steering ISUZU TF SERIES 2004 Manual Online

6G-8 ENGINE LUBRICATION (6VE1 3.5L)
3. Install crankcase, tighten crankcase fixing bolts
to the specified torque.
Torque : 10 N




m (1.0 kg




m/89 lb in)





013RW004
2. Install oil pan
1. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
2. Properly apply a 4.5 mm (0.17 in) wide bead o
f
sealant (TB-1207C or equivalent) to mounting
surface of oil pan.
Sealant beat must be continuous.
 The crankcase must be installed within 5
minutes after sealant application before the
sealant hardens.




013RW003

3. Install oil pan, tighten oil pan fixing bolts to the
specified torque.
Torque : 25 N




m (2.5 kg




m/18 lb ft)
3. Install axle housing assembly and tighten fixing
bolts to the specified torque (4WD model).
Axle case bolts
Torque : 116 N




m (11.8 kg




m/85 lb ft)
Mounting bolts
Torque : 168 N




m (17.2 kg




m/124 lb ft)




RTW34CSH000101
4. Install relay lever assembly and tighten fixing bolts.
Torque: 44 N




m (4.5 kg




m/32 lb ft)
5. Engage teeth of pitman arm and steering unit, and
tighten nut to the specified torque.
Torque : 216 N




m (22.0 kg




m/159 lb ft)
6. Install suspension cross member and tighten fixing
bolts to the specified torque.
Torque : 78 N




m (8.0 kg




m/58 lb ft)
7. Install radiator under fan shroud.
8. Install stone guard.
9. Install engine oil level dipstick.
10. Fill engine oil until full level on engine oil gauge
dipstick.

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.

6A-20 ENGINE MECHANICAL (C24SE)





6. Install power steering pump and V-belt.

Adjust
Adjust power steering pump V-belt tension according to the
corresponding operation.


Installation
7. Install radiator according to the corresponding operation.
8. Install air inlet hose.
9. Install all electrical cable connections, hoses and lines to
engine.
10. Install accelerator cable from inlet pipe.
11. Install bonnet.


Inspection
1. Check engine oil level.
2. Fill up cooling system and bleed according to the
corresponding operation.

ENGINE MECHANICAL (C24SE) 6A-21

Toothed Belt and Timing Check

Removal
1. Remove the belts on the bracket for alternator.
2. Remove the fan.
3. Remove the V-belt for power steering.
4. Remove the V-belt for A/C.
5. Remove the fan belt.
6. Remove the fan shroud.

7. Remove the crankshaft pulley while counterholding on
the fastening bolt of toothed belt drive gear.
8. Remove the toothed belt from cover.

Inspection
1. Turn the crankshaft in the engine rotational direction
mark(2) so that the notch (1) on the camshaft gear aligns
with the mark on toothed belt rear cover.
2. Check the timing belt for worn, cracks or oil adhesion.

3. Check that the cast on the water pump aligns with the
counterpart on cylinder block (arrowed).
4. The tension of a toothed belt is correctly adjusted when
the pointer and the center of the notch are aligned(I).
The tension of a run-in toothed belt (regardless of
mileage covered) is correctly adjusted when the pointer
is positioned approx. 4mm (0.16 in.) to the left of the
center of the notch(II).
Check the condition of the run-in toothed belt for
suitability for reuse. Only toothed belts of the toothed
belt tension rollers must be replaced and the source of oil
contamination must be eliminated.

6A-22 ENGINE MECHANICAL (C24SE)


Installation
1. Install the toothed belt to the cover.
2. Install the crankshaft pulley while counterholding on the
fastening bolt of toothed belt drive gear.
3. Install the fan shroud.


Tighten(Torque)
Crankshaft pulley bolts - 20 N

m (2.1 kgf

m)


4. Install the fan belt
5. Install the V-belt for A/C.
6. Install the V-belt for power steering.
7. Install the fan.
8. Install the belts on the bracket for alternator.

6A-24 ENGINE MECHANICAL (C24SE)
Toothed Belt, Replace
(Engine with toothed belt tension
roller)

Removal
1. Remove the belts on the bracket for alternator.
2. Remove the fan.
3. Remove the V-belt for power steering.
4. Remove the V-belt for A/C.
5. Remove the fan belt.
6. Remove the fan shroud.


7. Remove the crankshaft pulley while counterholding on
the fastening bolt of toothed belt drive gear.
8. Remove the toothed belt from cover.


Adjust
Turn the crankshaft in the engine rotational direction to
mark(2).
Align markings on toothed belt and on toothed belt rear cover.
Simultaneously, notch (1) on camshaft gear must align with the
mark on toothed belt rear cover.
Turn the crankshaft slowly and smoothly.

ENGINE MECHANICAL (C24SE) 6A-25








Adjust
Loosen the fastening bolt of the toothed belt tension roller and
turn the adjustment eccentric in the direction of arrow
(clockwise) until pointer (1) comes to the left stop.
Remove the toothed belt.

Installation
1. Install a new toothed belt while keeping tension side taut.

Adjust
Toothed belt tension - see operation " Toothed Belt Tension".


2. Install the toothed belt to the cover.
3. Install the crankshaft pulley while counterholding on the
fastening bolt of toothed belt drive gear.
4. Install the fan shroud.
5. Install the fan belt.
6. Install the V-belt for A/C.
7. Install the V-belt for power steering.
8. Install the fan.
9. Install the belts to the bracket for alternator.

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-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.

ENGINE MECHANICAL (C24SE) 6A-49






Reassembly
Reassemble clutch assembly.

Disassembly
Disassemble clutch assembly to flywheel using 5-8840-2634-0

Torque Angle-Method
Clutch assembly to flywheel-17.6Nm/1.8 kgf

m.


RTW46ASH002801
Oil Pan and Bearing Bridge
Removal
1. Remove the crossmember.
2. Shift downward the power steering unit (and front axle [4 4 model only]).
3. Loosen fixing bolts.
4. Remove oil pan from oil pump and cylinder block.
5. Remove oil intake pipe, oil intake pipe bracket, and oil baffle plate.
6. Remove the bearing bridge.