2004 ISUZU TF SERIES oil

ENGINE MECHANICAL 6A – 43

ENGINE OVERHAUL
REMOVAL
EXTERNAL PARTS


RTW36AMF000401

Removal Steps
1. Clutch Assembly or Flex Plate
2. Intake Pipe and Throttle Body
3-1. EGR Pipe
3-2. EGR cooler (EURO III model only)
4. EGR Valve
5. Oil Level Gauge
6. Fuel Filter Assembly (Except EURO III)
7. Fuel Filter Bracket (Except EURO III)
8. Fuel Injection Pipe with Clip
9. Power Steering Oil Pump Bracket
10. Intake Manifold
11. Engine Mounting Bracket and Foot
12. Injection Pump Cover
13. Injection Pump
14. Starter Motor
15. Oil Pressure Warning Switch
16. Fuel Leak Off Pipe
17. Oil Cooler Water Pipe
18. Cooling Fan Pulley
19. Heat Protector
20. Catalytic Converter
21. Turbocharger
22. Compressor Bracket
23. Vacuum Pump Oil Return Hose
24. Generator and Adjusting Plate
25. Water Inlet Pipe
26. Generator Bracket
27. Oil Cooler with Oil Filter
28. Exhaust Manifold

ENGINE MECHANICAL 6A – 45



4JA1L
RTW46ASH001001
4. EGR Valve
1) Remove four nuts and remove the EGR valve
assembly from the intake manifold.
2) Remove four bolts and remove the adapter from the
EGR valve assembly.




4JA1TC RTW46ASH000901
5. Oil Level Gauge
1) Disconnect PCV hose.
2) Remove two bolts and remove the engine oil level
gauge.


6. Fuel Filter Assembly (Except EURO III model)
1) Disconnect fuel hose.
2) Remove two bolts and remove the fuel filter.

7. Fuel Filter Bracket (Except EURO III model)
Remove three bolts and remove the fuel filter bracket with
leak pipe.



4JH1TC RTW36ASH001201
8. Fuel Injection Pipe with Clip
1) Loosen the injection pipe sleeve nuts at pump side
and nozzle side.
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clips.
3) Remove the injection pipe.
NOTE:
Plug the delivery holder ports with the caps to prevent the
entry of foreign material.

9. Power Steering Oil Pump Bracket


RTW36ASH000701
10. Intake Manifold
1) Disconnect the PCV hose from the cylinder head
cover.
2) Remove the intake manifold with gasket.

11. Engine Mounting Bracket and Foot
12. Injection Pump Cover

6A – 46 ENGINE MECHANICAL
13. Injection Pump
Rrefer to secton 6C-19 (Injection Iump)

14. Starter Motor
15. Oil Pressure Warning Switch
16. Fuel Leak Off Pipe
17. Oil Cooler Water Pipe
18. Cooling Fan Pulley
19. Heat Protector


20. Catalytic Converter




21. Turbocharger
1) Disconnect the water hose between thermostat
housing cover and turbocharger.
2) Disconnect the water hose between water inlet pipe
and turbocharger.
3) Remove the oil feed pipe.
4) Remove the oil return pipe.
5) Remove the turbocharger and the gasket.
NOTE:
Plug the turbocharger body oil ports and water ports after
removing the turbocharger assembly to prevent the entry
of foreign material.


22. Compressor Bracket
23. Vacuum Pump Oil Return Hose
24. Generator and Adjusting Plate
25. Water Inlet Pipe
26. Generator Bracket
27. Oil Cooler with Oil Filter
28. Exhaust Manifold


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037RY00001

ENGINE MECHANICAL 6A – 49

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Disassembly Steps-3
17. Flywheel 27. Piston and connecting rod with
18. Crank case upper bearing
19. Oil pump with oil pipe 28. Crankshaft bearing cap with
20. Camshaft timing gear lower bearing
21. Camshaft thrust plate 29. Crankshaft thrust bearing
22. Camshaft 30. Crankshaft
23. Timing gear case 31. Crankshaft upper bearing
24. Cylinder body rear plate 32. Tappet
25. Piston cooling oil jet 33. Crankshaft rear oil seal
26. Connecting rod bearing cap with 34. Cylinder body
lower bearing

6A – 52 ENGINE MECHANICAL


RTW36ASH000801
Idler Gear "A" End Play Measurement
Insert a feeler gauge between the idler gear and the thrust
collar to measure the gap and determine the idler gear
end play.
If the measured value exceeds the specified limit, the
thrust collar must be replaced.

Idler Gear End Play mm (in)
Standard Limit
0.07 (0.0028) 0.2 (0.0079)





4JA1T(L)
040R300009
14. Idle Gear Shaft
15. Crankshaft Timing Gear



4JA1TC/4JH1TC RTW36ASH001301
16. Injection Pump
1. Remove the injection pump cover (4JA1TC/4JH1TC
only).
2. Remove the injection pump bracket.
3. Pull the injection pump along with the injection pump
timing gear free toward the rear of the engine.

NOTE:
Plug the injection pump delivery ports with the caps to
prevent the entry of foreign material.









17. Flywheel
Loosen the flywheel bolts in numerical order a little at a
time.
Use the gear stoper to stop the flywheel gear.
Gear stoper: 5-8840-0214-0

18. Crank Case

19. Oil Pump With Oil Pipe

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ENGINE MECHANICAL 6A – 53
















20. Camshaft Timing Gear
1. Use a dial indicator to measure the camshaft end play.
This must be done before removing the camshaft
gear.
If the camshaft end play exceeds the specified limit,
the thrust plate must be replaced.

Camshaft End Play mm (in)
Standard Limit
0.050 - 0.114
(0.002 - 0.0044) 0.20
(0.008)
















2. Remove the camshaft timing gear bolt from the
camshaft.
Note:
Hold the camshaft stationary to prevent the camshaft
from turning.
3. Remove the sensor rotor plate.
4. Use the universal puller to pull out the camshaft
timing gear.
Universal Puller: 5-8521-0002-0
5. Remove the thrust plate.


21. Camshaft Thrust Plate


22. Camshaft
Jiggle the camshaft with your hand as you pull it free from
the front of the engine.



23. Timing Gear Case

24. Cylinder Body Rear Plate



25. Piston Cooling Oil Jet
The oiling jet uses thin steel tubing which is easily bent.
Accidental contact between the oiling jet and the cylinder
body, piston, or a tool will damage the oiling jet.
Never attempt to repair a damaged oiling jet. Replace it
with a new one.





014RT0001
901R100008
014RY00019
052RY00001

ENGINE MECHANICAL 6A – 55
2. Loosen the crankshaft bearing cap bolts in numerical
order a little at a time.
If the crankshaft bearings are to be reinstalled, mark
their fitting positions by tagging each bearing with the
cylinder number from which it was removed.

29. Crankshaft Thrust Bearing

30.Crankshaft



31. Crankshaft Upper Bearing
If the crankshaft upper bearings are to be reinstalled, mark
their fitting positions by tagging each bearing with the
cylinder number from which it was removed.




32. Tappet
If the tappets are to be reinstalled, mark their fitting
positions by tagging each tappet with the cylinder number
from which it was removed.












33. Crankshaft Rear Oil Seal

With the oil seal pushed in deep, install the special
tool as shown in the illustration and remove the oil
seal.
Oil Seal Remover: 5-8840-2360-0



34. Cylinder Body
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ENGINE MECHANICAL 6A – 57
CYLINDER HEAD



RTW46ALF001201


Disassembly Steps
1.
Intake manifold 6.
Intake and exhaust valve
2.
Intake manifold gasket 7.
Valve stem oil seal
3.
Split collar 8.
Valve spring lower seat
4.
Valve spring upper seat 9.
Cylinder head
5.
Valve spring