2004 ISUZU TF SERIES engine

ENGINE MECHANICAL 6A – 107


RTW36ASH002001




11. Piston and Connecting Rod with Upper Bearing
12. Connecting Rod Bearing Cap with Lower Bearing
1. Apply a coat of engine oil to the circumference of each
piston ring and piston.
2. Position the piston ring gaps as shown in the
illustration.
1. Oil ring
2. 2nd compression ring
3. 1st compression ring










3. Apply a coat of molybdenum disulfide grease to the two
piston skirts.
This will facilitate smooth break-in when the engine is
first started after reassembly.
4. Apply a coat of engine oil to the upper bearing
surfaces.
5. Apply a coat of engine oil to the cylinder wall.














6. Position the piston head front mark so that it is facing
the front of the engine.
7. Use the piston ring compressor to compress the piston
rings.
Piston Ring Compressor: 5-8840-9018-0
8. Use a hammer grip to push the piston in until the
connecting rod makes contact with the crankpin.
At the same time, rotate the crankshaft until the
crankpin is at BDC.



9. Align the bearing cap cylinder number marks and the
connecting rod cylinder number marks.
The cylinder number marks must be turned toward the
exhaust manifold.



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015R100007015R100006

6A – 108 ENGINE MECHANICAL











10. Apply a coat of engine oil to the threads and setting
faces of each connecting rod cap bolt.
11. Tighten the connecting rod caps to the two step of
anglar tigthen method.


Connecting Rod Bearing Cap Bolt Torque N·m (kg·m/Ib ft)
4JA1T (L),
4JA1TC 78-88 (8.0/57 – 9.0/65)
1st step ; 29.0–29.2 (3.00/22.0–3.01/22.2)4JH1TC
2nd step ; 45
-60







13. Piston Cooling Oil Jet
1. Install the piston cooling oil jet to the cylinder body.
2. Tighten the oil jet bolts and relief valve to the specified
torque.


Oil Jet Bolt Torque N·m(kg·m/lbft)
M8  1.25 19 (1.9/14)
M6  1.00 8 (0.8/6)


Relief Valve Torque N·m(kg·m/lbft)
29 (3.0/22)

NOTE:
Check that there is no interference between the piston
and the oiling jet by slowly rotating the crankshaft.












14. Oil Pump with Oil Pipe
Install the oil pump with the oil pipe and tighten the bolts to
the specified torque.


Oil Pump Bolt Torque N·m(kg·m/lbft)
19 (19/14)

NOTE:
Take care not to damage the O-rings when tightening
the oil pipe bolts.







15. Crankshaft Rear Oil Seal
Use a oil seal install to install the crankshaft rear oil seal.
Oil Seal Installer : 5-8840-2359-0


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051R100004

ENGINE MECHANICAL 6A – 109



16. Crank Case
1. Apply the recommended liquid gasket (Three bond
1207B) or its equivalent to arch gasket fitting surface
as shown in the illustration.
2. Install the crankcase front gasket (1) to the timing gear
case arches.
The gasket projection (2) must be facing forward.
NOTE:
ThreeBond 1207B is a fast-drying liquid gasket.
Install the arch packing to the crankcase immediately
aftter applying the gasket.










3. Install the rear arch gasket (2) to the No. 5 bearing
cap. Use your fingers to push the arch gasket into the
bearing cap groove.Take care not to scratch the arch
gasket outer surface.
Also apply the recommended liquid gasket (1207C) or
its equivalent to arch gasket fitting area as indicated in
the illustration.






4. Apply the recommended liquid gasket or its equivalent
to groove of the crankcase fitting surface as shown in
the illustration.

NOTE:
Be sure that the crank case fitting surface is
completely free of oil and dust before applying the
liquid gasket.












5. Install the crank case to the cylinder body.
6. Tighten the crank case bolts to the specified torque a
little at a time in the sequence shown in the illustration.


Crank Case Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)

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013RW011
013R100001

6A – 110 ENGINE MECHANICAL









17. Cylinder Body Rear Plate
1. Align the rear plate with the cylinder body knock pins.
2. Tighten the rear plate to the specified torque.


Rear Plate Torque N·m(kg·m/lbft)
82 (8.4/61)














18. Flywheel
1. Apply a coat of engine oil to the threads of the flywheel
bolts.
2. Align the flywheel with the crankshaft dowel pin.
3. Tighten the flywheel bolts in the numerical order shown
in the illustration.
Gear stoper: 5-8840-0214-0


Flywheel Bolt Torque N·m(kg·m/lbft)
118 (12/87)











19. Crankshaft Timing Gear
Use the crankshaft timing gear installer (1) to install the
crankshaft timing gear (2).
The crankshaft timing gear setting mark must be facing
outward.
Crankshaft Timing Gear Installer: 9-8522-0020-0


















20. Idler Gear Shaft
21. Idler Gear "A"
1. Turn the crankshaft clockwise to set the DTC of the
No.1 piston.
2. Apply engine oil to the idler gear and the idler gear
shaft.
The idler gear shaft oil hole (A) must be facing up.
3. Position the idler gear setting marks so that they are
facing the front of the engine.


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ENGINE MECHANICAL 6A – 111
























4. Align the idler gear setting mark with the crankshaft
timing gear (1) setting mark.
5. Align the idler gear setting mark with the camshaft
timing gear (2) setting mark.
6. Install the thrust collar and bolts to the cylinder body
through the shaft.
The thrust collar oil hole must be facing up, and the
thrust collar chamfered must be outward.
7. Tighten the idler gear bolt to the specified torque.


Idler Gear "A" Bolt Torque N·m(kg·m/lbft)
30 (3.1/22)

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22. Idler Gear "B" and Shaft
1. Apply engine oil to the idler gear and the idler gear shaft.
2.
Align the idler gear "B" (3) setting mark with the idler
gear "A" (4) setting mark.
3. Tighten the idler gear bolt to the specified torque.
4. Be sure to remove the lock bolt (5) from idle gear “B”.


Idler Gear "B" Bolt Torque N·m(kg·m/lbft)
76 (7.7/56)




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5. If the idle gear "B" is disassembled, reassemble in the
following procedure.
1) Drive pins into the main gear, the front gear, and the
rear gear.





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2) Install the main gear bearing from the front side of
the main gear (the side with the groove).
3) Place the main gear in a vise with copper plate so
that the rear side of the main gear facing up.
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6A – 112 ENGINE MECHANICAL




RTW31BSH000101

4) Set the spring as shown in the illustration.





RTW31BSH000201

5) Position the rear gear so that the pin is aligned with
the receiving end of the spring.




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6) Install the snap ring to the main gear groove.






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7) Install suitable bolts, nuts and washers to special tool
as shown in the illustration to rotate the scissors
gear.
End yoke holder: 5-8840-2447-0

ENGINE MECHANICAL 6A – 113




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8) Insert the bolts of the special tool into the rear gear
setting hole. Rotate the rear gear to mesh the teeth
of main gear and rear gear.
9) Insert a lock bolt (M6  1 L=30) into scissors gea
r
fixing hole to prevent the scissors gear from turning.
10) Place the main gear in a vise with copper plate so
that the front side of the main gear facing up.
11) Repeat steps 4 to 8 to install the front gear.
12) Lock the front gear, the main gear, and the rear gea
r
with lock bolt (inserted at Step 8).

6A – 114 ENGINE MECHANICAL








23. Injection Pump
1. Install the O-ring (1) to the injection pump flange (2).
2. Attach the noise insulator rubber to the cylinder body .
3. Install the injection pump to the timing gear case.Align
the idler gear "B" (3) mark with the injection pump timing
gear (4) mark.












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4JA1TC/4JH1TC:
4. Tighten the injection pump bolts (5) to the specified
torque.

Injection Pump Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)

5. Install the injection pump bracket (6) and the bracke
t
bolts (7) and (8) to the cylinder body.
Temporarily tighten the bracket bolts.
6. Tighten the bracket bolts (7) to the specified torque.
7. Tighten the bracket bolt (8) to the specified torque.
NOTE:
Tighten the bracket bolt (7) first.

Injection Pump Bracket Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)




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