water pump ISUZU TF SERIES 2004 User Guide

ENGINE MECHANICAL 6A – 43

ENGINE OVERHAUL
REMOVAL
EXTERNAL PARTS


RTW36AMF000401

Removal Steps
1. Clutch Assembly or Flex Plate
2. Intake Pipe and Throttle Body
3-1. EGR Pipe
3-2. EGR cooler (EURO III model only)
4. EGR Valve
5. Oil Level Gauge
6. Fuel Filter Assembly (Except EURO III)
7. Fuel Filter Bracket (Except EURO III)
8. Fuel Injection Pipe with Clip
9. Power Steering Oil Pump Bracket
10. Intake Manifold
11. Engine Mounting Bracket and Foot
12. Injection Pump Cover
13. Injection Pump
14. Starter Motor
15. Oil Pressure Warning Switch
16. Fuel Leak Off Pipe
17. Oil Cooler Water Pipe
18. Cooling Fan Pulley
19. Heat Protector
20. Catalytic Converter
21. Turbocharger
22. Compressor Bracket
23. Vacuum Pump Oil Return Hose
24. Generator and Adjusting Plate
25. Water Inlet Pipe
26. Generator Bracket
27. Oil Cooler with Oil Filter
28. Exhaust Manifold

6A – 46 ENGINE MECHANICAL
13. Injection Pump
Rrefer to secton 6C-19 (Injection Iump)

14. Starter Motor
15. Oil Pressure Warning Switch
16. Fuel Leak Off Pipe
17. Oil Cooler Water Pipe
18. Cooling Fan Pulley
19. Heat Protector


20. Catalytic Converter




21. Turbocharger
1) Disconnect the water hose between thermostat
housing cover and turbocharger.
2) Disconnect the water hose between water inlet pipe
and turbocharger.
3) Remove the oil feed pipe.
4) Remove the oil return pipe.
5) Remove the turbocharger and the gasket.
NOTE:
Plug the turbocharger body oil ports and water ports after
removing the turbocharger assembly to prevent the entry
of foreign material.


22. Compressor Bracket
23. Vacuum Pump Oil Return Hose
24. Generator and Adjusting Plate
25. Water Inlet Pipe
26. Generator Bracket
27. Oil Cooler with Oil Filter
28. Exhaust Manifold


027R100007
037RY00001

6A – 48 ENGINE MECHANICAL







RTW46ALF000101


Disassembly Steps-2
9. Crankshaft damper pulley
10. Timing gear case cove
11. Water pump
12. Idle gear "B" and shaft
13. Idle gear "A"
14. Idle gear shaft
15. Crankshaft timing gear
16. Injection pump

ENGINE MECHANICAL 6A – 51

10. Timing Gear Case Cover
The timing gear case is tightened together with the
injection pump at the 6 points indicated by the arrows in
the illustration.

11. Water Pump



12. Idle Gear B and shaft
Before removing the idle gear B, install bolt (M6,L=30) to
the hole marked with an arrow in the illustration to hold the
scissor gear in place.



13. Idler Gear "A"
1. Measure the camshaft timing gear backlash and the
crankshaft timing gear backlash before removing the
idler gear.
2. Measure the idler gear end play before removing the
idler gear.

NOTE:
Refer to the following items for details on the backlash
and end play measurement procedures.



Timing Gear Backlash Measurement
1. Set a dial indicator to the timing gear to measured.
Hold both the gear to be checked and the adjusting
gear stationary.
2. Move the gear to be checked as far as possible to
both the right and the left.
Take the dial indicator reading.
If the measured value exceeds the specified limit, the
timing gear must be replaced.

Timing Gear Backlash mm (in)
Standard Limit
0.10 - 0.17 (0.0039 - 0.0067) 0.30 (0.012)
020L200006
020L200020
020RY00019
020RY00020

6A – 102 ENGINE MECHANICAL







RTW46ALF000501


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 – 115



RTW46ASH002201




















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 – 118 ENGINE MECHANICAL

INSTALLATION
EXTERNAL PARTS





RTW36AMF000701
Installation Steps
1.
Exhaust Manifold 18. Engine Mounting Bracket and
2.
Oil Cooler with Oil Filter Foot
3. Generator Bracket 19. Intake Manifold
4. Water Inlet Pipe 20. Power Steering Oil Pump
5.
Generator and Adjusting Plate Bracket
6.
Vacuum Pump Oil Return Hose 21. Fuel Injection Pipe with Clip
7.
Compressor Bracket 22. Fuel Filter Bracket (Except
EURO III)
8. Turbocharger 23. Fuel Filter Assembly (Except
EURO III)
9. Catalytic Converter 24. Oil Level Gauge
10. Heat Protector 25. EGR Valve
11. Cooling Fan Pulley 26-1. EGR Pipe
12. Oil Cooler Water Pipe 26-2. EGR Cooler (EURO III model
only)
13. Fuel Leak Off Pipe 27. Intake Pipe and Throttle Body
(4JA1TC/4JH1TC only)
14. Oil Pressure Warning Switch 28. Clutch Assembly or Flex Plate
15. Starter Motor
16. Injection Pump
17. Injection Pump Cover

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)











066RY00002 032R300001
042RY00003

6A – 122 ENGINE MECHANICAL

















RTW46ASH001601































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)

033R300002











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
027R100007

ENGINE MECHANICAL 6A – 127

OIL PUMP AND OIL FILTER




RTW46ALF001501

The 4J series engine is equipped with a gear type oil pump.
The oil filter and the water cooled oil cooler integrated a single unit to increase the cooling effect.