oil ISUZU TF SERIES 2004 Workshop Manual

6A-58 ENGINE MECHANICAL (C24SE)









Clean
Plastigage from journals.

Lightly coat journals and bearings with engine oil.

Installation
Install bearing cap and shell using new bolts.

Torque - Angle Method
Main bearing cap bolt - 60 N

m (6.1 kgf

m) +40
to 50
.
Con-rod bearing cap bolts - 35 N

m (3.9 kgf

m) +45
.








2.Micrometer and gauge method.
Crankshaft removed.

Installation
1. Install caps and bearing shells to con-rods and cylinder
block.


Measure
Con-rod and main bearing diameters at three points I, II, III
(arrowed).
Divide the sum of the three measurements by three to obtain a
mean diameter.

The top illustration shows con-rod measuring points.
The second illustration shows main bearing measuring points.



Measure
Crankshaft main and con-rod bearing journals at points I and
II. Divide the sum of both measurements to obtain a mean
diameter.

Crankshaft must be replaced if mean diameter of main or con-
rod journals is below specified limit - see "Technical Data".

If crankshaft is serviceable subtract crankshaft mean journal
diameters from corresponding shell bearing mean diameters to
determine bearing clearance.

Permissible main bearing clearance - 0.015 to 0.04mm/0.0006
to 0.002in.
Permissible con-rod bearing clearance - 0.006 to
0.031mm/0.002 to 0.001in.

ENGINE MECHANICAL (C24SE) 6A-59






Bypass Valve
Removal
1. Remove oil filter.
2. Remove bypass valve by cutting thread in locking disc
with M 10 tap (3rd stage), turning in M 10 bolt and taking
out bypass valve from seating.
Installation
1. Install bypass valve using drift (diameter approx.
15mm/0.6in.).






Oil Filter
Removal
1. Remove oil filter using commercially available tool.

Installation
1. Install oil filter by hand and oil seal ring.
2. Fill up engine oil while preventing overflow.



Oil Pump
Removal
1. Remove rear toothed belt cover, and oil pan according to
the corresponding operations.
2. Remove oil filter, wiring plug from oil pressure switch, oil
pump from cylinder block, and oil pressure switch from
oil pump.









Clean
Sealing surfaces

Installation
1. Install oil pressure switch to oil pump, oil pump to cylinder
block, oil pan, bearing bridge wiring plug, oil filter and
toothed belt cover.

Tighten (Torque)
Oil pressure switch to oil pump - 30 N

m (3.2 kgf

m)
Oil pump to cylinder block - 6 N

m (0.6 kgf

m)
Oil intake pipe to oil pump - 8 N

m (0.8 kgf

m)
Intake pipe bracket to cylinder block - 8 N

m (0.8 kgf

m)
*Insert bolts with Locktite (Refer to General Description
Recommended Liguid Gasket)

6A-60 ENGINE MECHANICAL (C24SE)

Oil Pump Safety Valve
Removal
1. Remove closure plug.
2. Remove seal ring.
3. Remove spring.
4. Remove piston.








Installation
1. Install piston (observe installation position).
2. Install spring.
3. Install seal ring.
4. Install closure plug.

Tighten (Torque)
Closure plug - 30 N

m (3.0 kgf

m)












Oil Pump (Overhaul)
Removal
1. Remove oil pump according to the corresponding
operation.
2. Remove oil cover and pressure control valve.

Inspect
Clearance between gear pair and housing upper edge - see
“Technical Data”.
Check housing, cover and pressure control valve.

Installation
1. Install pump cover with Sealing Compound 15 03 166 (90
094 714).
2. Install oil pump safety valve according to the
corresponding operation.
3. Install oil pump according to the corresponding operation.

ENGINE MECHANICAL (C24SE) 6A-61
OPERATIONS ON OIL CIRCULATION

Cylinder Head Safety Valve
Removal
1. Remove cylinder head according to the corresponding
operation.
2. Make hole in core plugs with pointed drift, turn in self
tapping screw and edge out.

Important!
Cover oil duct in cylinder head with piece of cloth.

3. Pull out valve retainer, using commercially available tool.
4. Remove ball and spring.


5. Cut three threads in the ball seating with M 10 tap (3rd
stage).
6. Coat tap with grease.



7. Remove ball seating from cylinder head with
commercially available tool.
Do not damage cylinder head.

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-76 ENGINE MECHANICAL (C24SE)
TECHNICAL DATA
SOHC Gasoline Engine C24SE

Engine Oil Viscosity
The following engine oils can be used:
A = single-grade oils
B = multigrade oils
C = easy run oils
depending on the outside temperature.

Engine Oil Quality
It is important that the following API and CCMC classes are
used:


Engines Single and multigrade oils Easy run oils
Petrol API-SF/CC, SF/CD, SG/CC,
SG/CD, CCMC/G4 API-SF/CC, SF/CD, SG/CD
CCMC-G5/PD2




Important!
CD engine oils designed by manufacturers specially for diesel
engines are not suitable for petrol engines, unless a sufficient
performance class for petrol engines (e.g. API-SF/CCMC-G4)
is also indicated.

Disposal.
Observe the relevant national regulations when disposing of
used oil.


Engine Oil Filling Quantities

Engine Model Initial filling
(litres) Filling quantity
with filter change*
(litres) MIN to MAX
(litres)
2.4L 4.80 4.25 1.00
*Up to mark "MAX" on oil dipstick




Oil Pump
Backlash 0.1 to 0.2mm
Gaps in gears opposite housing 0.03 to 0.1mm
Oil pressure at idle speed Engine at operating
temperature (>70
C oil and
approx. 80
C coolant)
450 - 500 kpa
Oil drain plug M14  1.5

ENGINE MECHANICAL (C24SE) 6A-77

Cooling System
Radiator

Type: Cross-flow

Radiator core surface in cm
2: 2000

Cooling system capacity (in litres): 7.2



Anti-freeze Mixture
Anti-freeze Mixture

Required
Quantity Up to-10




C
Quantity in litres Up to-20




C
Quantity in litres Up to-30




C
Quantity in litres Up to-40




C
Quantity of litres
(in litres) Water
(80%) Anti-
Freeze
(20%) Water
(66%) Anti-
Freeze
(34%) Water
(56%) Anti-
Freeze
(44%) Water
(48%) Anti-
Freeze
(52%)
7.2 5.7 1.5 4.7 2.5 4.0 3.2 3.4 3.8



Cooling System (continued)
Fan

Type Visco Clutch Fan
Number of blades 5
Distribution of blades asymmetric
Diameter mm



Radiator cap

Boiling point 123
C
Opening pressure kPa (bar) 120 to 135 (1.20 to 1.35)



Thermostat

Start of opening 92
C
Fully opened 107
C
Type Bypassed



Idle Speeds, CO Content, Ignition
Adjustment

Applicable System Idle speed in min-1 (rpm)
Manual CO content
in vol. % Ignition timing in CA BTDC (adjustment
ensues at able speed,
ignition marks must align) with TDC
sensor measuring instrument:
Closed Loop System 825 *<0.4 *** 8 to 12
Open Loop System 825
**1.0+0.2
-0.5 *** 8 to 12
Note) * CO content adjustment not applicable.
** CO content adjustment refer to Section 6E1 (W/O catalytic converter system)
*** Ignition timing adjustment not possible.

6A-82 ENGINE MECHANICAL (C24SE)
Crankshaft, Cylinder Block (continued)
Piston Rings
2.4L
Square ring Height mm 1.2

Tapered ring Height mm 1.5

Oil scraper Height mm 2.5

Ring gap offset 180


Note that the upper steel band ring gap is offset 25 to 50mm to
the left and the lower 25 to 50mm to the right opposite the
intermediate ring gap.

Piston Pin

Length mm 61.5
Diameter mm 21
Type Shrunk into con-rod
Play mm 2.4L
in piston 0.010-0.015
in con-rod none
Installation When installing piston pins,
heat con-rods to approx.
280
C in oil bath. This
temperature should under no
circumstances be exceeded.


Crankshaft, Cylinder Block (continued)
The permissible weight variation of con-rods without piston and
bearing shell inside an engine is 8 g.
As the con-rods do not have balancing studs, reworking is not
possible.
Con-rods can only be replaced in sets.

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

6B-2 ENGINE COOLING
General Description
Legend
1 Water Pump
2 Thermostat
3 Radiator
4 Reserve Tank5 Coolant Distributor
6 Cylinder Block and Head
7 Throttle Body
8 Heater




The Cooling System is a pressurized type, where the water
pump, which is cambelt driven, forces the circulation of
the coolant through the cylinder block and head. The
thermostat regulates the flow of coolant between the
radiator and the bypass circuit. The heater is part of the
bypass circuit. The throttle body pre-heat is a separate
circuit which is not regulated by the thermostat. An oil
cooler may be fitted as part of this circuit.