dimensions ISUZU TF SERIES 2004 Workshop Manual

4B-40 REAR AXLE




425RS063


Reassembly
Adjustment of Clearance between
Friction Disc and Plate
1. Measuring depth of differential case
mm(in)

Standard (A-B) 80.58 (3.17)
(C) 10.58 (0.42)



425RS064

2. Measuring overall length of pressure ring, friction
disc and plate assembly

Assemble pinion shaft with pressure ring,
then friction disc and plate.


Measure length between plates at both ends
over V-shape groove. (D)




425
RS065

3. After A, B, C and D dimensions are measured,
perform adjustment with the following procedure.


Measure spring plate :
1.75 mm (0.69 in) 
4 pcs (E)


Measure thickness of plate spring
Standard dimension :
1.75 mm (0.069 in) 
2 pcs (F)
4. Select a friction disc or plate so that ((A-B+C) -
(D+E) = 0.06 to 0.20 mm (0.002 to 0.008 in.) and
also the difference in total dimension of friction
disc and plate and spring plate (left/right side)
does not exceed 0.05 mm (0.002 in.).
Thickness : 1.65, 1.75, 1.85 mm (0.065, 0.069,
0.073 in)

Adjusting Backlash of Side Gear in
Axial Direction
1. Measuring depth of differential case
mm(in)

Standard (F-B) 82.03 (3.23)
(G) 12.03 (0.47)

6A-12 ENGINE MECHANICAL (C24SE)
Engine - General C24SE
Fuel system Electronically controlled Multi Port Fuel Injection System
Fuel pump type Electric
Fuel pressure kg/cm2 (psi/Pa) 3.4 (48.4/334)
Fuel filter type Cartridge paper element
Air cleaner type Dry paper element
Battery Type/V-Ax No. of units 34B19L/50D20L
Alternator
Capacity V-A(W) 12-90 (1080), 12-100 (1200)
Starter
Output V-kW 1.4
Exhaust system CO Adjustment (1) Applicable to Open Loop System (Not equipped H2OS)
(2) Not applicable to Closed Loop System (Equipped H2OS)
Compression Ratio (with Tolerance) 9.6:10.25
Cylinder Head Material Aluminum Alloy (gravity cast)
Cylinder Block Material Cast Iron
No. of Mounting Points (including trans.) 3
Engine Installation Angles
-Longitudinal4 60'
-Lateral 7 50' (towards exhaust side)
Overall Dimensions (L




W




H):
- TF (2.4Litre/2WD) 610
564
708mm
- TF (2.4Litre/4WD) 610
564
746mm
Engine Weight
Engine Weight
- TF (2.4Liter/Man)140kg
Camshaft Type SOHC
No. of Valves per Cylinder
- Inlet1
- Exhaust 1
Spark Plug Location Side
Port Arrangement Cross Flow
Working Principle Spark Ignition 4-stroke

ENGINE MECHANICAL (C24SE) 6A-75









Spark Plug Thread
Recondition
Ream thread and recut using commercially available spark
plug thread drill (observe manufacturer's instructions).

Removal
Remove thread bush on spark plug. (dimensions (A) =
17mm/0.67in.)

Tighten (Torque)
Spark plug with thread bush into cylinder head - 25N

m (2.5
kgf
m) - use.

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

6A-84 ENGINE MECHANICAL (C24SE)
Piston Pins

Dimensions
Length mm
Diameter mm
61.5
21
Type Shank-fit in con-rod
Clearance
In piston mm
In con-rod mm 2.4L
0.010 to 0.015
0
Installation See operation “Con-rod, Replace”

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

6E–276 ENGINE DRIVEABILITY AND EMISSIONS
Oil in the combustion chamber.
The spark plug gap is not set correctly.
If spark plug fouling is ex cessive, check the fuel and al
system for possible causes of trouble. If fuel and al
system are normal, install spark plugs of a higher heat
range which have the same physical dimensions as the
original equipment spark plugs.
The following symptoms are characteristics of spark
plugs that are running too hot:
Fuel mixture is too lean.
Heat range is incorrect.
If vehicle usage does not conform to normal driving
conditions, a more suitable spark plug may be
substituted.
If fuel and al system are normal, in most cases of this
sort, the problem can be corrected by using a colder
type spark plug with the same physical dimensions as
the original equipment spark plug.
3. Check the gaskets for damage and replace if
necessary.
4. Measure the spark plug gap. The specification is 1.0
to 1.1mm (0.039 to 0.043").
5. Adjust the spark gap by bending the grounded
electrode.Installation
1. Tighten the spark plug to the 25N·m (2.5kgf·m).
2. Push the spark plug cable in until it snaps in.
Installation Procedure
1. Install the spark plug to the cylinder head.
2. Tighten the spark plug with specified tightening
torque.
Tightening Torque
Bolt: 25N·m (2.5kgf·m)
3. Connect the spark plug cable to the spark plug.
4. Connect the negative battery cable.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.
Verify proper connection of spark plug cables for each
cylinders.

FRAME AND BUMPER 2A-1

SECTION 2A
FRAME AND BUMPER
TABLE OF CONTENTS
PAGE
Front Bumper ..................................................................................................................... 2A- 2
Rear Step Bumper ............................................................................................................. 2A- 4
Rear Bumper And Rear Guard ASM ................................................................................. 2A- 7
Frame Dimensions............................................................................................................. 2A- 9

FRAME AND BUMPER 2A-9
FRAME DIMENSIONS 4




2, LWB, REGULAR CAB MODEL

RTW32AXF002601