2004 ISUZU TF SERIES oil

6A-56 ENGINE MECHANICAL (C24SE)




5. Apply a bead of sealant (TB-1207C or equivalent) in the
grooves of both bearing shells.

Important!
After installation of bearing cover, press in sealing compound
again from above, until compound emerges at the joints.


Torque - Angle Method
Bearing cover to cylinder block - 50 N
m (5.1 kgf
m) +40 to
50
Con-rod bearing cover to con-rod - 35 N

m (3.5 kgf

m) +45
to
60
.
Use new bolts.

6. Install oil pump, oil pan, bearing bridge rear crankshaft
sealing, flywheel/drive plate, and aggregates according to
the corresponding operations.









Inspection
Bearing play - bearing cover removed

Measure
With "Plastigage" (ductile plastic threads)
Cut threads to length of bearing width and lay axiaity between
crankshaft journal and bearing shell (arrowed).
Install bearing cover with correct torque.

Important!
Grease crankshaft journal and lubricate bearing shell slightly
so that the thread does not tear when the bearing cover is
moved.


Crankshaft
Inspection
End play when bearing shells are installed.
Front end contact surfaces of flywheel/flexible plate.
Permissible end play - see "Technical Data "

ENGINE MECHANICAL (C24SE) 6A-57


Inspection
Out-of-round (run-out)-middle bearing shell removed when
mounting on front and rear bearing.
Permissible out-of-round - see "Technical Data"



Bearing Free Play Measurement
Two methods for measuring bearing free play are described -
1. Plastigage method and 2. micrometer and gauge method.
The two procedures are suitable for measuring both con-rod
and main bearing free play.
For both methods ensure con-rod and main bearing caps are
identified (1) prior to removal as they are machine matched.











1.Plastigage Method
Removal
1. Remove bearing cap and shell.
2. Lightly coat journals and bearings with engine oil to
prevent Plastigage from tearing when cap is removed.

Installation
1. Lay a length of Plastigage across width of crank pin and
fit bearing cap and shell using old bolts at this stage.

Important!
Do not allow crankshaft to rotate.

Torque - Angle Method
Main bearing cap bolt - 60 N

m (6.1 kgf

m) +40
+ to 50
.
Con-rod bearing cap bolts - 35 N

m (3.6 kgf

m) +45
.




Removal
1. Remove bearing cap and shell.

Measure
Width of Plastigage -use scale supplied with Plastigage.

If con-rod bearing clearance exceeds 0.031mm/0.001in or
main journal bearing clearance exceeds 0.04mm/0.02in. -
check crankshaft journal diameters - see corresponding
operation.
Replace bearing if crankshaft is within specification - see
"Technical Data"

6A-58 ENGINE MECHANICAL (C24SE)









Clean
Plastigage from journals.

Lightly coat journals and bearings with engine oil.

Installation
Install bearing cap and shell using new bolts.

Torque - Angle Method
Main bearing cap bolt - 60 N

m (6.1 kgf

m) +40
to 50
.
Con-rod bearing cap bolts - 35 N

m (3.9 kgf

m) +45
.








2.Micrometer and gauge method.
Crankshaft removed.

Installation
1. Install caps and bearing shells to con-rods and cylinder
block.


Measure
Con-rod and main bearing diameters at three points I, II, III
(arrowed).
Divide the sum of the three measurements by three to obtain a
mean diameter.

The top illustration shows con-rod measuring points.
The second illustration shows main bearing measuring points.



Measure
Crankshaft main and con-rod bearing journals at points I and
II. Divide the sum of both measurements to obtain a mean
diameter.

Crankshaft must be replaced if mean diameter of main or con-
rod journals is below specified limit - see "Technical Data".

If crankshaft is serviceable subtract crankshaft mean journal
diameters from corresponding shell bearing mean diameters to
determine bearing clearance.

Permissible main bearing clearance - 0.015 to 0.04mm/0.0006
to 0.002in.
Permissible con-rod bearing clearance - 0.006 to
0.031mm/0.002 to 0.001in.

ENGINE MECHANICAL (C24SE) 6A-59






Bypass Valve
Removal
1. Remove oil filter.
2. Remove bypass valve by cutting thread in locking disc
with M 10 tap (3rd stage), turning in M 10 bolt and taking
out bypass valve from seating.
Installation
1. Install bypass valve using drift (diameter approx.
15mm/0.6in.).






Oil Filter
Removal
1. Remove oil filter using commercially available tool.

Installation
1. Install oil filter by hand and oil seal ring.
2. Fill up engine oil while preventing overflow.



Oil Pump
Removal
1. Remove rear toothed belt cover, and oil pan according to
the corresponding operations.
2. Remove oil filter, wiring plug from oil pressure switch, oil
pump from cylinder block, and oil pressure switch from
oil pump.









Clean
Sealing surfaces

Installation
1. Install oil pressure switch to oil pump, oil pump to cylinder
block, oil pan, bearing bridge wiring plug, oil filter and
toothed belt cover.

Tighten (Torque)
Oil pressure switch to oil pump - 30 N

m (3.2 kgf

m)
Oil pump to cylinder block - 6 N

m (0.6 kgf

m)
Oil intake pipe to oil pump - 8 N

m (0.8 kgf

m)
Intake pipe bracket to cylinder block - 8 N

m (0.8 kgf

m)
*Insert bolts with Locktite (Refer to General Description
Recommended Liguid Gasket)

6A-60 ENGINE MECHANICAL (C24SE)

Oil Pump Safety Valve
Removal
1. Remove closure plug.
2. Remove seal ring.
3. Remove spring.
4. Remove piston.








Installation
1. Install piston (observe installation position).
2. Install spring.
3. Install seal ring.
4. Install closure plug.

Tighten (Torque)
Closure plug - 30 N

m (3.0 kgf

m)












Oil Pump (Overhaul)
Removal
1. Remove oil pump according to the corresponding
operation.
2. Remove oil cover and pressure control valve.

Inspect
Clearance between gear pair and housing upper edge - see
“Technical Data”.
Check housing, cover and pressure control valve.

Installation
1. Install pump cover with Sealing Compound 15 03 166 (90
094 714).
2. Install oil pump safety valve according to the
corresponding operation.
3. Install oil pump according to the corresponding operation.

ENGINE MECHANICAL (C24SE) 6A-61
OPERATIONS ON OIL CIRCULATION

Cylinder Head Safety Valve
Removal
1. Remove cylinder head according to the corresponding
operation.
2. Make hole in core plugs with pointed drift, turn in self
tapping screw and edge out.

Important!
Cover oil duct in cylinder head with piece of cloth.

3. Pull out valve retainer, using commercially available tool.
4. Remove ball and spring.


5. Cut three threads in the ball seating with M 10 tap (3rd
stage).
6. Coat tap with grease.



7. Remove ball seating from cylinder head with
commercially available tool.
Do not damage cylinder head.

6A-70 ENGINE MECHANICAL (C24SE)
Installation

(2.4L)
1. Install the ECM to the ECM bracket on engine.
2. Tighten the four screws to the bracket.
3. Connect the connector.









ECT
Removal
1. Remove wiring harness plug and coolant temperature
sensor.

Tighten (Torque)
Temperature sensor to intake pipe - 10 N

m (1.0 kgf

m)
Wiring harness plug to temperature sensor

Inspection
Coolant level







Idle Air Control (IAC) Valve
Removal
1. Remove wiring harness plug, hose clamps and idle
speed adjuster.

Installation
1. Install idle speed adjuster, hose clamps and wiring
harness plug.






Ignition Coil
Removal
1. Remove 2 bolts, plug and ignition coil.

Installation
1. Install ignition coil, plug and bolts.

6A-76 ENGINE MECHANICAL (C24SE)
TECHNICAL DATA
SOHC Gasoline Engine C24SE

Engine Oil Viscosity
The following engine oils can be used:
A = single-grade oils
B = multigrade oils
C = easy run oils
depending on the outside temperature.

Engine Oil Quality
It is important that the following API and CCMC classes are
used:


Engines Single and multigrade oils Easy run oils
Petrol API-SF/CC, SF/CD, SG/CC,
SG/CD, CCMC/G4 API-SF/CC, SF/CD, SG/CD
CCMC-G5/PD2




Important!
CD engine oils designed by manufacturers specially for diesel
engines are not suitable for petrol engines, unless a sufficient
performance class for petrol engines (e.g. API-SF/CCMC-G4)
is also indicated.

Disposal.
Observe the relevant national regulations when disposing of
used oil.


Engine Oil Filling Quantities

Engine Model Initial filling
(litres) Filling quantity
with filter change*
(litres) MIN to MAX
(litres)
2.4L 4.80 4.25 1.00
*Up to mark "MAX" on oil dipstick




Oil Pump
Backlash 0.1 to 0.2mm
Gaps in gears opposite housing 0.03 to 0.1mm
Oil pressure at idle speed Engine at operating
temperature (>70
C oil and
approx. 80
C coolant)
450 - 500 kpa
Oil drain plug M14  1.5