ISUZU TF SERIES 2004 Workshop Manual

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.

6A-44 ENGINE MECHANICAL (C24SE)








Valve, Grind
Valves can be reused once or twice after regrinding-only if
there are no crater-like burns on the valve cone.
Excessive grinding can cause the upper valve head edge to
become too thin.

Important!
Valve stem protection must not exceed dimension “A”-use 5-
8840-2596-0.
Do not regrind valve stem ends.
For all valve reworking note that angle of valve head is 44
and
the valve seat 45
-see also “Technical Data”.











Valve, Grind In
Grind-In the valve to improve valve seating.
Grind-In by rhythmically lifting valves and turning uniformly.
Use commercially available grinding tool.

Important!
Use only fine-grained pastes for grinding.
Lubricate valve stem before grinding in.

Clean
After grinding, carefully clean valve and valve soat.







Valve Guide, Ream
Measure
Diameter of valve guide-dial gauge and internal measuring
instrument.

Important!
Valve oversizes are available ex-works.
Oversize identification, on the valve guide and on the valve
stem end with the following specified identificaton
flgures/letters-see also “Technical Data”.



Identification Mark
Size Production Customer Service Reamer

Normal none K
0.075 mm 1 K1
0.150mm 2 K2

Ream valve guide from the upper side of the cylinder head to
the next oversize (use 5-8840-2599-0).
After reaming, cross out identification mark and stamp in new
identification mark.

ENGINE MECHANICAL (C24SE) 6A-45



Valve Seating, Mill
Place cylinder head on block of wood.
Inlet and exhaust, Guide Drift and Valve Seat Cutter 5-8840-
2593-0.
Valve seat-45, side face, upper correction-30, side face
(arrows on cutter).
Valve seat width:

Inlet-1.0 to 1.5 mm/0.04 to 0.06 in.
Exhaust-1.7 to 2.2 mm/0.072 to 0.088 in.




Inspection
Valve stem projection-use 5-8840-2596-0.

Important!
If dimension “A” is exceeded, use new valves.
Check valve stem projection again. If dimension “A” is
exceeded, replace cylinder head.








Cylinder Head, Overhaul
Cylinder head disassembled.

Valve, Grind
Important!
Ensure that there are no crater-like burns on the valve cone.

Regrinding possible once or twice.
Grinding of valve stem end is not permitted.

Angle at valve head-44




Inspection
Check valve stem projection as shown 5-8840-2596-0.



Valve, Grind in
Lubricate valve stem, use fine-graining grinding paste.

Lift up valve from seat rythmically using valve grinding tool (1)
for distribution of grinding paste.

6A-46 ENGINE MECHANICAL (C24SE)





Inspection
Check contact pattern (I
) on valve seat and in cylinder head.

Clean
Valves, valve guides, cylinder head.

Flywheel

Removal
1. Remove transmission and clutch.
2. Remove flywheel while locking with 5-88400-446-0.







Torque - Angle Method
Flywheel to crankshaft - 65 Nm/6.5 kgf

m.+30
to 45


Important!
Use new bolts.
Do not apply grease to the thread.

Installation
1. Install clutch and transmission.



Component Parts
Flywheel and Ring gear. (Manual Transmission)

ENGINE MECHANICAL (C24SE) 6A-47

Starter Ring Gear (Manual Transmission)
Removal
1. Remove flywheel according to the corresponding
operation.
2. Drill starter ring gear underneath tooth gap approx.
8mm/0.30in. deep with 8mm/0.25in. diameter drill.



3. Separate starter ring gear with chisel on the drilling point.



Installation
1. Install starter ring gear with inner chamfered edge to
flywheel.
2. Heat starter ring gear evenly to 180
C /356
F to 230
C
/446
F (yellow paint mark)
3. Install flywheel according to the corresponding operation.


Inspection
Lateral run-out of starter ring gear - max. 0.5mm/0.02in.

6A-48 ENGINE MECHANICAL (C24SE)
Seal Ring, Crankshaft
(Oil Pump Housing)

Removal
1. Remove toothed belt rear cover according to the
corresponding operation.
2. Remove sealing ring by making hole in middle of ring,
turning in self-tapping screw and edging out.


Installation
1 Install the protective sleeve to the crankshaft.
2. Coat the sealing lip with protective grease.
3. Install the sealing ring.
4. Install the sealing ring using 5-8840-0455-0.
5. Install the rear toothed belt cover and toothed belt
according to the corresponding operations.
6. Replace the sealing ring with a new one.
7. Tighten the belt to the crankshaft.



Seal Ring, Crankshaft Rear
Removal
1. Remove transmission and clutch.
2. Remove flywheel or flex plate according to the
corresponding operations.
3. Make hole in middle of sealing ring, turn in self-tapping
screw and edge out.



Installation
1. Install protective sleeve.
2. Coat sealing lip with Protective Grease.
3. Install sealing ring using 5-8840-0459-0 and 5-8840-
2597-0.
4. Install flywheel, clutch and transmission.

ENGINE MECHANICAL (C24SE) 6A-49






Reassembly
Reassemble clutch assembly.

Disassembly
Disassemble clutch assembly to flywheel using 5-8840-2634-0

Torque Angle-Method
Clutch assembly to flywheel-17.6Nm/1.8 kgf

m.


RTW46ASH002801
Oil Pan and Bearing Bridge
Removal
1. Remove the crossmember.
2. Shift downward the power steering unit (and front axle [4 4 model only]).
3. Loosen fixing bolts.
4. Remove oil pan from oil pump and cylinder block.
5. Remove oil intake pipe, oil intake pipe bracket, and oil baffle plate.
6. Remove the bearing bridge.

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)