
Removal
1. Remove wiring harness plug, hose clamps and idle
speed adjuster.

Installation
1. Install idle speed adjuster, hose clamps and wiring
harness plug.






Ignition Coil
Removal
1. Remove 2 bolts, plug and ignition coil.

Installation
1. Install ignition coil, plug and bolts.

6A-76 ENGINE MECHANICAL (C24SE)
TECHNICAL DATA
SOHC Gasoline Engine C24SE

Engine Oil Viscosity
The following engine oils can be used:
A = single-grade oils
B = multigrade oils
C = easy run oils
depending on the outside temperature.

Engine Oil Quality
It is important that the following API and CCMC classes are
used:


Engines Single and multigrade oils Easy run oils
Petrol API-SF/CC, SF/CD, SG/CC,
SG/CD, CCMC/G4 API-SF/CC, SF/CD, SG/CD
CCMC-G5/PD2




Important!
CD engine oils designed by manufacturers specially for diesel
engines are not suitable for petrol engines, unless a sufficient
performance class for petrol engines (e.g. API-SF/CCMC-G4)
is also indicated.

Disposal.
Observe the relevant national regulations when disposing of
used oil.


Engine Oil Filling Quantities

Engine Model Initial filling
(litres) Filling quantity
with filter change*
(litres) MIN to MAX
(litres)
2.4L 4.80 4.25 1.00
*Up to mark "MAX" on oil dipstick




Oil Pump
Backlash 0.1 to 0.2mm
Gaps in gears opposite housing 0.03 to 0.1mm
Oil pressure at idle speed Engine at operating
temperature (>70
C oil and
approx. 80
C coolant)
450 - 500 kpa
Oil drain plug M14  1.5

ENGINE MECHANICAL (C24SE) 6A-77

Cooling System
Radiator

Type: Cross-flow

Radiator core surface in cm
2: 2000

Cooling system capacity (in litres): 7.2



Anti-freeze Mixture
Anti-freeze Mixture

Required
Quantity Up to-10




C
Quantity in litres Up to-20




C
Quantity in litres Up to-30




C
Quantity in litres Up to-40




C
Quantity of litres
(in litres) Water
(80%) Anti-
Freeze
(20%) Water
(66%) Anti-
Freeze
(34%) Water
(56%) Anti-
Freeze
(44%) Water
(48%) Anti-
Freeze
(52%)
7.2 5.7 1.5 4.7 2.5 4.0 3.2 3.4 3.8



Cooling System (continued)
Fan

Type Visco Clutch Fan
Number of blades 5
Distribution of blades asymmetric
Diameter mm



Radiator cap

Boiling point 123
C
Opening pressure kPa (bar) 120 to 135 (1.20 to 1.35)



Thermostat

Start of opening 92
C
Fully opened 107
C
Type Bypassed



Idle Speeds, CO Content, Ignition
Adjustment

Applicable System Idle speed in min-1 (rpm)
Manual CO content
in vol. % Ignition timing in CA BTDC (adjustment
ensues at able speed,
ignition marks must align) with TDC
sensor measuring instrument:
Closed Loop System 825 *<0.4 *** 8 to 12
Open Loop System 825
**1.0+0.2
-0.5 *** 8 to 12
Note) * CO content adjustment not applicable.
** CO content adjustment refer to Section 6E1 (W/O catalytic converter system)
*** Ignition timing adjustment not possible.

6A-82 ENGINE MECHANICAL (C24SE)
Crankshaft, Cylinder Block (continued)
Piston Rings
2.4L
Square ring Height mm 1.2

Tapered ring Height mm 1.5

Oil scraper Height mm 2.5

Ring gap offset 180


Note that the upper steel band ring gap is offset 25 to 50mm to
the left and the lower 25 to 50mm to the right opposite the
intermediate ring gap.

Piston Pin

Length mm 61.5
Diameter mm 21
Type Shrunk into con-rod
Play mm 2.4L
in piston 0.010-0.015
in con-rod none
Installation When installing piston pins,
heat con-rods to approx.
280
C in oil bath. This
temperature should under no
circumstances be exceeded.


Crankshaft, Cylinder Block (continued)
The permissible weight variation of con-rods without piston and
bearing shell inside an engine is 8 g.
As the con-rods do not have balancing studs, reworking is not
possible.
Con-rods can only be replaced in sets.

ENGINE MECHANICAL (C24SE) 6A-87
Recommended Torque Values
Nm (kgfm)

Bearing cover to cylinder block ....................................................................................... 60
1) 6.1 +40
to 50

Bracket for alternator to cylinder block ............................................................................ 40 4.1
Bracket for engine damping block to transmission ......................................................... 60
2) 6.1
Bracket for engine damping block to engine block ......................................................... 60 6.1
Bracket for pump/compressor to engine block ............................................................... 35 3.6
Camshaft housing cover to housing ................................................................................ 8 0.8
Camshaft timing gear to camshaft .................................................................................. 50 5.1
Clamping bracket for alternator to intake manifold ......................................................... 25 2.5
Clamping bracket to alternator ........................................................................................ 25 2.5
Con-rod bearing cap to con-rod ...................................................................................... 35
1) 3.5 +45
to 60

Crankshaft pulley bolts .................................................................................................... 20 2.0
Cylinder head to cylinder block ........................................................................................ 25
1)2) 2.5 +90
+90

+90

Engine damping block to engine bracket ........................................................................ 8.5 8.7
Engine damping block to side member ........................................................................... 52
1) 5.3
Exhaust manifold to cylinder head .................................................................................. 22 2.2

1) Use new bolts
2) Use new locking plates


Recommended Torque Values
Nm (kgfm)

Flywheel to crankshaft ..................................................................................................... 65
1) 6.6 +30
to 45

Front exhaust pipe to exhaust manifold .......................................................................... 25 2.5
Guide sleeve for pressure bearing to transmission ......................................................... 22 2.2
Intake manifold to cylinder head ...................................................................................... 22 2.2
Lower alternator bracket ................................................................................................. 25 2.5
Oil drain plug to oil pan .................................................................................................... 45 4.6
Oil intake pipe bracket to cylinder block .......................................................................... 6
2) 0.6
Oil intake pipe to oil pump ............................................................................................... 8 0.8
Oil pan to cylinder block .................................................................................................. 8
2)3) 0.8
Bearing bridge to cylinder block ...................................................................................... 8 2)3) 0.8
Oil pressure switch to oil pump ....................................................................................... 30 3.2
Pump for power steering (ribbed V-belt) to engine block ................................................ 30 3.2
Spark plugs in cylinder head ........................................................................................... 20 2.3
Starter support to cylinder block ...................................................................................... 25 2.5
Starter to cylinder block - engine side ............................................................................. 45 4.6
Starter to cylinder block - transmission side .................................................................... 75 7.6
Thermostat housing to cylinder head .............................................................................. 15 1.5
Toothed belt drive gear to crankshaft .............................................................................. 130
1) 13.3
Toothed belt front cover .................................................................................................. 4 0.4
Toothed belt rear cover ................................................................................................... 6 0.6
Toothed belt tension roller to oil pump ............................................................................ 20 2.3
(M10) ............................................................................ 45 4.6
Transmission to engine block ......................................................................................... 76 7.7
(M12) ............................................................................ 60 6.1
Water pump to cylinder block .......................................................................................... 17 1.7

1) Use new bolts
2) Use Locking Compound
3) Maximum installation time - 10 minutes

6B-2 ENGINE COOLING
General Description
Legend
1 Water Pump
2 Thermostat
3 Radiator
4 Reserve Tank5 Coolant Distributor
6 Cylinder Block and Head
7 Throttle Body
8 Heater




The Cooling System is a pressurized type, where the water
pump, which is cambelt driven, forces the circulation of
the coolant through the cylinder block and head. The
thermostat regulates the flow of coolant between the
radiator and the bypass circuit. The heater is part of the
bypass circuit. The throttle body pre-heat is a separate
circuit which is not regulated by the thermostat. An oil
cooler may be fitted as part of this circuit.

ENGINE COOLING 6B-5
Diagnosis
Engine Cooling Trouble
Condition Possible cause Correction
Engine overheating Low Engine Coolant level Replenish
Thermo mater unit faulty Replace
Faulty thermostat Replace
Faulty Engine Coolant temperature
sensor Repair or replace
Clogged radiator Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of
improper engine oil Replenish or change oil
Clogged exhaust system Clean exhaust system or replace
faulty parts
Faulty Throttle Position sensor Replace throttle valve assembly
Open or shorted Throttle Position
sensor circuit Repair or replace
Damaged cylinder head gasket Replace
Loosen V-belt tension Adjust belt tension or replace.
Collapsed hoses Replace
Faulty Fan clutch Replace
Engine overcooling Faulty thermostat Replace
Engine slow to warm-up Faulty thermostat Replace
Thermo unit faulty Replace

6B-6 ENGINE COOLING

















Draining and Refilling Cooling
System
Before draining the cooling system, inspect the system and
perform any necessary service to ensure that it is clean, does
not leak and is in proper working order. The engine coolant
(EC) level should be between the "MIN" and "MAX" lines of
reserve tank when the engine is cold. If low, check for leakage
and add EC up to the "MAX" line. There should not be any
excessive deposit of rust or scales around the radiator cap or
radiator filler hole, and the EC should also be free from oil.
Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening the drain
plug at the bottom of the radiator.
2. Remove the radiator cap.
WARNING: TO AVOID THE DANGER OF BEING BURNED,
DO NOT REMOVE THE CAP WHILE THE ENGINE AND
RADIATOR ARE STILL HOT. SCALDING FLUID AND
STEAM CAN BE BLOWN OUT UNDER PRESSURE.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with soap
and water. Flush it well with clean water, then drain it. Install
the reserve tank and hoses.
4. Refill the cooling system with the EC using a solution that is
at least 50 percent antifreeze.
5. Fill the radiator to the base of the filler neck.
Fill the EC reserve tank to "MAX" line when the engine is
cold.
6. Block the drive wheels and firmly apply the parking brake.
Shift an automatic transmission to "P" (Park) or a manual
transmission to neutral.
7. Remove the radiator cap. Start the engine and warm it up a
t
2,500 - 3,000 rpm for about 30 minutes.
8. When the air comes out from the radiator filler neck and the
EC level has gone down, replenish with the EC. Repeat this
procedure until the EC level does not go down. Then stop
the engine and install the radiator cap. Let the engine cool
down.
9. After the engine has cooled, replenish with EC up to the
"MAX" line of the reserve tank.
10. Start the engine. With the engine running at 3,000 rpm,
make sure there is no running water sound from the heate
r
core (behind the center console).
11. If the running water sound is heard, repeat steps 8 to 10.

ENGINE FUEL (C24SE) 6C-3


When working on the fuel system, there are several things to
keep in mind:


Any time the fuel system is being worked on, disconnect the
negative battery cable except for those tests where battery
voltage is required.


Always keep a dry chemical (Class B) fire extinguisher near
the work area.

Replace all pipes with the same pipe and fittings that were
removed.

Clean and inspect "O" rings. Replace if required.


Always relieve the line pressure before servicing any fuel
system components.

Do not attempt repairs on the fuel system until you have
read the instructions and checked the pictures relating to
that repair.

Adhere to all Notices and Cautions.
All gasoline engines are designed to use only unleaded
gasoline. Unleaded gasoline must be used for proper emission
control system operation.
Its use will also minimize spark plug fouling and extend engine
oil life. Using leaded gasoline can damage the emission control
system and could result in loss of emission warranty coverage.
All cars are equipped with an Evaporative Emission Control
System. The purpose of the system is to minimize the escape
of fuel vapors to the atmosphere.



Service Precaution
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or othe
r
corrosion inhibitors) on threaded fasteners or fastene
r
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts
and systems.