Cylinder head removal ISUZU TF SERIES 2004 Owner's Manual

ENGINE MECHANICAL (C24SE) 6A-27



Seal Ring, Camshaft Housing, Timing Side
Removal
1. Remove front toothed belt cover toothed belt from
camshaft timing gear according to the corresponding
operation.
2. Remove camshaft housing cover and camshaft timing
gear.
3. Remove sealing ring by making hole in middle of ring,
turning in self-tapping screw and edging out.


Installation
1. Install sealing ring by using 5-8840-0451-0 with camshaft
sprocket bolt and washer.
2. Install coat seal lips of shaft seal ring slightly.



Seal Ring, Thermostat Housing, Cylinder Head
Removal
1. Open radiator drain tap and collect coolant.
2. Remove toothed belt rear cover and toothed belt
according to the corresponding operation.
3. Remove camshaft housing cover.
4. Remove camshaft timing gear by counterholding
camshaft with a flat spanner.
5. Remove cable from temperature sensor.






6. Remove upper inner hex bolts of rear toothed belt cover.
7. Turn rear toothed belt cover to one side.
8. Remove thermostat housing.
9. Remove sealing ring from cylinder head.

Clean
Sealing surfaces in cylinder head and thermostat housing.

Installation
1. Install sealing ring in recess of cylinder head.

6A-28 ENGINE MECHANICAL (C24SE)


2. Install cable to temperature sensor.
3. Install upper bolts of rear toothed belt rear cover.
4. Install camshaft timing gear then check timing according
to the corresponding operation.
5. Install camshaft housing cover.
6. Install toothed belt and front cover.
7. Fill up and bleed cooling system according to the
corresponding operation.


Tighten (Torque)
Thermostat housing to cylinder head - 15 N
m/1.5 kgf
m.




Seal Ring - Front Camshaft Housing, Replace
Removal
Mark running direction of toothed belt.
Remove toothed belt-see operation “Toothed Belt, Replace”.

Camshaft housing cover, camshaft pulley-counterhold on hex
of camshaft.


Removal
Screw self-tapping screw into seal ring.

Edge out seal ring.

Installation
Lightly coat sealing lip of seal ring with protective grease.

Install seal ring with 5-8840-0451-0 into camshaft housing-use
screw and washer of camshaft pulley.

6A-34 ENGINE MECHANICAL (C24SE)
OPERATIONS ON CYLINDER HEAD AND CAMSHAFT
HOUSING
Camshaft



Removal
1. Remove cylinder head according to the corresponding
operation.
2. Remove camshaft housing from cylinder head and lay
housing on base provided
3. Remove rear sealing gasket and plate camshaft housing
with taking care not to damage housing.
4. Remove thrust plate.





5. Remove camshaft.
6. Remove front sealing gasket and plate from camshaft
housing with taking care not to damage housing.

Inspection
All parts.







Installation
1. Install camshaft.
2. Coat sliding surfaces with molybdenum disulphate paste.

Tighten (Torque)
Thrust plate for camshaft housing - 8 N

m (0.8 kgf

m)

ENGINE MECHANICAL (C24SE) 6A-35
Camshaft Housing, Removal and
Installation

Cylinder Head
Important!
Remove cylinder head only from cold engine (room
temperature).



Removal
1. Remove ground cable from battery.
2. Open radiator drain tap and collect coolant.
3. Remove air intake hose.
4. Remove all cable connections, hoses and lines to the
cylinder head.
5. Remove accelerator cable on the throttle valve.
6. Remove V-belt for alternator.



7. Remove front toothed belt cover according to the
corresponding operation.
8. Bring piston of 1st cylinder to TDC and mark the position.
9. Remove camshaft housing cover.
10. Remove camshaft timing gear after releasing tension on
toothed belt.


11. Remove upper bolts of rear toothed belt cover.
12. Remove exhaust pipe from exhaust manifold.
13. Remove cylinder head after loosening bolts from outside
inwards (at first quarter turn then half turn) in a spiral
pattern.
14. Remove camshaft housing from cylinder head.
15. Remove rocker arm, pressure parts and hydraulic valve
lifter adjuster.

ENGINE MECHANICAL (C24SE) 6A-37


Hydraulic Valve Lifters, Replace
Removal
1. Remove the spark plug connectors and spark plugs.
2. Remove the camshaft housing cover.


Removal
3. Turn the crankshaft at fastening bolt of toothed belt drive
gear in the direction of the engine rotation until the cam
of hydraulic valve lifter being replaced stands vertically.


Removal
4. Apply 5-8840-0457-0 to the camshaft housing, valve
spring cap and tension valve spring.


Removal
5. Remove the cam follower from camshaft housing.
Note thrust pieces.
6. Remove hydraulic valve lifter from camshaft housing.



Camshaft Housing, Replace
Removal
Cylinder head-see operation “Cylinder Head. Remove and
Install”.

ENGINE MECHANICAL (C24SE) 6A-39







Camshaft Housing, Check for Plane Surface
Clean
Sealing surfaces.

Inspection
Check length and width of sealing surface for deformation and
diagnosis for warpage and use straight edge feeler gauge.

Measure
Height of camshaft housing (sealing surface to sealing
surface).
Dimension I: (74.0 mm)



Cylinder Head, Removal and Installation
Important
Only remove cylinder head with engine cold (room
temperature).




Removal
1. Remove the alternator, power steering and V-belts.



Removal
2. Loosen the fastening bolts from alternator.
3. Loosen the lower alternator fastening bolt by swinging
the alternator to the rear.



Removal
4. Remove the front toothed belt cover.
5. Remove the toothed belt from camshaft pulley.
See operation "Timing Check and Adjust".

6A-40 ENGINE MECHANICAL (C24SE)




Removal
6. Remove the camshaft housing cover and camshaft
pulley by counter-holding at the hex head of camshaft.




Removal
7. Remove the fastening bolts from camshaft housing.



Removal
8. Remove the exhaust pipe from exhaust manifold.
9. Loosen the cylinder head bolts spirally from the outside
inwards (first 1/4, then 1/2 revolution).



Removal
1. Remove the camshaft housing from cylinder head.
2. Remove the cam followers, thrust pieces and hydraulic
valve lifters.
Note the allocation.
3. Remove the cylinder head.




Clean
Sealing surfaces, bores and threads of cylinder head bolts.

Inspection
Check cylinder head and cylinder block for plane surfface-see
operations “Cylinder Head, Check for Plane Surface” and
“Cylinder Block, Check for Plane Surface.”

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.

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-51
OPERATIONS ON CRANK DRIVE
Con-Rod Bearing








Removal
1. Remove oil pan and bearing bridge according to the corresponding operation.
2. Remove con-rod bearing cap and con-rod bearing after marking both sides.

Clean
Con-rod journal, con-rod bearing cap










Installation
1. Install new bearing shafts lightly coated with engine oil.
2. Install con-rod bearing cap.

Torque-Angle Method
Con-rod bearing cap to con-rod - 35N

m (3.5 kgf

m) +45 
to
60 


Important!
Use new bolts.

3. Install oil pan and bearing bridge according to the corresponding operation.



Piston with Con-Rod
Removal
1. Remove cylinder head and oil pan according to the corresponding operations.
2. Remove piston with con-rod after marking con-rod bearing cap.





Inspection
Remove and install all parts, if applicable.

Important!
Ring gap offset:
Piston rings - 180 
.
Oil scraper rings - 25 to 50 mm/1 to 2 in. from gap of
intermediate ring to the left and to the right.