Timing ISUZU TF SERIES 2004 Workshop Manual

ENGINE MECHANICAL (C24SE) 6A-41


Installation
1. Install the cylinder head gasket.
Mark "OBEN/TOP" on top and turn it towards timing side
of engine.
2. Place cylinder head on cylinder block.

1
2
3


Installation
1. Insert the hydraulic valve lifters (3), thrust pieces (2) and
cam followers (1) with MoS2 paste.
Note allocation.
2. Apply a bead of Sealing Compound TB1207C to sealing
surface of cylinder head.
3. Install the camshaft housing on cylinder head.



Torque-Angle Method
Cylinder head and camshaft housing with new cylinder head
bolts to cylinder block.

Cylinder head bolts in sequence shown.



Installation
1. Install the rear toothed belt cover to camshaft housing.
2. Install the camshaft pulley to camshaft.
3. Install the camshaft housing cover to housing.




Installation
1. Install the toothed belt on camshaft pulley.
See operation "Timing Adjust".
2. Install the front toothed belt cover.

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.

6A-64 ENGINE MECHANICAL (C24SE)
Important!
Do not loosen or open the radiator cap when coolant is hot.
Doing so may cause hot water or steam to splash out, resulting
in burn. When opening the radiator cap, be sure to confirm the
coolant is cold. Cover a thick cloth over the cap and loosen it
slowly to reduce pressure, then open the cap.
6. Close the radiator cap firmly and run the engine at
approx. 2000 rpm. In addition, set the heater temperature
adjuster to the max position to circulate coolant in the
heater conduit system.
7. Confirm that the temperature gauge reads half or more
of full scale and that the thermostat is activated.
Then continue idling 5 minutes more and switch off the
engine, and allow it to cool.
8. After the engine cools down, check the coolant level and
refill it if necessary. When the level is lowered extremely,
check the coolant conduit system and reservoir hose for
leak.
9. Pour coolant into the reservoir to MAX level.







Refill Coolant
Important!
After closing the cooling system, let engine run warm until
thermostat opens (coolant approx. 92C/197.6F)

Inspection
Coolant level
Allow engine to cool. If necessary, refill coolant.

Check that cooling system self-bleeds during engine warming-
up phase.


Ignition Timing, Check
No Adjustment

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.

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

ENGINE COOLING 6B-3


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 other
corrosion inhibitors) on threaded fasteners or fastener
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.


Water pump
The water pump is centrifugal type and is driven by timing belt.


Thermostat
The thermostat is a bypass type and is a wax pellet type with a
air hole.





110RS001
Radiator
The radiator is a flow type with corrugated fins.

ENGINE COOLING 6B-7
Water Pump
Water Pump and Associated Parts








Legend
1 Water Pump Assembly 2 O-Ring
3 Bolt

2 3 1

















Removal
1. Disconnect battery ground cable.
2. Drain coolant.
3. Disconnect radiator hose (on inlet pipe side).
4. Remove timing belt, refer to "Timing Belt" in this manual.
5. Remove water pump assembly.
Inspection
Make necessary repair and parts replacement if extreme wear
or damage is found during inspection. Should any of the
following problems occur, the entire water pump assembly
must be replaced:

6B-8 ENGINE COOLING











Crack in the water pump body

EC leakage from the seal unit

Play or abnormal noise in the bearing

Cracks or corrosion in the impeller
Installation
1. Before installing water pump, coat sealing surface with
silicon grease.
2. Install water pump assembly and tighten bolts to the
specified torque.
Torque: 25 N




m (2.5 kgf




m)
3. Timing belt

Install timing belt, refer to timing belt installation step in
"Timing Belt" in this manual.
4. Connect radiator hose and replenish EC.
5. Connect battery ground cable.

6D2-2 IGNITION SYSTEM



General Description
Ignition is done by the Ignition Module that fires.
Since the cylinder on exhaust stroke requires less energy to
fire its spark plug, energy from the ignition coils can be utilized
to fire the mating cylinder on compression stroke.
A notch in the timing disc on the crankshaft activates the crank
angle sensor which then sends information such as firing order
and starting timing of ignition coil to the ECM.
By receiving signals such as crank position, engine speed,
water temperature and Manifold Absolute Pressure (MAP), the
ECM controls the ignition timing.




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 other
corrosion inhibitors) on threaded fasteners or fastener
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.




Diagnosis
Refer to Section Drivability and Emissions for the diagnosis to
electronic ignition system (El system).





Ignition Coil
Removal
1. Disconnect battery ground cable.
2. Disconnect the Ignition coil connector.
3. Remove the ignition coil.



Installation
1. Install the ignition coil.
Connect ignition coil connector and ignition coil, then tighten
bolt to the specified torque.
Torque: 20 N




m (2.0 kgf




m)
2. Connect battery ground cable.

STARTING AND CHARGING SYSTEM 6D3-13

5. During current output tests please make sure that the
ammeter is securely connceted into the charge circuit.
6. Some battery powered timing lights can produce high
transient voltages when connected or disconnected. Onl
y
disconnect or connect timing lights when the engine is
switched off.
7. Make sure the warning lamp circuit is functioning normall
y
before commencing tests.
8. Battery isolation switches must only be operated when the
engine is stopped.
9. To protect the charging system when using 240 vol
t
chargers it is recommeneded that the battery is
disconnected whilst charging.
10. Due to the very low resistance value of the stator winding i
t
may not be possible to obtain accurate readings withou
t
special equipment.
11. 12 volts must never be connected to the "L" terminal of the
regulator as this will damage the lamp driver circuit.
12. No loads apart from the warning lamp can be connected to
the "L" termainal. The "W" terminal is provided for this
purpose.

Disassembly
1. Mark the relative positions of the end housings in relation to
the stator assembly to aid reassembly. Use a permanen
t
marking pen do not use centre punched as this can cause
misalignmnet of the housings.
2. Remove the EP regulator from the slipring end housing b
y
removing the two screws. Tilt the regulator slightly from the
plug connection until the regulator clears the housing, then
lift clear.
3. Remove the four through bolts.
4. Carefully remove the stator assembly along with the slipring
end housing taking care not to put strain on the stator wires.
5. To disconnect the stator from the rectifier assembly, grasp
the stator wires close to the wire loop with a pair of long
nosed pliers, heat the joint with a soldering iron, when the
point becomes plastic apply a slight twisting motion to the
wires, then pull upwards to release the wires. Remove the
stator.
This procedure opens the wire loop to release the stato
r
connections easily.
6. To remove the rectifier remove the three retaining scre
w
and the B+ terminal nut and washers.

Note: the B+ bolt and the positive heatsink retaining screw are
fitted with mica insulating washers.
These must be discarded and replaced with new washers and
heatsink compound.