engine ISUZU TF SERIES 2004 Workshop Manual

6A-34 ENGINE MECHANICAL (C24SE)
OPERATIONS ON CYLINDER HEAD AND CAMSHAFT
HOUSING
Camshaft



Removal
1. Remove cylinder head according to the corresponding
operation.
2. Remove camshaft housing from cylinder head and lay
housing on base provided
3. Remove rear sealing gasket and plate camshaft housing
with taking care not to damage housing.
4. Remove thrust plate.





5. Remove camshaft.
6. Remove front sealing gasket and plate from camshaft
housing with taking care not to damage housing.

Inspection
All parts.







Installation
1. Install camshaft.
2. Coat sliding surfaces with molybdenum disulphate paste.

Tighten (Torque)
Thrust plate for camshaft housing - 8 N

m (0.8 kgf

m)

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-37


Hydraulic Valve Lifters, Replace
Removal
1. Remove the spark plug connectors and spark plugs.
2. Remove the camshaft housing cover.


Removal
3. Turn the crankshaft at fastening bolt of toothed belt drive
gear in the direction of the engine rotation until the cam
of hydraulic valve lifter being replaced stands vertically.


Removal
4. Apply 5-8840-0457-0 to the camshaft housing, valve
spring cap and tension valve spring.


Removal
5. Remove the cam follower from camshaft housing.
Note thrust pieces.
6. Remove hydraulic valve lifter from camshaft housing.



Camshaft Housing, Replace
Removal
Cylinder head-see operation “Cylinder Head. Remove and
Install”.

6A-38 ENGINE MECHANICAL (C24SE)




Inspection
All parts, if necessary replace.

When replacing camshaft, always replace all cam followers.








Installation
Insert hydraulic valve lifter (1) in camshaft housing.

Coat sliding surfaces of rocker arm with Mcs, Paste and insert
in camshaft housing.

Adjust
Adjustment of the hydraulic valve liters is not required.
Pretension is provided by the design.


Installation
1. Remove 5-8840-0457-0 and install the camshaft housing
cover.
2. Insert the spark plug connectors.







Tighten (Torque)
Guide plate to camshaft housing.
Insert camshaft with MoS
2 paste.

Installation
1. Install the front seal ring in camshaft housing with
5-8840-0451-0.
2. Install the camshaft housing rear cover.
3. Install the cylinder head.

ENGINE MECHANICAL (C24SE) 6A-39







Camshaft Housing, Check for Plane Surface
Clean
Sealing surfaces.

Inspection
Check length and width of sealing surface for deformation and
diagnosis for warpage and use straight edge feeler gauge.

Measure
Height of camshaft housing (sealing surface to sealing
surface).
Dimension I: (74.0 mm)



Cylinder Head, Removal and Installation
Important
Only remove cylinder head with engine cold (room
temperature).




Removal
1. Remove the alternator, power steering and V-belts.



Removal
2. Loosen the fastening bolts from alternator.
3. Loosen the lower alternator fastening bolt by swinging
the alternator to the rear.



Removal
4. Remove the front toothed belt cover.
5. Remove the toothed belt from camshaft pulley.
See operation "Timing Check and Adjust".

6A-40 ENGINE MECHANICAL (C24SE)




Removal
6. Remove the camshaft housing cover and camshaft
pulley by counter-holding at the hex head of camshaft.




Removal
7. Remove the fastening bolts from camshaft housing.



Removal
8. Remove the exhaust pipe from exhaust manifold.
9. Loosen the cylinder head bolts spirally from the outside
inwards (first 1/4, then 1/2 revolution).



Removal
1. Remove the camshaft housing from cylinder head.
2. Remove the cam followers, thrust pieces and hydraulic
valve lifters.
Note the allocation.
3. Remove the cylinder head.




Clean
Sealing surfaces, bores and threads of cylinder head bolts.

Inspection
Check cylinder head and cylinder block for plane surfface-see
operations “Cylinder Head, Check for Plane Surface” and
“Cylinder Block, Check for Plane Surface.”

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-42 ENGINE MECHANICAL (C24SE)


Installation
1. Install the fastening bolts.
2. Loosen the lower alternator fastening bolt.
3. Install the alternator, power steering and V-belts.



Cylinder Head, Disassemble and Assemble
Removal
1. Remove the hydraulic valve lifters.
Lay aside in installation positions.
2. Remove the spark plugs, exhaust manifold and intake
manifold from cylinder head.




Removal
1. Mark valves.
2. Remove the tension valve springs with 5-8840-2594-0
(1).
3. Remove valve keepers, valve spring cap and valve
spring.



Removal
1. Remove the valve and valve stem seal.
2. Remove the valve spacer ring (1-exhaust) and valve
spring seat (2-intake).
3. Remove valve from cylinder head.

Clean
Sealing surfaces.

ENGINE MECHANICAL (C24SE) 6A-43


Inspection
Sealing surfaces for plane surface, guides, sliding and bearing
points for wear-see operation “Cylinder Head. Overhaul”.



Installation
1. Coat the valves with engine oil and insert in cylinder
head.
2. Install the valve spacer ring or valve rotator(exhaust) and
valve spring seal(intake).
3. Push the accompanying assembly sleeve onto valve
stem and coat with engine oil.
4. Insert a new valve stem seal with 5-8840-2601-0 (1).
5. Drive the valve stem seal carefully in to stop with light
hammer blow.







Installation
1. Install the valve springs and valve spring caps.
2. Install the tension valve springs with 5-8840-2594-0 (1),
valve keeper.

Important!
Note markings made on valves.




Tighten (Torque)
Exhaust manifold and intake manifold with new gaskets to
cylinder head.

Thermostat housing with new seal ring to cylinder head:





Tighten (Torque)
Spark plugs with spark plug wrench to cylinder head.

Installation
1. Coat hydraulic valves lifters (1) with oil.
2. Insert them in cylinder head.
Note installation position.