oil ISUZU TF SERIES 2004 Workshop Manual

ENGINE MECHANICAL 6A – 93
REASSEMBLY
INTERNAL PARTS
MINOR COMPONENT
ROCKER ARM SHAFT AND ROCKER ARM


020RY00029


Reassembly Steps
1.
Rocker arm shaft 5.
Rocker arm
2.
Rocker arm shaft snap ring 6.
Rocker arm shaft spring
3.
Rocker arm 7.
Rocker arm shaft snap ring
4.
Rocker arm shaft bracket









Reassembly
1. Rocker Arm Shaft
1. Position the rocker arm shaft with the large oil hole (4

) facing the front of the engine.
2. Install the rocker arm shaft together with the rocker
arm, the rocker arm shaft bracket, and the spring.
2. Rocker Arm Shaft Snap Ring
3. Rocker Arm
4. Rocker Arm Shaft Bracket
5. Rocker Arm
6. Rocker Arm Shaft Spring
7. Rocker Arm Shaft Snap Ring

014RY00037

6A – 94 ENGINE MECHANICAL
CYLINDER HEAD




RTW46ALF001301


Reassembly Steps
1.
Cylinder head 6.
Valve spring upper seat
2.
Valve spring lower seat 7.
Split collar
3.
Valve stem oil seal 8.
Intake manifold gasket
4. Intake and exhaust valve 9. Intake manifold
5.
Valve spring

ENGINE MECHANICAL 6A – 95
















Reassembly
1. Cylinder Head
2. Valve Spring Lower Seat
3. Valve Stem Oil Seal
1. Apply a coat of engine oil to the oil seal inner face.
2. Use an oil seal installer to install the oil seal to the
valve guide.
Oil Seal Installer: 5-8840-2033-0
4. Intake and Exhaust Valve
1. Apply a coat of engine oil to each valve stem before
installation.
2. Install the intake and exhaust valves.
3. Turn the cylinder head up to install the valve
springs.Take care not to allow the installed valves to
fall free.







5. Valve Spring
Install the valve spring with their fine pitched end (painted)
facing down.

6. Valve Spring Upper Seat









7. Split Collar
1. Use the spring compressor to compress the valve
spring into position.
Spring Compressor: 9-8523-1423-0
2. Install the split collars to the valve stem.
3. Set the split collars by tapping around the head of the
collar with a rubber hammer.





RTW46ASH002301








8. Intake manifold gasket
9. Intake manifold
1. Install the manifold gasket with the end having the
sharp corners facing the rear of the engine.
2. Install the intake manifold to the cylinder head.
3. Tighten the manifold bolt/nuts to the specified torque.


Manifold Bolt/Nut Torque N·m(kg·m/lbft)
Bolt 19 (1.9/14)
Nut 24 (2.4/17)

011RW027
011LX055

014RY00039

ENGINE MECHANICAL 6A – 97


Reassembly
1. Piston
2. Connecting Rod
1. Clamp the connecting rod in a vise.Take care not to
damage the connecting rod.
2. Use a pair of pliers to install the piston pin snap ring to
the piston.





RTW36ASH001801
Install the piston to the connecting rod so that the piston
head front mark (1) and the connecting rod mark (2) are
facing in the same direction.
3. Piston Pin Snap Ring




RTW36ASH001901


4. Piston Pin
1. Apply a coat of engine oil to the piston pin and the
piston pin hole.
2. Use your fingers to force the piston pin into the piston
until it makes contact with the snap ring.



5. Piston Pin Snap Ring
1. Use your fingers to force the piston pin snap ring into
the piston snap ring groove.
2. Check that the connecting rod moves smoothly on the
piston pin.



F06MV015
015R100001

6A – 98 ENGINE MECHANICAL


RTW36ASH002001




































6. Piston Ring
1. Use a piston ring replacer to install the three piston
rings.
Piston Ring Replacer
Install the piston rings in the order shown in the
illustration.
1. Oil ring
2. 2nd compression ring
3. 1st compression ring

NOTE:
Install the compression rings with the stamped side
facing up.
Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil
before installing the oil ring.

2. Apply engine oil to the piston ring surfaces.
3. Check that the piston rings rotate smoothly in the
piston ring grooves





7. Connecting Rod Bearing
Carefully wipe any oil or other foreign material from the
connecting rod bearing back face and the connecting rod
bearing fitting surface.




015R100006

ENGINE MECHANICAL 6A – 99

POSITIVE CRANKCASE VENTILATION (PCV) VALVE



RTW46AMF000101


Reassembly Steps
1. Positive Crankcase Ventilation
(PCV) Valve 5.
Fixing bolt
2.
Rubber space 6.
Oil filler cap
3.
Cylinder head insulator cover

4.
Breather pipe

6A – 100 ENGINE MECHANICAL














Reassembly
1. PCV Valve
Install the PCV valve and tighten the bolts to specified
torque.


PCV Valve Bolts Torque N·m(kg·m/lb in)
2 (0.2/17)
2. Rubber Spacer
3. Cylinder Head Insulator Cover







RTW36ASH001401












4. Breather Hose
Apply LOCTITE 262 or equivalent to the new breather pipe.
Do not reuse the breather pipe.
5. Fixing Bolt


Fixing Bolt Torque N·m(kg·m/lb in)
19 (1.9/14)

6. Oil Filler Cap


010R100014

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


014R300004

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.


015R100004015R100003
014LX088
015LX125

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.


015LX115
015LX127
015LX128
015LX129