Transmission ISUZU TF SERIES 2004 Manual PDF

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

6A-18 ENGINE MECHANICAL (C24SE)
OPERATIONS ON ENGINE AGGREGATES
Engine Damping Blocks (Engine Without
Transmission)
Removal
1. Remove bonnet.
2. Remove radiator.
3. Remove air inlet hose.
4. Remove power steering pump drive belt and power
steering pump from engine.


5. Remove all cable connections, hoses and lines from
engine.
6. Remove accelerator cable from inlet pipe.


7. Remove exhaust pipe from manifold.



8. Remove lower nine bolts and transmission from engine
block.
9. Remove clutch slave cylinder and allow to hang free.
10. Remove starter from engine block.

11. Remove upper bolts of left and right engine mounting
from damping blocks.
12. Raise engine slightly.
13. Remove lower bolts of left and right damping blocks.
14. Remove damping blocks.

ENGINE MECHANICAL (C24SE) 6A-19













Attach engine to cable, support transmission with car jack and
remove upper transmission fastening bolt.

Press off engine from transmission and lift out of engine
compartment.

Installation
Lower engine into engine compartment and insert guide
bushings on cylinder block into transmission.

Tighten (Torque)
Transmission to cylinder block (M10) -45 N

m (4.6 kgf

m)
Transmission to cylinder block (M12) -60 N
m (6.1 kgf
m)







Installation
1. Install engine to vehicle and transmission.
2. Install clutch slave cylinder.

Tighten (Torque)
Transmission to engine block bolts - 76 N
m (7.6 kgf
m)


RTW46ASH000401





3. Install left engine damping block to sidemember.
4. Install left and right engine damping blocks to engine
brackets.

Tighten (Torque)
Engine damper block to sidememebr - 50 N

m (5.1 kgf

m)
Engine damper block to engine bracket - 85 N

m (8.6 kgf

m)


5. Install exhaust pipe to manifold.

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-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.

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-6 ENGINE COOLING

















Draining and Refilling Cooling
System
Before draining the cooling system, inspect the system and
perform any necessary service to ensure that it is clean, does
not leak and is in proper working order. The engine coolant
(EC) level should be between the "MIN" and "MAX" lines of
reserve tank when the engine is cold. If low, check for leakage
and add EC up to the "MAX" line. There should not be any
excessive deposit of rust or scales around the radiator cap or
radiator filler hole, and the EC should also be free from oil.
Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening the drain
plug at the bottom of the radiator.
2. Remove the radiator cap.
WARNING: TO AVOID THE DANGER OF BEING BURNED,
DO NOT REMOVE THE CAP WHILE THE ENGINE AND
RADIATOR ARE STILL HOT. SCALDING FLUID AND
STEAM CAN BE BLOWN OUT UNDER PRESSURE.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with soap
and water. Flush it well with clean water, then drain it. Install
the reserve tank and hoses.
4. Refill the cooling system with the EC using a solution that is
at least 50 percent antifreeze.
5. Fill the radiator to the base of the filler neck.
Fill the EC reserve tank to "MAX" line when the engine is
cold.
6. Block the drive wheels and firmly apply the parking brake.
Shift an automatic transmission to "P" (Park) or a manual
transmission to neutral.
7. Remove the radiator cap. Start the engine and warm it up a
t
2,500 - 3,000 rpm for about 30 minutes.
8. When the air comes out from the radiator filler neck and the
EC level has gone down, replenish with the EC. Repeat this
procedure until the EC level does not go down. Then stop
the engine and install the radiator cap. Let the engine cool
down.
9. After the engine has cooled, replenish with EC up to the
"MAX" line of the reserve tank.
10. Start the engine. With the engine running at 3,000 rpm,
make sure there is no running water sound from the heate
r
core (behind the center console).
11. If the running water sound is heard, repeat steps 8 to 10.

ENGINE ELECTRICAL 6D1-5











































Battery fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes, skin,
fabric, or a painted surface, immediately and thoroughly rinse
the affected area with clean tap water.
Never allow metal tools or jumper cables to come in contact
with the positive battery terminal, or any other metal surface of
the vahicle. This will protect against a short circuit.
Always keep batteries out of reach of young children.
Jump Starting Procedure
1. Set the vehicle parking brake.
If the vahicle is equipped with an automatic transmission,
place the selector level in the "PARK" position.
If the vehicle is equipped with a manual transmission, place
the shift lever in the "NEUTRAL" position.
Turn "OFF" the ignition.
Turn "OFF" all lights and any other accessory requiring
electrical power.
2. Look at the built-in hydrometer.
If the indication area of the built-in hydrometer is completely
clear, do not try to jump start.
3.
Attach the end of one jumper cable to the positive terminal
of the booster battery.

Attach the other end of the same cable to the positive
terminal of the discharged battery.
Do not allow the vehicles to touch each other. This will
cause a ground connection, effectively neutralizing the
charging procedure.
Be sure that the booster battery has a 12 volt rating.
4.
Attach one end of the remaining cable to the negative
terminal of the booster battery.

Attach the other end of the same cable to a solid engine
ground (such as the air conditioning compressor bracket o
r
the generator mounting bracket) of the vehicle with the
discharged battery.
The ground connection must be at least 450 mm (18 in.)
from the battery of the vehicle whose battery is being
charged.
WARNING: NEVER ATTACH THE END OF THE JUMPER
CABLE DIRECTLY TO THE NEGATIVE TERMINAL OF THE
DEAD BATTERY.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical accessories have
been turned "OFF".
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above directions in
reverse order.
Be sure to first disconnect the negative cable from the
vehicle with the discharged battery.