torque ISUZU TF SERIES 2004 Workshop Manual

ENGINE MECHANICAL 6A – 115



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4JA1T(L):
4. Tighten the injection pump bolts to the specified torque.
5. Install the injection pump bracket (4) and the bracke
t
bolts (5) and (6) to the cylinder body. Temporarily tighten
the bracket bolts.
6. Tighten the bracket bolts (5) to the specified torque.
7. Tighten the bracket bolts (6) to the specified torque.


Injection pump Bracket Bolt Torque (6) N·m(kg·m/lbft)
19 (1.9/14)

Injection pump Bracket Bolt Torque (5) N·m(kg·m/lbft)
40 (4.1/30)



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24. Water Pump
1. Apply the recommended liquid gasket or its equivalent
to the water pump at the position shown in the
illustration.
Do not apply an excessive amount of liquid gasket.
2. Tighten the water pump bolts to the specified torque.


Water Pump Bolt Torque N·m(kg·m/lbft)
20 (2.0/14)













25.Timing Gear Case Cover
1.
Align the gear case with the timing gear case knock pin
and then install the timing gear case cover.
2. Tighten the gear case cover bolts to the specified
torque.


Gear Case Cover Bolt Torque N·m(kg·m/lbft)
M8 19 (1.9/14)
M12 76 (7.7/56)

























26. Crankshaft Damper Pulley
Tighten the crankshaft damper pulley bolt to the specified
torque.
Note:
Hold the flywheel ring gear stationary to prevent the
crankshaft from turning when tightening the damper
pulley bolt.


Crankshaft Damper Pulley Bolt Torque N·m(kg·m/lbft)
206 (21/152)
Take care not to damage the crankshaft damper pulley
boss.


014R100014 020R300004

6A – 116 ENGINE MECHANICAL


27. Cylinder Head Gasket
The cylinder head gasket "TOP" mark must be facing up.

NOTE:
Before the gasket installation, measure the piston
head projection and select the appropriate head
gasket.
Refer to "INSPECTION AND REPAIR", "Cylinder Head
Gasket Selection".









28. Cylinder Head
1. Align the cylinder body dowels and the cylinder head
dowel holes.
Carefully place the cylinder head on the cylinder head
gasket.
2. Apply a coat of engine oil to the cylinder head bolt
threads and setting faces.















3. Tighten the cylinder head bolts in three steps of anglar
tightening methed.
Follow the numerical sequence shown in the
illustration.


Cylinder Head Bolt Torque N·m(kg·m/lbft)
1st step 49 (5.0/36)
2nd step
60
- 75

3rd step
60
- 75













30. Rocker Arm Shaft and Rocker Arm
Tighten the rocker arm shaft bracket bolts in the numerical
order shown in the illustration.


Rocker Arm Shaft Braket Bolt Torque N·m(kg·m/lbft)
54 (5.5/40)











31. Thermostat Housing
1. Install the thermostat housing.
2. Tighten the thermostat housing bolts to the specified
torque.


Thermostat Housing Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)

014LX083 011LX073
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ENGINE MECHANICAL 6A – 117


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33. Injection Nozzle Holder
1. Install the injection nozzle gasket and the O-ring to the
injection nozzle holder.
Be sure that the O-ring fits snugly in the injection
nozzle groove.
2. Install the nozzle holder toghther with the nozzle holder
bracket to the cylinder head.










3. Tighten the nozzle holder bracket bolt to the specified
torque.


Injection Nozzle Holder Bracket Bolt
Torque N·m(kg·m/lbft)
37 (3.8/28)













Note on Valve Clearance Adjustment
Valve clearances must be adjusted before the cylinder
head cover is reinstalled.Refer to "Valve Clearance
Adjustment" in the "Servicing" Section of this manual.


Valve Clearance (At Cold) mm(in)
0.4 (0.0157)


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34. Cylinder Head Cover
1. Apply engine oil to the rocker arm and the valve spring.
2. Install the cylinder head cover gasket to the head
cover. Check to see that the head cover gasket has no
loose areas.
3. Tighten the cylinder head cover nuts in the numerical
order shown in the illustration.


Cylinder Head Cover Bolt Torque N·m(kg·m/lbft)
13 (1.3/9.4)
4. Connect the positive crankcase ventilation (PCV) hose
to the cylinder head cover.




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ENGINE MECHANICAL 6A – 119












Installation
1. Exhaust Manifold
1) Install the exhaust manifold to the cylinder head with
the manifold gasket.
2) Tighten the exhaust manifold bolts and nuts to the
specified torque a little at a time.
Exhaust Manifold Bolt and Nuts
Torque N·m(kg·m/Ib ft)
27 (2.7/20)




3) Install the exhaust manifold bracket to the manifold
and the cylinder body.
Manifold Bracket Bolt Torque N·m(kg·m/Ib ft)
19 (1.9/14)






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2. Oil Cooler with Oil Filter
1) Install the O-ring to the oil filter body flange groove.
2) Install the oil filter body to cylinder block and tighten to
the specified torque.
Oil Filter Body Bolt and Nut
Torque N·m(kg·m/Ib ft)
BOLT 19 (1.9/14)
NUT 24 (2.4/17)









3. Generator Bracket
Install the generator bracket to the cylinder body and
tighten the bracket bolts to the specified torque.
Bracket Bolt Torque N·m(kg·m/Ib ft)
40 (4.1/30)




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027R100004
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6A – 120 ENGINE MECHANICAL









4. Water Inlet Pipe
1) Tighten the water inlet pipe bolts to the specified
torque.
Suction Pipe Bolt Torque N·m(kg·m/Ib ft)
19 (1.9/14)





5. Generator and Adjusting Plate
1) Install the generator to the bracket (1).
2) Temporarily tighten the generator bolt (2) and
adjusting plate bolts (3).
The bolts will be finally tightened after installation of
the cooling fan drive belt.



3) Connect the vacuum pump rubber hose (4) to the
vacuum pump (5), and the oil pan (6).
6. Vacuum Pump Oil Return Hose
Connect the vacuum oil pipe (7) to the vacuum pump, and
the cylinder body

052R300001
7. Compressor Bracket
1) Install the compressor bracket to the cylinder head.
2) Tighten the bracket bolts to the specified torque.
Bracket Bolt Torque N·m(kg·m/Ib ft)
M8
1.25
19 (1.9/14)
M10
1.25
40 (4.1/30)











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ENGINE MECHANICAL 6A – 121
















8. Turbocharger
1) Install the turbocharger and the gasket.
2) Temporarily tighten the turbocharger nuts at this time.
They will be fully tightened after the installation of the
turbocharger oil pipe.
Always install new nuts and new gasket.











3) Install the oil return pipe with gasket to the
turbocharger.
4) Tighten the turbocharger oil return pipe to the
specified torque.
Bracket Bolt Torque N·m(kg·m/Ib ft)
8 (0.8/6)




5) Before installing the oil feed pipe, supply 10 - 20 cc of
clean engine oil to the turbocharger center housing
through the oil feed opening.
6) Turn the rotating assembly with your hand to
thoroughly lubricate the internal parts.
7) Tighten the oil feed pipe to the specified torque.
Turbocharger Oil Feed Pipe Joint
Bolt Torque N·m(kg·m/Ib ft)
M10
1.5
22 (2.25/16)
M14
1.5
54 (5.5/40)

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8) Tighten the turbocharger nut to the specified torque.
Turbocharger Nut Torque N·m(kg·m/Ib ft)
27 (2.7/20)




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6A – 122 ENGINE MECHANICAL

















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9) Install the water feed adapter (1) with the gaskets to
turbocharger and tighten to the specified torque.
Adapter Torque N·m(kg·m/Ib ft)
39 (4.0/29)

10) Install the water feed pipe with the gaskets and tighten
to the specified torque.
Water Return Pipe Torque N·m(kg·m/Ib ft)
39 (4.0/29)

11) Install the water return pipe with the gaskets and
tighten to the specified torque.
Water Return Torque N·m(kg·m/Ib ft)
39 (4.0/29)

12) Clamp the water feed pipe to the oil return pipe of the
turbocharger.
Fixing Bolt (3) Torque N·m(kg·m/Ib ft)
8 (0.8/6)

13) Install the hoses for the water feed and return.






















9. Catalytic Converter
Install the catalytic converter with gasket and tighten the
nut to the specified torque.
Catalytic converter Nut Torque N·m(kg·m/Ib ft)
27 (2.7/20)

Do not install the catalytic converter, if drop down it.
10. Heat Protector
Install the heat protector and tighten the bolt to the
specified torque.
Heat Protector Bolt Torque N·m(kg·m/Ib ft)
9 (0.9/6.5 Ib in)

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11. Cooling Fan Pulley
1) Install the cooling fan pulley to the water pump.
2) Tighten the cooling fan pulley nuts to the specified
torque.
Pulley Nut Torque N·m(kg·m/Ib ft)
8 (0.8/6)

12. Oil Cooler Water Pipe
13. Fuel Leak Off Pipe
14. Oil Pressure Warning Switch
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ENGINE MECHANICAL 6A – 123




15. Starter Motor
Tighten the starter motor bolts to the specified torque.
Starter Motor Bolt Torque N·m(kg·m/Ib ft)
85 (8.7/63)

16. Injection Pump
17. Injection Pump Cover (4JA1TC/4JH1TC only)


18. Engine Foot
Install the engine foot to the cylinder body and tighten the
bracket bolts to the specified torque.
Engine Foot Bolt Torque N·m(kg·m/Ib ft)
Right Side M10
1.25
40 (4.1/30)
M10
1.25
40 (4.1/30) Left Side
M14
1.50
127 (13/93)









4JA1L, 4JH1TC
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4JA1TC
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19. Intake Manifold
1) Install the manifold gasket to the intake manifold.
2) Connect the intake rubber hose to the intake duct.
3) Tighten the intake manifold bolts and the flange nuts
to the specified torque.
Intake Manifold Bolt Torque N·m(kg·m/Ib ft)
19 (1.9/14)

Intake Manifold Flange Nut Torque N·m(kg·m/Ib ft)
24 (2.4/18)

4) Connect the PCV hose to the cylinder head cover.

5) Install the fan drive belt and adjust the belt tension
referring SERVICING of this section

6A – 124 ENGINE MECHANICAL
20. Power Steering Oil Pump Bracket
Oil Pump Braket Nut and Bolt Torque N·m(kg·m/Ib ft)
1M10
1.25
37 (3.8/28)
2
3M8
1.25
18 (1.8/13) (Bolt ID:8)






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21. Fuel Injection Pipe with Clip
1) Temporarily tighten the injection pipe sleeve nut.
2) Set the clip in the illustrated position.
Note:
Make absolutely sure that the clip is correctly
positioned.
An improperly positioned clip will result in injection
pipe breakage and fuel pulsing noise.
3) Tighten the injection pipe sleeve nut to the specified
torque.
Torque
Injection Pump Side (4JA1TC/4JH1TC) N·m(kg·m/Ib ft)
40 (4.1/30)

Injection Pipe Sleeve Nuts N·m(kg·m/Ib ft)
29 (3.0/22)

Injection Pipe Clip Nuts N·m(kg·m/Ib ft)
8 (0.8/6)




















22. Fuel Filter Bracket (Except EURO III model)
Install the fuel filter bracket and tighten fixing bolts to the
specified torque.
Fuel Filter Bracket Bolt Torque N·m(kg·m/Ib ft)
21 (2.1/15)

23. Fuel Filter Assembly (Except EURO III model)
Install the fuel filter assembly and tighten fixing bolts to the
specified torque.
Fuel Filter Assembly Bolt Torque N·m(kg·m/Ib ft)
21 (2.1/15)








24. Oil Level Gauge
Install the oil level gauge and tighten fixing bolts to the
specified torque.
Oil Level Gauge Bolt Torque N·m(kg·m/Ib ft)

M8 19 (1.9/14)
M6 8 (0.8/6)

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ENGINE MECHANICAL 6A – 125







25. EGR Valve
Install the EGR valve assembly to the intake minifold with
the two gasket.
Tighten the four nuts to the specified torque.
Nut Tolque N·m(kg·m/Ib ft)
31 (3.1/23)

Connector the vacuum hose.





025R100008
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26-1. EGR Pipe
Install the EGR valve adapter with the gasket to the EGR
valve assembly and install the EGR pipe with the gasket.
Tighten fixing bolts and nuts to the specified torque.
EGR Valve Adapter Bolts N·m(kg·m/Ib ft)
24 (2.4/17)

EGR Pipe Bolts and Nuts N·m(kg·m/Ib ft)
27 (2.7/20)


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26-2. EGR Cooler (EURO III model only)
27. Intake Pipe and Throttle Body (4JA1TC/4JH1TC only)
Install the throttle body with the gasket to the intake
manifold and install the intake duct with the gasket.
Tighten the two bolts and the two nuts to the specified
torque.
Throttle Body and Intake Duct N·m(kg·m/Ib ft)
Bolt 19 (1.9/14)
Nut 24 (2.4/17)
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28. Clutch Assembly or Flex Plate