ESP ISUZU TF SERIES 2004 Manual PDF

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.

ENGINE MECHANICAL (C24SE) 6A-47

Starter Ring Gear (Manual Transmission)
Removal
1. Remove flywheel according to the corresponding
operation.
2. Drill starter ring gear underneath tooth gap approx.
8mm/0.30in. deep with 8mm/0.25in. diameter drill.



3. Separate starter ring gear with chisel on the drilling point.



Installation
1. Install starter ring gear with inner chamfered edge to
flywheel.
2. Heat starter ring gear evenly to 180
C /356
F to 230
C
/446
F (yellow paint mark)
3. Install flywheel according to the corresponding operation.


Inspection
Lateral run-out of starter ring gear - max. 0.5mm/0.02in.

6A-48 ENGINE MECHANICAL (C24SE)
Seal Ring, Crankshaft
(Oil Pump Housing)

Removal
1. Remove toothed belt rear cover according to the
corresponding operation.
2. Remove sealing ring by making hole in middle of ring,
turning in self-tapping screw and edging out.


Installation
1 Install the protective sleeve to the crankshaft.
2. Coat the sealing lip with protective grease.
3. Install the sealing ring.
4. Install the sealing ring using 5-8840-0455-0.
5. Install the rear toothed belt cover and toothed belt
according to the corresponding operations.
6. Replace the sealing ring with a new one.
7. Tighten the belt to the crankshaft.



Seal Ring, Crankshaft Rear
Removal
1. Remove transmission and clutch.
2. Remove flywheel or flex plate according to the
corresponding operations.
3. Make hole in middle of sealing ring, turn in self-tapping
screw and edge out.



Installation
1. Install protective sleeve.
2. Coat sealing lip with Protective Grease.
3. Install sealing ring using 5-8840-0459-0 and 5-8840-
2597-0.
4. Install flywheel, clutch and transmission.

ENGINE MECHANICAL (C24SE) 6A-51
OPERATIONS ON CRANK DRIVE
Con-Rod Bearing








Removal
1. Remove oil pan and bearing bridge according to the corresponding operation.
2. Remove con-rod bearing cap and con-rod bearing after marking both sides.

Clean
Con-rod journal, con-rod bearing cap










Installation
1. Install new bearing shafts lightly coated with engine oil.
2. Install con-rod bearing cap.

Torque-Angle Method
Con-rod bearing cap to con-rod - 35N

m (3.5 kgf

m) +45 
to
60 


Important!
Use new bolts.

3. Install oil pan and bearing bridge according to the corresponding operation.



Piston with Con-Rod
Removal
1. Remove cylinder head and oil pan according to the corresponding operations.
2. Remove piston with con-rod after marking con-rod bearing cap.





Inspection
Remove and install all parts, if applicable.

Important!
Ring gap offset:
Piston rings - 180 
.
Oil scraper rings - 25 to 50 mm/1 to 2 in. from gap of
intermediate ring to the left and to the right.

6A-52 ENGINE MECHANICAL (C24SE)






Installation
1. Install piston with con-rod by inserting with engine oil.
2. Coat piston rings with engine oil and compress with
piston ring compressor.

Important!
Installation position:
Arrow / notch on piston head on timing side of engine
Beads on con-rod on clutch side






Torque-Angle Method
Piston to cylinder block.
Con-rod bearing cap to con-rod-35N
m (3.5 kgf
m) +45 to 60

Important!
Use new bolts.


Installation
1. Install oil pan and cylinder head according to the
corresponding operations.
2. Install sealing Gasket or replace if damaged.
3. Install camshaft housing to cylinder head.
4. Install cylinder head according to the corresponding
operation.



Con-Rod
Removal
1. Remove piston with con-rod according to the
corresponding operation.
2. Disassemble con-rod piston assembly by pressing out
piston pin, using 5-8840-0468-0.


Installation
1. Slide guide drift (5-8840-0468-0) in horizontal position
through piston and con-rod as far as side plate stops.
2. Tighten bolts evenly so that the piston rests flush on the
rear plate.
3. Remove centre piece from guide drift and insert piston
bolts (lubricated) into guide drift.

ENGINE MECHANICAL (C24SE) 6A-53

4. Heat a new con-rod to 280
C in the oil bath.
5. Install the con-rod to the piston and insert the piston pin.


Important!
Since the con-rods have no weight balancing studs, re-working
is not possible.
Exchange con-rods in sets only.
Installation position, beads on con-rod point to the flattening on
the piston pin eye.
Firmly seated piston pin cannot be pushed in. Carry out
installation quickly.








Piston Rings
Removal
1. Remove piston with con-rod according to the
corresponding operation.
2. Remove piston rings using commercially available ring
installer or piston ring clamp pliers.

Clean
Piston ring grooves - ground piece of old piston ring



Inspection
Piston ring gap
For piston ring sizes, permissible piston ring gaps - see
"Technical Data"

6A-54 ENGINE MECHANICAL (C24SE)

RTW46ASH002401
Installation
1. Install oil scraper ring.
2. Offset ring gaps of steel band rings each 25 to 50 mm/1
to 2in. to the left or right of the intermediate ring gap.
3. Install piston rings.
4. Offset ring gaps by approx. 180
.
5. Install second piston ring with identification mark "TOP"
facing upwards.
6. Install piston with con-rod according to the corresponding
operation.

ENGINE MECHANICAL (C24SE) 6A-55
OPERATIONS ON REMOVED ENGINE
Crankshaft




















Removal
1. Mount the engine on an engine overhaul stand with
appropriate adapters.
2. Remove the aggregates, flywheel/drive disc, oil pan,
bearing bridge and oil pump according to the
corresponding operation.
3. Mark the con-rod bearing cover.
4. Remove the crankshaft bearing cover.
5. Remove the crankshaft from cylinder block.

Inspection
Remove and install all parts if necessary.

Crankshaft pulse pickup sensor rotor inspection and repair.
Inspect the crankshaft pulse pickup sensor rotor for excessive
wear and damage.
Replace the crankshaft pulse pickup rotor if the inspection
results exceed wear and damage limits.

Installation
1. Install the crankshaft pulse pickup sensor.
Torque: 13N




m (1.3 kgf




m)
2. Install new bearing shells into the cylinder block and
bearing cover.
3. Coat the bearing shafts with engine oil.
For oversizes-see “Technical Data”
4. Install a new crankshaft into the cylinder block.







Note
The sealing of the crankshaft can be corrected with light
blows with a rubber hammer on the crank arm (arrowed).

6A-56 ENGINE MECHANICAL (C24SE)




5. Apply a bead of sealant (TB-1207C or equivalent) in the
grooves of both bearing shells.

Important!
After installation of bearing cover, press in sealing compound
again from above, until compound emerges at the joints.


Torque - Angle Method
Bearing cover to cylinder block - 50 N
m (5.1 kgf
m) +40 to
50
Con-rod bearing cover to con-rod - 35 N

m (3.5 kgf

m) +45
to
60
.
Use new bolts.

6. Install oil pump, oil pan, bearing bridge rear crankshaft
sealing, flywheel/drive plate, and aggregates according to
the corresponding operations.









Inspection
Bearing play - bearing cover removed

Measure
With "Plastigage" (ductile plastic threads)
Cut threads to length of bearing width and lay axiaity between
crankshaft journal and bearing shell (arrowed).
Install bearing cover with correct torque.

Important!
Grease crankshaft journal and lubricate bearing shell slightly
so that the thread does not tear when the bearing cover is
moved.


Crankshaft
Inspection
End play when bearing shells are installed.
Front end contact surfaces of flywheel/flexible plate.
Permissible end play - see "Technical Data "