2004 ISUZU TF SERIES engine remove

6A – 42 ENGINE MECHANICAL

ENGINE REPAIR KIT





RTW36ALF000601

Removal Steps
1. Cylinder head gasket
2. Head cover gasket
3. Head cover cap nut gasket
4. Drain cock gasket
5. Crankshaft rear oil seal
6. Gear case gasket
7. Oil pan drain plug gasket
8. Oil pan gasket
9. Oil filter gasket
10. Joint bolt gasket 11. Vacuum pump gasket
12. Water pump O-ring
13. Water outlet pipe gasket
14. Intake pipe gasket
15. Thermostat housing gasket
16. Intake manifold gasket
17. Exhaust manifold gasket
18. Nozzle holder O-ring
19. Nozzle holder gasket
20. Crankshaft front oil seal

NOTE
Discard all O-rings, gaskets, and seals removed at disassembly and replace them with new ones. Reuse of
these parts will result in oil, water, and gas leakage.

6A – 44 ENGINE MECHANICAL
Removal
1. Clutch Assembly or Flex Plate
Remove the clutch assembly or the flex plate.



4JA1L RTW46ASH000801
2. Intake Pipe and Throttle Body (4JA1TC/4JH1TC only)
1) Loosen hose clamp between turbocharger and intake
duct.
2) Remove the rubber hose.
3) Remove the intake pipe and the throttle body.
(4JA1TC/4JH1TC only)

RTW36ASH000201




4JA1L
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3-1. EGR Pipe
1) Remove two bolts from the exhaust manifold.
2) Remove two nuts from the EGR valve adapter.
3) Remove the EGR pipe with gaskets.

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3-2. EGR Cooler (EURO III model only) 4JA1TC/4JH1TC
4JH1TC

ENGINE MECHANICAL 6A – 45



4JA1L
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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.




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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


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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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6A – 50 ENGINE MECHANICAL
Disassembly
1. Water Bypass Hose
2. Thermostat Housing with Thermo Switch
3. Cylinder Head Cover
4. Injection Nozzle and Bracket
1. Remove the injection nozzle bracket bolts.







2. Use the injection nozzle remover and the sliding
hammer to remove the injection nozzle together.
Injection Nozzle Remover: 5-8840-2723-0
Sliding Hammer: 5-8840-0019-0



5. Rocker Arm Shaft and Rocker Arm
Loosen the rocker arm shaft bracket bolts in numerical
order a little at a time.
Note:
Failure to loosen the rocker arm shaft bracket bolts in
numerical order a little at a time will adversely affect the
rocker arm shaft.

6. Push Rod



7. Cylinder Head
Loosen the cylinder head bolts in numerical order a little at
a time.
Note:
Failure to loosen the cylinder head bolts in numerical
order a little at a time will adversely affect the cylinder
head lower surface.

8. Cylinder Head Gasket
9. Crankshaft Damper Pulley


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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)
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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.





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901R100008
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6A – 54 ENGINE MECHANICAL
26. Connecting Rod Bearing Cap with Lower Bearing
If the connecting rod lower bearings are to be reinstalled,
mark their fitting positions by tagging each bearing with the
cylinder number from which it was removed.






27. Piston and Connecting Rod with Upper Bearing
1. Remove carbon deposits from the upper portion of the
cylinder wall with a scraper before removing the piston
and connecting rod.
2. Move the piston to the top of the cylinder and tap it
with a hammer grip or a similar object from the
connecting rod lower side to drive it out.





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If the connecting rod upper bearings are to be reinstalled,
mark their fitting positions by tagging each bearing with the
cylinder number from which it was removed.


















28. Crankshaft Bearing Cap with Lower Bearing
1. Measure the crankshaft end play at the center journal
of the crankshaft.
Do this before removing the crankshaft bearing caps.
If the measured value exceeds the specified limit, the
crankshaft thrust bearing must be replaced.

Crankshaft End Play mm (in)
Standard Limit
0.10 (0.004) 0.30 (0.012)

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