light ISUZU TF SERIES 2004 Workshop Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2004, Model line: TF SERIES, Model: ISUZU TF SERIES 2004Pages: 4264, PDF Size: 72.63 MB
Page 2448 of 4264
6A-28 ENGINE MECHANICAL (C24SE)
2. Install cable to temperature sensor.
3. Install upper bolts of rear toothed belt rear cover.
4. Install camshaft timing gear then check timing according
to the corresponding operation.
5. Install camshaft housing cover.
6. Install toothed belt and front cover.
7. Fill up and bleed cooling system according to the
corresponding operation.
Tighten (Torque)
Thermostat housing to cylinder head - 15 Nm/1.5 kgfm.
Seal Ring - Front Camshaft Housing, Replace
Removal
Mark running direction of toothed belt.
Remove toothed belt-see operation “Toothed Belt, Replace”.
Camshaft housing cover, camshaft pulley-counterhold on hex
of camshaft.
Removal
Screw self-tapping screw into seal ring.
Edge out seal ring.
Installation
Lightly coat sealing lip of seal ring with protective grease.
Install seal ring with 5-8840-0451-0 into camshaft housing-use
screw and washer of camshaft pulley.
Page 2463 of 4264
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.
Page 2470 of 4264
6A-50 ENGINE MECHANICAL (C24SE)
Clean
Sealing surfaces.
013RW004
Installation
1. Apply a bead of Sealing Compound, TB120TC or eguivalent to joint of oil pump.
2. Apply the recommended light gasket to the oil pan fitting surface as shown in the illustration.
3. Install the bearing bridge.
4. Install baffle plate, or reuse baffle plate.
Caution
Baffle plates can be retrofitted without difficulty - replace baffle
plate.
5. Install oil intake pipe to oil pump and oil intake pipe bracket to cylinder block.
6. Install oil pan and new gasket to cylinder block and insert bolts with Locking Compound 15 10 177 (90 167 347).
Maximum assembly time including torque check is 10
min.
7. Return the power steering unit (and front axle [4
4 model
only]).
8. Install the crossmember.
Tighten (Torque)
Oil intake pipe to oil pump -8N
m (0.8 kgf
m)
Oil intake pipe bracket to cylinder block - 6 N
m (0.6 kgf
m)
Oil pan to cylinder block - 8 N
m (0.8 kgf
m)
Bearing bridge to cylinder block – 8 N
m (0.8 kgf
m)
Page 2471 of 4264
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.
Page 2475 of 4264
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).
Page 2476 of 4264
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 Nm (5.1 kgfm) +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 "
Page 2477 of 4264
ENGINE MECHANICAL (C24SE) 6A-57
Inspection
Out-of-round (run-out)-middle bearing shell removed when
mounting on front and rear bearing.
Permissible out-of-round - see "Technical Data"
Bearing Free Play Measurement
Two methods for measuring bearing free play are described -
1. Plastigage method and 2. micrometer and gauge method.
The two procedures are suitable for measuring both con-rod
and main bearing free play.
For both methods ensure con-rod and main bearing caps are
identified (1) prior to removal as they are machine matched.
1.Plastigage Method
Removal
1. Remove bearing cap and shell.
2. Lightly coat journals and bearings with engine oil to
prevent Plastigage from tearing when cap is removed.
Installation
1. Lay a length of Plastigage across width of crank pin and
fit bearing cap and shell using old bolts at this stage.
Important!
Do not allow crankshaft to rotate.
Torque - Angle Method
Main bearing cap bolt - 60 N
m (6.1 kgf
m) +40
+ to 50
.
Con-rod bearing cap bolts - 35 N
m (3.6 kgf
m) +45
.
Removal
1. Remove bearing cap and shell.
Measure
Width of Plastigage -use scale supplied with Plastigage.
If con-rod bearing clearance exceeds 0.031mm/0.001in or
main journal bearing clearance exceeds 0.04mm/0.02in. -
check crankshaft journal diameters - see corresponding
operation.
Replace bearing if crankshaft is within specification - see
"Technical Data"
Page 2478 of 4264
6A-58 ENGINE MECHANICAL (C24SE)
Clean
Plastigage from journals.
Lightly coat journals and bearings with engine oil.
Installation
Install bearing cap and shell using new bolts.
Torque - Angle Method
Main bearing cap bolt - 60 N
m (6.1 kgf
m) +40
to 50
.
Con-rod bearing cap bolts - 35 N
m (3.9 kgf
m) +45
.
2.Micrometer and gauge method.
Crankshaft removed.
Installation
1. Install caps and bearing shells to con-rods and cylinder
block.
Measure
Con-rod and main bearing diameters at three points I, II, III
(arrowed).
Divide the sum of the three measurements by three to obtain a
mean diameter.
The top illustration shows con-rod measuring points.
The second illustration shows main bearing measuring points.
Measure
Crankshaft main and con-rod bearing journals at points I and
II. Divide the sum of both measurements to obtain a mean
diameter.
Crankshaft must be replaced if mean diameter of main or con-
rod journals is below specified limit - see "Technical Data".
If crankshaft is serviceable subtract crankshaft mean journal
diameters from corresponding shell bearing mean diameters to
determine bearing clearance.
Permissible main bearing clearance - 0.015 to 0.04mm/0.0006
to 0.002in.
Permissible con-rod bearing clearance - 0.006 to
0.031mm/0.002 to 0.001in.
Page 2534 of 4264
6C-10 ENGINE FUEL (C24SE)
Fuel Tube / Quick – Connector Fittings
Precautions
Do not light a match or create a flame.
Keep flames away from your work area to preven
t
flammable materials from catching fire.
Disconnect battery ground cable to preven
t
electrical shorts.
Pre-treat piping system or associated parts from
thermal damage or from spattering when welding
or similar heat-generating work.
Cautions During Work
140R100032
Legend
(1) O-ring
(2) Port
(3) Connector
(4) Plastic Tube
Do not expose the assembly to battery electrolyte or do
not wipe the assembly with a cloth used to wipe off spil
t
battery electorolyte.
Piping that has been splattered with battery electrolyte
or battery electrolyte soaked cloth that was wiped on the
piping cannot be used.
Removal
1. Open the fuel cap to relieve the fuel pressure in the
tank.
Use compressed air to remove any dirt on the fuel
quick connect fittings prior to disconnecting the
fittings.
141R100002
When disconnecting the fuel pipe, cover the area
with a cloth to prevent fuel from splashing as the
fuel pipe may still have some pressure in it.
2. For removal of the quick connector, hold the quick
connector in one hand, and pull out the connento
r
with the other hand while pressing the square
relieve button of the connector, as illustrated.
140R100037
NOTE: Do not use tools of any kind. Only use bare
hands when disconnecting the connector. Use a
lubricant (light oil) and/or push and pull the connecto
r
until the pipe is disconnected.
Cover the connectors that was removed with a
plastic bag, to prevent dust or rain water from
entering.
Page 2535 of 4264
ENGINE FUEL (C24SE) 6C-11
140R100028
Reuse of Quick–Connector
Replace the port and connector if scratch, dent or
crack is found.
Remove any dirt build up on the port when installing
the connector. Replace the connector, if there is any
forms of rust, dent, scratch.
After cleaning the port, insert it straight into the
connector until it clicks. After it clicks, try pulling a
t
49N (5kgf) it out to make sure that it is not drawn
and is securely locked.
140R100036
Assembling Advice
By applying engine oil or light oil to the pipe, port makes
pipe assembly easier. The pipe assembly should take
place immediately after applying oil (to prevent dus
t
from sticking to the pipe surface –which may
decrease sealing ability).
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Turn the ignition key to the “ON" position and listen
for pump start-up sound. Inspect for leaks, the
fuel pressure will increase as the fuel pump is
actuated.
3. Perform leak inspection (step 2) several times.
4. Start the engine and observe the engine idle speed.
The presence of dirt in the fuel system may affec
t
the fuel injection system.