ISUZU TF SERIES 2004 Workshop Manual

ENGINE MECHANICAL 6A – 101
MAJOR COMPONENT



Reassembly Steps-1
1.
Cylinder body 10.
Camshaft timing gear
2.
Tappet 11. Piston and connecting rod with
upper bearing
3.
Crankshaft upper bearing 12. Connecting rod bearing cap with
lower bearing
4.
Crankshaft 13.
Piston cooling oil pipe
5.
Crankshaft thrust bearing 14.
Oil pump with oil pipe
6. Crankshaft bearing cap with
lower bearing 15.
Crankshaft rear oil seal
7.
Camshaft 16.
Crank case
8.
Timing gear case 17.
Cylinder body rear plate
9.
Camshaft thrust plate 18.
Flywheel


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6A – 102 ENGINE MECHANICAL







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Reassembly Steps-2
19.
Crankshaft timing gear 23.
Injection pump
20.
Idler gear shaft 24.
Water pump
21.
Idler gear "A" 25.
Timing gear case cover
22.
Idler gear "B" and shaft 26.
Crankshaft damper pulley

ENGINE MECHANICAL 6A – 103




Reassembly Steps-3
27.
Cylinder head gasket 31. Thermostat housing with thermo
switch
28.
Cylinder head 32.
Water by-pass hose
29.
Push rod 33.
Injection nozzle and bracket
30. Rocker arm shaft and rocker
arm 34.
Cylinder head cover with gasket

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6A – 104 ENGINE MECHANICAL



Reassembly
1. Cylinder Body
Use compressed air to thoroughly clean the inside and
outside surfaces of the cylinder body, the oil holes, and the
water jackets.








2. Tappet
1. Apply a coat of engine oil to the tappet and the
cylinder body tappet insert holes.
2. Locate the position mark applied at disassembly (if
the tappet is to be reused).

NOTE:
The tappet must be installed before the camshaft
installation.





3. Crankshaft Upper Bearing
The crankshaft upper bearings have an oil hole and an oil
groove. The lower bearings do not.
1. Carefully wipe any foreign material from the upper
bearing.

NOTE:
Do not apply engine oil to the bearing back faces and
the cylinder body bearing fitting surfaces.

2. Locate the position mark applied at disassembly if the
removed upper bearings are to be reused.




4. Crankshaft
Apply an ample coat of engine oil to the crankshaft journals
and the crankshaft bearing surfaces before installing the
crankshaft.


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ENGINE MECHANICAL 6A – 105






5. Crankshaft Thrust Bearing
Apply an ample coat of engine oil to the thrust bearings
before installation.
Install the thrust bearings to the crankshaft center journal.
The thrust bearing oil grooves must be facing the sliding
faces.
















6. Crankshaft Bearing Cap With Lower Bearing
Before the crankshaft bearing installation, select the
appropriate bearings in accordance with the description in
CRANK BEARING SELECTION of INSPECTION AND
REPAIR.
1. Apply the recommended liquid gasket or its equivalent
to the No. 5 crankshaft bearing cap cylinder body fitting
surfaces at the points shown in the illustration.
NOTE:
Be sure that the bearing cap fitting surface is
completely free of oil before applying the liquid
gasket. Three bond 1207B Do not allow the liquid
gasket to obstruct the cylinder thread holes and
bearings.
ThreeBond 1207B is a fast-drying liquid gasket.
Tighten the bearing caps immediately after applying
the gasket.









2. Install the bearing caps with the bearing cap head
arrow mark facing the front of the engine.The bearing
cap numbers must be facing up.
3. Apply engine oil to the crankshaft bearing cap bolts.















4. Tighten the crankshaft bearing cap bolts to the
specified torque a little at time in the sequence shown
in the illustration.


Crankshaft Bearing Cap Torque N·m(kg·m/lbft)
167 (17/123)

5. Check to see the crankshaft turns smoothly by rotating
it manually.


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6A – 106 ENGINE MECHANICAL


7. Camshaft
1. Apply a coat of engine oil to the camshaft and the
camshaft bearings.
2. Install the camshaft to the cylinder body.
Take care not to damage the camshaft bearings.











8. Timing Gear Case
Tighten the timing gear case with timing gear case gasket
to the specified torque.


Timing Gear Case Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)











9. Camshaft Thrust Plate
Install the thrust plate to the cylinder body and tighten the
thrust plate bolts to the specified torque.


Thrust Plate Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)




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10. Camshaft Timing Gear
1. Install the camshaft timing gear to the camshaft. The
timing gear mark must be facing outward.
2. Tighten the timing gear to the specified torque.


Timing Gear Bolt Torque N·m(kg·m/lbft)
110 (11.2/82)
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ENGINE MECHANICAL 6A – 107


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11. Piston and Connecting Rod with Upper Bearing
12. Connecting Rod Bearing Cap with Lower Bearing
1. Apply a coat of engine oil to the circumference of each
piston ring and piston.
2. Position the piston ring gaps as shown in the
illustration.
1. Oil ring
2. 2nd compression ring
3. 1st compression ring










3. Apply a coat of molybdenum disulfide grease to the two
piston skirts.
This will facilitate smooth break-in when the engine is
first started after reassembly.
4. Apply a coat of engine oil to the upper bearing
surfaces.
5. Apply a coat of engine oil to the cylinder wall.














6. Position the piston head front mark so that it is facing
the front of the engine.
7. Use the piston ring compressor to compress the piston
rings.
Piston Ring Compressor: 5-8840-9018-0
8. Use a hammer grip to push the piston in until the
connecting rod makes contact with the crankpin.
At the same time, rotate the crankshaft until the
crankpin is at BDC.



9. Align the bearing cap cylinder number marks and the
connecting rod cylinder number marks.
The cylinder number marks must be turned toward the
exhaust manifold.



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6A – 108 ENGINE MECHANICAL











10. Apply a coat of engine oil to the threads and setting
faces of each connecting rod cap bolt.
11. Tighten the connecting rod caps to the two step of
anglar tigthen method.


Connecting Rod Bearing Cap Bolt Torque N·m (kg·m/Ib ft)
4JA1T (L),
4JA1TC 78-88 (8.0/57 – 9.0/65)
1st step ; 29.0–29.2 (3.00/22.0–3.01/22.2)4JH1TC
2nd step ; 45
-60







13. Piston Cooling Oil Jet
1. Install the piston cooling oil jet to the cylinder body.
2. Tighten the oil jet bolts and relief valve to the specified
torque.


Oil Jet Bolt Torque N·m(kg·m/lbft)
M8  1.25 19 (1.9/14)
M6  1.00 8 (0.8/6)


Relief Valve Torque N·m(kg·m/lbft)
29 (3.0/22)

NOTE:
Check that there is no interference between the piston
and the oiling jet by slowly rotating the crankshaft.












14. Oil Pump with Oil Pipe
Install the oil pump with the oil pipe and tighten the bolts to
the specified torque.


Oil Pump Bolt Torque N·m(kg·m/lbft)
19 (19/14)

NOTE:
Take care not to damage the O-rings when tightening
the oil pipe bolts.







15. Crankshaft Rear Oil Seal
Use a oil seal install to install the crankshaft rear oil seal.
Oil Seal Installer : 5-8840-2359-0


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ENGINE MECHANICAL 6A – 109



16. Crank Case
1. Apply the recommended liquid gasket (Three bond
1207B) or its equivalent to arch gasket fitting surface
as shown in the illustration.
2. Install the crankcase front gasket (1) to the timing gear
case arches.
The gasket projection (2) must be facing forward.
NOTE:
ThreeBond 1207B is a fast-drying liquid gasket.
Install the arch packing to the crankcase immediately
aftter applying the gasket.










3. Install the rear arch gasket (2) to the No. 5 bearing
cap. Use your fingers to push the arch gasket into the
bearing cap groove.Take care not to scratch the arch
gasket outer surface.
Also apply the recommended liquid gasket (1207C) or
its equivalent to arch gasket fitting area as indicated in
the illustration.






4. Apply the recommended liquid gasket or its equivalent
to groove of the crankcase fitting surface as shown in
the illustration.

NOTE:
Be sure that the crank case fitting surface is
completely free of oil and dust before applying the
liquid gasket.












5. Install the crank case to the cylinder body.
6. Tighten the crank case bolts to the specified torque a
little at a time in the sequence shown in the illustration.


Crank Case Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)

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6A – 110 ENGINE MECHANICAL









17. Cylinder Body Rear Plate
1. Align the rear plate with the cylinder body knock pins.
2. Tighten the rear plate to the specified torque.


Rear Plate Torque N·m(kg·m/lbft)
82 (8.4/61)














18. Flywheel
1. Apply a coat of engine oil to the threads of the flywheel
bolts.
2. Align the flywheel with the crankshaft dowel pin.
3. Tighten the flywheel bolts in the numerical order shown
in the illustration.
Gear stoper: 5-8840-0214-0


Flywheel Bolt Torque N·m(kg·m/lbft)
118 (12/87)











19. Crankshaft Timing Gear
Use the crankshaft timing gear installer (1) to install the
crankshaft timing gear (2).
The crankshaft timing gear setting mark must be facing
outward.
Crankshaft Timing Gear Installer: 9-8522-0020-0


















20. Idler Gear Shaft
21. Idler Gear "A"
1. Turn the crankshaft clockwise to set the DTC of the
No.1 piston.
2. Apply engine oil to the idler gear and the idler gear
shaft.
The idler gear shaft oil hole (A) must be facing up.
3. Position the idler gear setting marks so that they are
facing the front of the engine.


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