engine mechanical ISUZU TF SERIES 2004 Workshop Manual

6E-374 3.5L ENGINE DRIVEABILITY AND EMISSIONS
FUEL PRESSURE RELIEF
Caution:
To reduce the risk of the fire and personal injury, it
is necessary to relive the fuel system pressure
before servicing the fuel system components.
Caution:
After relieving the fuel system pressure, a small
amount of fuel may be released when servicing fuel
lines or connections. Reduce the chance o
f
personal injury by covering the fuel line fitting with
a short towel before disconnecting the fittings. The
towel will absorb any fuel that may leak out. When
the disconnect is completed, place the towel in an
approved container.

1. Remove the fuel filler cap.
2. Remove the fuel pump relay.
3. Start the engine and allow it to stall.
4. Crank the engine for about 30 seconds.
5. Disconnect the negative battery cable.



FUEL RAIL ASSEMBLY

Removal Procedure
NOTE:
 Do not attempt to remove the fuel inlet fitting on
the fuel rail. It is staked in place. Removing the
fuel inlet fitting will result in damage to the fuel
rail or the internal O-ring seal.
 Use care when removing the fuel rail assembly in
order to prevent damage to the injector electrical
connector terminals and the injector spray tips.
 Fittings should be capped and holes plugged
during servicing to prevent dirt and othe
r
contaminants from entering open lines and
passages.
Important: Before removal, the fuel rail assembly may
be cleaned with a spray type engine cleaner. Follow the
spray package instructions. Do not immerse the fuel
rails in liquid cleaning solvent.
1. Depressurize the fuel system. Refer to Fuel
Pressure Relief Procedure in this Section.
2. Disconnect the negative battery cable.
3. Remove the engine cover.
4. Disconnect the accelerator pedal cable from throttle
body and cable bracket.

5. Disconnect the connectors from, solenoid valve,
sensing valve.
6. Disconnect the vacuum hose on canister solenoid
and positive crankcase ventilation hose.
7. Remove the common chamber Refer to the
common chamber in Engine Mechanical.
1. Lift up carefully on the fuel injectors. Do no
t
separate the fuel injectors from the fuel rail.
2. If an injector becomes separated from the fuel
rail, the infector O-ring seals and the retaine
r
clip must be replaced.
3. Drain residual fuel into an approved container.




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8. If removal of the fuel pressure regulator is
necessary, refer to Fuel Pressure Regulator.
9. If removal of the fuel injectors is necessary, refer to
Fuel Injectors.

Installation Procedure
1. If the fuel injectors were removed, install them.
Refer to Fuel Injectors.
2. If the fuel pressure regulator was removed, install
it. Refer to Fuel Pressure Regulator.

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-375
3. Install the common chamber. Refer to common
chamber in engine Mechanical.




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4. Connect the vacuum hose on Canister Solenoid
and positive crankcase ventilation hose.
5. Connect the connectors to, solenoid valve.
6. Connect the accelerator pedal cable to throttle
body and cable bracket.
7. Install the engine cover.
8. Connect the negative battery cable.
9. Crank the engine until it starts. Cranking the
engine may take longer than usual due to trapped
air in the fuel rail and in the injectors.

FUEL INJECTORS

Removal Procedure
NOTE: If the fuel injectors are leaking, the engine oil
may be contaminated with fuel. Check the oil fo
r
signs of contamination and change the oil and the
filter if necessary.
NOTE: Use care in removing the fuel injectors in
order to prevent damage to the fuel injecto
r
electrical connector pins or the fuel injector
nozzles. The fuel injector is an electrical component
and should not be immersed in any type of cleane
r
as this may damage the fuel injector.
Important: Fuel injectors are serviced as a complete
assembly only.
1. Disconnect the negative battery cable.
2. Remove the upper intake manifold. Refer to
Common Chamber in Engine Mechanical..
3. Remove the fuel rail. Refer to Fuel Rail.




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6E-376 3.5L ENGINE DRIVEABILITY AND EMISSIONS
4. Remove the injector retainer clip.






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5. Remove the fuel injector assembly.
6. Remove the O-ring from the fuel injector.
7. Remove the O-ring backup from the fuel injector .

Inspection Procedure
1. Inspect the O-rings for cracks or leaks.
2. Replace worn or damaged O-rings.
3. Lubricate the new O-rings with engine oil before
installation.

Installation Procedure
1. Install the O-ring backup on the fuel injector.
2. Install the new O-ring on the fuel injector.
3. Install the fuel injector on the fuel rail.






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4. Use new fuel injector retainer clips to retain the fuel
injector to the fuel rail.
5. Coat the end of the fuel injector with engine oil.
6. Install the fuel rail. Refer to Fuel Rail.




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7. Install the upper intake manifold. Refer to Common
Chamber in Engine Mechanical.
8. Install the engine cover.
9. Connect the negative battery cable.

ENGINE DIAGNOSIS (C24SE) 6-9
Abnormal Noise Due to Hydraulic Lash Adjuster
Should abnormal noise due to the hydraulic lash
adjuster trouble be heard immediately after the engine
is started, inspect as follows:

Condition Possible cause Correction
Abnormal noise is heard Air contaminated Bleed
HLA is spongy Check ball valve broken Repair
Safety valve in cylinder head
broken Replace
Valve clearance is not zero HLA inside stick Replace HLA assembly

Troubleshooting Procedure
Short out each spark plug in sequence using insulated
spark plug wire removers. Locate cylinder with
defective bearing by listening for abnormal noise that
stops when spark plug is shorted out.

Condition Possible cause Correction
Noise from connecting rods or
from connecting rod bearings
(Faulty connecting rods or
connecting rod bearings usually
make an abnormal noise slightly
higher than the crank bearing
noise, which becomes more
evident when engine is
accelerated) Bearing or crankshaft pin worn Replace connecting rod bearings
and crankshaft or regrind
crankshaft and install the under
size bearing
Crankpin out of round Replace connecting rod bearings
and crankshaft or regrind
crankshaft and install the under
size bearing
Connecting rod bent Correct or replace
Connecting rod bearing seized Replace connecting rod bearings
and crankshaft or regrind
crankshaft and install the under
size bearing

Troubleshooting Procedure
Abnormal noise stops when the spark plug on the
cylinder with defective parts is shorted out.

Condition Possible cause Correction
Piston and cylinder
(Faulty piston or cylinder usually
makes a combined mechanical
thumping noise which increases
when engine is suddenly
accelerated but diminishes
gradually as the engine warms up) Piston clearance increased due to
cylinder wear Replace piston and cylinder body
Piston seized Replace piston and cylinder body
Piston ring broken Replace piston and cylinder body
Piston defective Replace pistons and others

ENGINE MECHANICAL (C24SE) 6A-1
SECTION 6A
ENGINE MECHANICAL
CONTENTS
PAGE
General Description......................................................................................................... 6A- 4
ENGINE PICTORIAL .................................................................................................... 6A- 6
Main Data and Specification ........................................................................................... 6A-11
CRANKCASE VENTILATION SYSTEM ....................................................................... 6A-16
ENGINE ASSEMBLY & LOOSE PARTS ..................................................................... 6A-17
OPERATIONS ON ENGINE AGGREGATES .................................................................... 6A-18
Engine Damping Blocks(Engine without Transmission)......................................... 6A-18
Toothed Belt and Timing Check ............................................................................... 6A-21
Toothed Belt Tension, Adjust .................................................................................... 6A-23
Toothed Belt, Replace ................................................................................................ 6A-24
OPERATIONS ON INSTALLED ENGINE ......................................................................... 6A-26
Gasket, Exhaust Manifold, Cylinder Head ................................................................ 6A-26
Gasket, Intake Manifold, Cylinder Head .................................................................... 6A-26
Seal Ring, Camshaft Housing, Timing Side .............................................................. 6A-27
Seal Ring, Thermostat Housing, Cylinder Head ....................................................... 6A-27
Seal Ring - Front Camshaft Housing, Replace ......................................................... 6A-28
Toother Belt Rear Cover ............................................................................................. 6A-30
Toother Belt Tension Roller ....................................................................................... 6A-31
COMPONENT PARTS ...................................................................................................... 6A-32
Cylinder Head .............................................................................................................. 6A-32
Hydraulic Valve Lifter.................................................................................................. 6A-33
OPERATIONS ON CYLINDER HEAD AND CAMSHAFT HOUSING ............................... 6A-34
Camshaft...................................................................................................................... 6A-34
Camshaft Housing Removal and Installation ........................................................... 6A-35
Cylinder Head .............................................................................................................. 6A-35
Hydraulic Valve Lifers, Replace ................................................................................. 6A-37
Camshaft Housing, Replace....................................................................................... 6A-37

6A-2 ENGINE MECHANICAL (C24SE)
PAGE
Camshaft Housing, Check for Plance Surface ......................................................... 6A-39
Cylinder Head, Removal and Installation .................................................................. 6A-39
Cylinder Head, Disassemble and Assemble ............................................................. 6A-42
Valve, Grind ................................................................................................................. 6A-44
Valve Guide, Ream ..................................................................................................... 6A-44
Valve Seating, Mill ....................................................................................................... 6A-45
Cylinder Head, Overhaul............................................................................................. 6A-45
Flywheel ....................................................................................................................... 6A-46
Starter Ring Gear(Manual Transmission) ................................................................. 6A-47
Seal Ring, Crankshaft ................................................................................................. 6A-48
Seal Ring, Crankshaft Rear ........................................................................................ 6A-48
Oil Pan and Bearing Bridge........................................................................................ 6A-49
OPERATIONS ON CRANK DRIVE ................................................................................... 6A-51
Con-Rod Bearing......................................................................................................... 6A-51
Piston with Con-Rod ................................................................................................... 6A-51
Con-Rod ....................................................................................................................... 6A-52
Pistion Rings ............................................................................................................... 6A-53
OPERATIONS ON REMOVED ENGINE ........................................................................... 6A-55
Crankshaft ................................................................................................................... 6A-55
Bearing Free Play Measurement ................................................................................ 6A-57
Plastigage Method ...................................................................................................... 6A-57
Micrometer and gauge method .................................................................................. 6A-58
Bypass Valve ............................................................................................................... 6A-59
Oil Filter ....................................................................................................................... 6A-59
Oil Pump ...................................................................................................................... 6A-59
Oil Pump Safety Valve ................................................................................................ 6A-60
Oil Pump(Overhaul) .................................................................................................... 6A-60
OPERATIONS ON OIL CIRCULATION ............................................................................ 6A-61
Cylinder Head Safety Valve ........................................................................................ 6A-61
OPERATIONS ON COOLING SYSYTEM ......................................................................... 6A-63
Cooling System, Check for Leakes ........................................................................... 6A-63
Cooling System, Fill Up and Bleed ............................................................................ 6A-63
Refill Coolant ............................................................................................................... 6A-64
Ignition Timing, Check................................................................................................ 6A-64

ENGINE MECHANICAL (C24SE) 6A-3
PAGE
ENGINE EXTERNAL PARTS ............................................................................................ 6A-65
Radiator ....................................................................................................................... 6A-65
Thermostat................................................................................................................... 6A-66
Water Pump ................................................................................................................. 6A-66
Coating sealing surfaces with Silicone Grease ....................................................... 6A-67
Alternator ..................................................................................................................... 6A-67
Starter .......................................................................................................................... 6A-67
V-belt Tension of Alternator ....................................................................................... 6A-68
FUEL INJECTION SYSTEM.............................................................................................. 6A-69
Map Sensor.................................................................................................................. 6A-69
Pressure Regulator ..................................................................................................... 6A-69
ECM (Engine Control Module).................................................................................... 6A-69
ECT ............................................................................................................................... 6A-70
Idle Air Control(IAC) Valve.......................................................................................... 6A-70
Ignition Coil ................................................................................................................. 6A-70
Crank Position Sensor................................................................................................ 6A-71
FUEL INJECTOR .............................................................................................................. 6A-72
Knock Sensor .............................................................................................................. 6A-72
Oxygen Sensor ............................................................................................................ 6A-73
Throttle Valve Position Sensor .................................................................................. 6A-73
Acclelerator Pedal and Cable..................................................................................... 6A-73
Air Cleaner Filter ......................................................................................................... 6A-74
Spark Plug Thread ...................................................................................................... 6A-75
TECHNICAL DATA ........................................................................................................... 6A-76
Recommended Troque Values................................................................................... 6A-87
SPECIAL SERVICE TOOL................................................................................................ 6A-88

6A-4 ENGINE MECHANICAL (C24SE)
GENERAL DESCRIPTION

Engine Cleanliness And Care
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances
that are measured in the thousandths of a millimeter (ten thousandths of an inch). Accordingly, when any internal
engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that
proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is
considered standard shop practice even if not specifically stated.

A liberal coating of engine oil should be applied to all friction areas during assembly to protect and lubricate
the surfaces on initial operation.

Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft journal
bearings are removed for service, they should be retained in order.


At the time of installation, they should be installed in the same locations and with the same mating surfaced as
when removed.

Battery cables should be disconnected before any major work is performed on the engine. Failure to
disconnect cables may result in damage to wire harness or other electrical parts.

The four cylinders of this engine are identified by numbers; cylinders 1, 2, 3 and 4, as counted from crankshaft
pulley.
General Information on Engine Service
The following information on engine service should be noted carefully, as it is important in preventing damage and

ENGINE MECHANICAL (C24SE) 6A-5
contributing to reliable engine performance:

When raising or supporting the engine for any reason, do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump strainer, jacking against the oil pan may cause damage to the
oil pick up unit.

The 12-volt electrical system is capable of damaging circuits. When performing any work where electrical
terminals could possible be grounded, the ground cable of the battery should be disconnected at the battery.

Any time the intake air duct or air cleaner is removed, the intake opening should be covered. This will protect
against accidental entrance of foreign material into the cylinder which could cause extensive damage when
the engine is started.

Cylinder Block
The cylinder block is made of cast iron. The crankshaft is supported by five bearings. The bearing cap is made of
nodular cast iron.

Cylinder Head
The cylinder head is made of aluminum alloy casting with a spark plug in the center.

Valve Train
Valve system is a single over head camshaft.
The valves clearance adjustment are hydraulic.
Hydraulic valve lifter adjustment, no adjustment necessary.

Intake Manifold
The intake manifold is made of aluminum alloy.

Exhaust Manifold
The exhaust manifold is made of high Si-Mo nodular iron.

Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade that meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made of cast hardened steel. The connecting rod bearings are
made of modular cast iron. The connecting rod bearings are made of steel backed with tri-metal babbitt metal.

Crankshaft and Bearings
The crank shaft is made of modular cast iron. Pins and journal are graded for correct size selection for their bearing.

6A-6 ENGINE MECHANICAL (C24SE)
ENGINE PICTORIAL
Front View
“4WD OIL PAN”