torque ISUZU TF SERIES 2004 Workshop Manual

6A-66 ENGINE MECHANICAL (C24SE)

Installation
Follow the removal procedure in the reverse order to install the
radiator.



Thermostat
Removal
1. Remove water outlet nozzles with thermostat from
thermostat housing.
2. Remove coolant hose and collect coolant.







Important!
Remove and Install thermostat only together with water outlet
nozzles.

Tighten (Torque)
Water outlet nozzles to thermostat housing - 8 N

m (0.8 kgf

m)

Installation
1. Install coolant hose.
2. Fill cooling system and bleed according to the
corresponding operation.










Water Pump
Removal
1. Remove lower hose band from pipe band and collect
coolant.
2. Remove front toothed belt cover according to the
corresponding operation.
3. Remove water pump from cylinder block after releasing
tension on toothed belt.

Clean
Sealing surfaces

ENGINE MECHANICAL (C24SE) 6A-67

Coating sealing surfaces with Silicone Grease
Installation
1. Install water pump to cylinder block with new rubber O-
ring.
2. Apply tension to toothed belt according to the
corresponding operation.
3. Install coolant hoses.
4. Fill cooling system and bleed according to the
corresponding operation.










Alternator
Removal
1. Remove ground cable from battery.
2. Remove cable connection from alternator and V-belt.
3. Remove alternator from retaining strap and lower
fastening.

Installation
1. Install alternator by tightening firmly by hand.
2. Install V-belt and apply tension according to the
corresponding operation.
3. Install cable connections to alternator.
4. Install ground cable to battery.




Starter
Removeal
1. Remove cable connections from starter.
2. Remove upper bolt of transmission side.
3. Remove lower bolt of engine side.

Tighten (Torque)
Starter to cylinder block:
Engine side - 51 N

m (5.2 kgf

m)
Transmission side - 75 N

m (7.6 kgf

m)

Starter support to cylinder block - 25 N

m (2.5 kgf

m)

Re-connect cables.

6A-68 ENGINE MECHANICAL (C24SE)
V-belt Tension of Alternator

Measure
Measure V-belt tension of alternator.
Permitted values for new V-belt are approx. 311-489N (31-50
kgf).
Note:
V-belt to deflection as loaded with 10kg : 8-12mm.





Adjust
Adjust V-belt tension by loosening clamping bracket and lower
alternator bracket and moving alternator.

Tighten (Torque)
Clamping bracket to alternator - 35 N

m (3.6 kgf

m)
Lower alternator bracket - 25 N

m (2.6 kgf

m)

V-Belt Tension of Power Steering Pump
Measure
Measure V-belt tension of power steering pump. Permitted
values for new belt are approx. 578-712N (59-73 kgf) and 534-
667N (54-68 kgf) for used belt.
Note:
V-belt to deflection as loaded with 10kg : 8-12mm.





Adjust
Adjust V-belt tension by loosening clamping bolt, lower pump
bracket, and adjusting nuts and moving steering pump.

Tighten (Torque)
Adjusting nuts - 18 N

m (1.8 kgf

m)
Clamping bolt - 25 N

m (2.6 kgf

m)
Lower pump bracket - 26 N
m (2.6 kgf
m)

6A-70 ENGINE MECHANICAL (C24SE)
Installation

(2.4L)
1. Install the ECM to the ECM bracket on engine.
2. Tighten the four screws to the bracket.
3. Connect the connector.









ECT
Removal
1. Remove wiring harness plug and coolant temperature
sensor.

Tighten (Torque)
Temperature sensor to intake pipe - 10 N

m (1.0 kgf

m)
Wiring harness plug to temperature sensor

Inspection
Coolant level







Idle Air Control (IAC) Valve
Removal
1. Remove wiring harness plug, hose clamps and idle
speed adjuster.

Installation
1. Install idle speed adjuster, hose clamps and wiring
harness plug.






Ignition Coil
Removal
1. Remove 2 bolts, plug and ignition coil.

Installation
1. Install ignition coil, plug and bolts.

6A-72 ENGINE MECHANICAL (C24SE)
FUEL INJECTOR



Removal
Caution: To reduce the risk of fire and personal injury, it is
necessary to relieve 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 of personal injury by
covering the fuel line fitting with a shop 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. Depressurize the fuel system.
2. Disconnect the fuel inlet.
3. Disconnect the fuel return line.
4. Remove the fuel rail from the intake manifold.
5. Remove the fuel injector from the fuel rail by disengaging
claws.

Installation
1. Install the fuel injector to the fuel rail by engaging claws.
2. Install the fuel rail to the intake manifold.
3. Connect the fuel return line firmly.
4. Connect the fuel supply line firmly.





Knock sensor
Removal
1. Remove fixing bolts.
2. Disconnect the connector at the other side.


Tighten (Torque)
Oxygen sensor in exhaust pipe - 30N

m (3.2 kgf

m)
When re-using, insert oxygen sensor.

ENGINE MECHANICAL (C24SE) 6A-73




Oxygen Sensor (If applicable)
Removal
1. Remove wiring harness plug.
2. Remove oxygen sensor from the front exhaust pipe.


Tighten (Torque)
Oxygen sensor in exhaust pipe - 30 N

m (3.1 kgf

m)









Throttle Valve Position Sensor
Removal
1. Remove wiring harness connector.
2. Remove throttle valve position sensor.

Installation
1. Install throttle valve position sensor.
2. Install wiring harness connector.


Accelerator Pedal and Cable
Removal
1. Remove pad stopper from pedal stop bolt.





Installation
1. Install pad stopper.

Inspection
Ensure that accelerator pedal is fully in idle position and
accelerator level at engine is in closed position.

Pull outer sleeve of accelerator cable towards pedal and check
that clip on sleeve is in slot nearest to grommet.

Reposition clip if necessary, and check that full throttle and idle
positions are obtained at engine lever.

ENGINE MECHANICAL (C24SE) 6A-75









Spark Plug Thread
Recondition
Ream thread and recut using commercially available spark
plug thread drill (observe manufacturer's instructions).

Removal
Remove thread bush on spark plug. (dimensions (A) =
17mm/0.67in.)

Tighten (Torque)
Spark plug with thread bush into cylinder head - 25N

m (2.5
kgf
m) - use.

ENGINE MECHANICAL (C24SE) 6A-87
Recommended Torque Values
Nm (kgfm)

Bearing cover to cylinder block ....................................................................................... 60
1) 6.1 +40
to 50

Bracket for alternator to cylinder block ............................................................................ 40 4.1
Bracket for engine damping block to transmission ......................................................... 60
2) 6.1
Bracket for engine damping block to engine block ......................................................... 60 6.1
Bracket for pump/compressor to engine block ............................................................... 35 3.6
Camshaft housing cover to housing ................................................................................ 8 0.8
Camshaft timing gear to camshaft .................................................................................. 50 5.1
Clamping bracket for alternator to intake manifold ......................................................... 25 2.5
Clamping bracket to alternator ........................................................................................ 25 2.5
Con-rod bearing cap to con-rod ...................................................................................... 35
1) 3.5 +45
to 60

Crankshaft pulley bolts .................................................................................................... 20 2.0
Cylinder head to cylinder block ........................................................................................ 25
1)2) 2.5 +90
+90

+90

Engine damping block to engine bracket ........................................................................ 8.5 8.7
Engine damping block to side member ........................................................................... 52
1) 5.3
Exhaust manifold to cylinder head .................................................................................. 22 2.2

1) Use new bolts
2) Use new locking plates


Recommended Torque Values
Nm (kgfm)

Flywheel to crankshaft ..................................................................................................... 65
1) 6.6 +30
to 45

Front exhaust pipe to exhaust manifold .......................................................................... 25 2.5
Guide sleeve for pressure bearing to transmission ......................................................... 22 2.2
Intake manifold to cylinder head ...................................................................................... 22 2.2
Lower alternator bracket ................................................................................................. 25 2.5
Oil drain plug to oil pan .................................................................................................... 45 4.6
Oil intake pipe bracket to cylinder block .......................................................................... 6
2) 0.6
Oil intake pipe to oil pump ............................................................................................... 8 0.8
Oil pan to cylinder block .................................................................................................. 8
2)3) 0.8
Bearing bridge to cylinder block ...................................................................................... 8 2)3) 0.8
Oil pressure switch to oil pump ....................................................................................... 30 3.2
Pump for power steering (ribbed V-belt) to engine block ................................................ 30 3.2
Spark plugs in cylinder head ........................................................................................... 20 2.3
Starter support to cylinder block ...................................................................................... 25 2.5
Starter to cylinder block - engine side ............................................................................. 45 4.6
Starter to cylinder block - transmission side .................................................................... 75 7.6
Thermostat housing to cylinder head .............................................................................. 15 1.5
Toothed belt drive gear to crankshaft .............................................................................. 130
1) 13.3
Toothed belt front cover .................................................................................................. 4 0.4
Toothed belt rear cover ................................................................................................... 6 0.6
Toothed belt tension roller to oil pump ............................................................................ 20 2.3
(M10) ............................................................................ 45 4.6
Transmission to engine block ......................................................................................... 76 7.7
(M12) ............................................................................ 60 6.1
Water pump to cylinder block .......................................................................................... 17 1.7

1) Use new bolts
2) Use Locking Compound
3) Maximum installation time - 10 minutes

ENGINE COOLING 6B-3


Service Precaution
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or fastener
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts
and systems.


Water pump
The water pump is centrifugal type and is driven by timing belt.


Thermostat
The thermostat is a bypass type and is a wax pellet type with a
air hole.





110RS001
Radiator
The radiator is a flow type with corrugated fins.

6B-8 ENGINE COOLING











Crack in the water pump body

EC leakage from the seal unit

Play or abnormal noise in the bearing

Cracks or corrosion in the impeller
Installation
1. Before installing water pump, coat sealing surface with
silicon grease.
2. Install water pump assembly and tighten bolts to the
specified torque.
Torque: 25 N




m (2.5 kgf




m)
3. Timing belt

Install timing belt, refer to timing belt installation step in
"Timing Belt" in this manual.
4. Connect radiator hose and replenish EC.
5. Connect battery ground cable.