check oil ISUZU TF SERIES 2004 Workshop Manual

ENGINE MECHANICAL (6VE1 3.5L) 6A-59
Valve Guide Replacement
1. Using Valve guide replacer: 5
8840
2442
0,
drive out the valve guide from the combustion
chamber side.


014RS008
2. Apply engine oil to the outside of the valve guide.
Using valve guide replacer 5
8840
2442
0,
drive in a new valve guide from the camshaft side,
and check the valve guide height.
Valve guide upper end height: 13.0 mm (0.5118
in)
(Measured from the cylinder head upper face)





014RW046
3. Check the clearance. If the clearance is less than
the specified value, ream the inside diameter o
f
valve guide. Using a sharp 6 mm reamer, ream the
valve guide to obtain the specified clearance.

Valve Seat
1. Measure the protrusion of the valve stem when a
new valve is installed in the cylinder head. If the
protrusion of the valve stem exceeds the limit,
replace the valve seat insert or the cylinder head
assembly.
Protrusion of valve stem
Intake
Standard: 39.32 mm (1.5480 in)
Limit: 39.47 mm (1.5539 in)
Exhaust
Standard: 39.30 mm (1.5472 in)
Limit: 39.45 mm (1.5531 in)





014RW047

6A-62 ENGINE MECHANICAL (6VE1 3.5L)
5. Install lower valve spring seat, valve spring and
upper valve spring seat then put split collars on the
upper spring seat, using the 5
8840
2446
0 valve
spring compresor and 5
8840
2547
0 valve
spring compressor adapter to install the spli
t
collars.



014RW042
6. Install tappet with shim.
7. Install camshaft assembly.
 Refer to installation procedure for Camshaft in
this manual.
Valve Clearance Adjustments
NOTE: To adjust valve clearance, apply engine oil to
the cam as well as to the adjusting shim (2) with the
cylinder head built on the cylinder block, give a fe
w
turns to the camshaft by means of timing pulley
tightening bolt, and measure valve clearance when the
nose of cam is just opposite to maximum cam lift (1) as
shown in illustration below.







014RW081
Legend
(1) Cam
(2) Shim
(3) Tappet

Valve Clearance Standard Value (cold)
Intake: 0.23 mm




0.33 mm
(0.0091 in




0.0130 in)
Exhaust: 0.25 mm




0.35 mm
(0.0098 in




0.0138 in)
Selection of Adjusting Shim
Shim to be selected = (Thickness of removed
shim) + (Valve clearance measurement
Standard
value) Based on the above formula, the best suited
shim should be selected from 41 sorts of shim
(differently thick at 0.02mm (0.0008 in) intervals from
2.40mm (0.0945 in) through 3.2mm (0.1260 in) thick).
Install the shim and check valve clearance.

6A-72 ENGINE MECHANICAL (6VE1 3.5L)
3. Remove oil pipe and O-ring (3).
4. Remove oil strainer and O-ring (4).
5. Remove oil pump assembly (5).
6. Remove crankcase side bolts (6).
7. Remove oil gallery (7).
8. Remove piston and connecting rod assembly (8).
Refer to “Piston, Piston Ring and Connecting Rod"
in this manual.
9. Remove flywheel (9).
10. Remove rear oil seal retainer (10).
11. Remove main bearing cap (11).
12. Remove crankshaft (12).
Inspection and Repair
1. Crankshaft
Set the dial indicator as shown in the illustration
and measure the crankshaft thrust clearance. I
f
the thrust clearance exceeds the specified limit,
replace the thrust bearings as a set.
Thrust Clearance
Standard : 0.06 mm




0.24 mm
(0.0024 in




0.0094 in)
Limit : 0.30 mm (0.0118 in)




015RS003

Main Bearing Clearance
1. Remove the bearing caps and measure the oil
clearance.
2. Remove the main bearing cap fixing bolts in the
sequence shown in the illustration.

Arrange the removed main bearing caps in the
cylinder number order.
Remove the main bearings.



015RS004
3. Remove the crankshaft. Remove the main
bearings.
4. Clean the upper and lower bearings as well as the
crankshaft main journal.
5. Check the bearings for damage or excessive wear.
The bearings must be replaced as a set if damage
or excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to
their original positions.
Carefully install the crankshaft.
7. Set the lower bearings to the bearing cap original
position.
8.
Apply plastigage to the crankshaft journal unit as
shown in the illustration.
NOTE: Do not set the plastigage on the oil hole.


015RS005
9. Install main bearing caps, oil gallery and crank
case bolts in the order shown, and tighten each
bolt to the specified torque.
NOTE: Do not apply engine oil to the crank case side

6A-76 ENGINE MECHANICAL (6VE1 3.5L)




015RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin

 Apply engine oil to the oil seal lip.

Align the cylinder block dowel pin holes with the
rear retainer dowel pins.
 Tighten the rear retainer fixing bolts. New bolts
should be used when installing rear retainer.
Torque: 18 N
 m (1.8 Kg
 m/13 lb ft)
NOTE: Be very careful not to disengage the oil seal
garter spring during installation of the rear retainer.
If the seal was removed from retainer fo
r
replacement, apply engine oil to the oil seal lip
and install the oil seal using 5
8840
2286
0 oil
seal installer.




015RW001





015RS017
3. Flywheel (9)
1. Thoroughly clean and remove the oil from the
threads of crankshaft.
2. Remove the oil from the crankshaft and
flywheel mounting faces.
3. Mount the flywheel on the crankshaft and then
install the washer.
4. Hold the crankshaft to prevent from rotating
then install the bolts in the order shown to the
specified torque.
Torque: 54 N
 m (5.5 Kg
 m/40 lb ft)
NOTE: Do not reuse the bolt and do not apply oil o
r
thread lock to the bolt.


015RS018
4. Piston and connecting rod assembly (8)

Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaf
t
pins. Check to see that the piston ring end gaps
are correctly positioned.

ENGINE MECHANICAL (6VE1 3.5L) 6A-77



015RS019
Legend
(1) No.1 Compression Ring
(2) No.2 Compression Ring
(3) Oil Ring Side Rail Upper
(4) Oil Ring Side Rail Lower
(5) Piston Front Mark

 Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor.
The front marks must be facing the front of the
engine.
 Match the numbered caps with the numbers on
the connecting rods. Align the punched marks
on the connecting rods and caps.
 Apply engine oil to the threads and seating
faces of the nuts.
 Tighten the nuts.
Torque: 54 N
 m (5.5 Kg
 m/40 lb ft)

After tightening the cap nuts, check to see that
the crankshaft rotates smoothly.
NOTE: Do not apply engine oil to the bearing back
faces.


015RS020
5. Install oil gallery (7) and tighten the bolts in 2
steps, in the order shown.
1st step: 29 N
 m (3.0 Kg
 m/22 lb ft)
2nd step: 55
  
  65
 




051RS009
6. Cylinder block side bolts (6)
 Tighten all the bolts to the specified torque in
the order shown.
NOTE: Do not apply engine oil to the crank case side
bolts.
Torque: 39 N
 m (4.0 Kg
 m/29 lb ft)

6A-80 ENGINE MECHANICAL (6VE1 3.5L)
5. Remove oil strainer and O-ring (5).
6. Remove oil gallery (6).
7. Remove connecting rod cap with connecting rod
lower bearing (12).
8. Remove piston and connecting rod assembly (7).
NOTE: Before removing piston and connecting rod
assembly, measure thrust clearance.






015RS031
 Remove any ridge or carbon build up from the
top end of the cylinder.
9. Remove the piston rings (8) with a piston ring
expander. Arrange the removed piston rings in the
cylinder number order.

015RS022
10. Remove the piston pin (9) using 5
8840
0551
0
piston pin service set and piston support with a
press.
NOTE: Keep the parts removed from each cylinde
r
separate. All parts must be reinstalled in their original
positions. Heating the connecting rod will permit easy
removal of the piston pin.


015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin

11. Piston (10)
12. Connecting rod (11)
Inspection and Repair
Pistons (10)
Carefully clean away all the carbon adhering to the
piston head and the piston ring grooves.
NOTE: Never use a wire brush to clean the pistons.
Damage will result. Visually check each piston fo
r
cracking, scoring, and other signs of excessive wear. If
any of the above conditions are found, the piston must
be replaced.
Piston Diameter
1. Measure the piston outside diameter with
micrometer at the piston grading position and a
right angle to the piston pin.
Piston grading position (from piston head)
Piston grading position : 43.0 mm (1.6929 in)

ENGINE MECHANICAL (6VE1 3.5L) 6A-83
3. Insert the new pin into the piston and rotate it. If
the pin rotates smoothly with no backlash, the
clearance is normal. If there is backlash o
r
roughness, measure the clearance. If the
clearance exceeds the specified limit, the piston
must be replaced.
Clearance
Standard : 0.010 mm




0.017 mm
(0.0004 in.




0.0007 in)
Limit : 0.040 mm (0.0016 in)
Connecting Rods (11)
1. Check the connecting rod alignment If either the
bend or the twist exceeds the specified limit, the
connecting rod must be replaced.
Bend per 100 mm (3.937 in)
Limit: 0.15 (0.0059)
Twist per 100 mm (3.937 in)
Limit: 0.20 (0.0078)





015RS030
2. Measure the connecting rod thrust clearance. Use
a feeler gauge to measure the thrust clearance a
t
the large end of the connecting rod If the clearance
exceeds the specified limit, the connecting rod
must be replaced.
Standard : 0.16 mm




0.35 mm
(0.0063 in.




0.0138 in)
Limit : 0.40 mm (0.0157 in)







015RS031
3. Measure the oil clearance between the connecting
rod and the crankshaft.
1. Remove the connecting rod cap nuts and the
rod caps (12).

Arrange the removed rod caps in the cylinder
number order.
2. Clean the rod bearings and the crankshaft pins.
3. Carefully check the rod bearings. If even one
bearing is found to be damaged or badly worn,
the entire bearing assembly must be replaced
as a set. Reinstall the bearings in their original
positions. Apply plastigage to the crank pin.






015RS032
4. Reinstall the rod caps (12) to their original
positions.
Tighten the rod cap nuts.
Torque: 54 N
 m (5.5 kg
 m/40 lb ft)

ENGINE MECHANICAL (6VE1 3.5L) 6A-85



RUW36ASH000501
 With 5
8840
0551
0 Piston pin service set
and a press, press fit the piston pin.
NOTE: Heat the connecting rod small end to a suitable
temperature to ensure smooth installation.


015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin

4. Install piston ring with the piston ring expander.
The No.2 compression ring must be set with the
T2 mark (1) facing up.



015RS027
 Install piston rings in the following sequence.
1. Oil ring
1. Expander ring
2. Upper side rail
3. Lower side rail
2. 2nd compression ring
 The 2nd compression ring must be set with the
T2 mark facing up.
3. 1st compression ring
 The compression ring must be set with
direction of origin.
 After installation, apply engine oil to the entire
circumference of the piston rings. Check to see
that all the rings rotate smoothly.





015RS038

6A-88 ENGINE MECHANICAL (6VE1 3.5L)
Disassembly
1. Remove cylinder head assembly.
2. Remove cylinder head gasket.
3. Remove crankcase with oil pan.
4. Remove oil pipe and O-ring.
5. Remove oil strainer and O-ring.
6. Remove oil pump assembly.
7. Remove crankcase side bolts.
8. Remove oil gallery.
9. Remove piston and connecting rod assembly.
10. Remove flywheel.
11. Remove rear oil seal retainer assembly.
12. Remove main bearing cap.
13. Remove crankshaft.
14. Remove cylinder block.
Inspection and Repair
1. Remove the cylinder head gasket and any other
material adhering to the upper surface of the
cylinder block. Be very careful not to allow any
material to accidentally drop into the cylinder block.
Be very careful not to scratch the cylinder block.
2. Carefully remove the oil pump, rear oil seal
retainer, and crankcase assembly installation
surface seal.
3. Wipe the cylinder block clean.
4. Visually inspect the cylinder block. If necessary,
use a flaw detector to perform a dye penetrate and
hydraulic (or air pressure) test. If cracking or othe
r
damage is discovered, the cylinder block must
either be repaired or replaced.
Flatness
1. Using a straight
edge and feeler gauge, check
that the upper surface of the cylinder block is no
t
warped.
NOTE: Be very careful not to allow any material to
accidentally drop into the upper surface of the cylinde
r
block. Be very careful not to scratch the upper surface
of the cylinder block.
2. The cylinder block must be reground or replaced i
f
the warpage exceeds the limit.
Warpage
Limit : 0.15 mm (0.0059 in)
Maximum repairable limit: 0.15 mm (0.0059 in)




012RS004
Cylinder Bore
Use a cylinder gauge to measure the cylinder bore
diameter in both the axial and thrust directions. Each
measurement should be made at six points.
CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
upper surface of the cylinder block.
Cylinder Bore Inside Diameter
Limit : 93.530 mm (3.6823 in)
If the measurement exceed the specified limit, the
cylinder block must be replaced.
Diameter
Grade A : 93.400 mm




93.410 mm
(3.6772 in




3.6776 in)
Grade B : 93.411 mm




93.420 mm
(3.6776 in




3.6779 in)
Grade C : 93.421 mm




93.430 mm
(3.6780 in




3.6783 in)

6A-90 ENGINE MECHANICAL (6VE1 3.5L)




015RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin

 Apply engine oil to oil seal lip and align a dowel
pin hole in the cylinder block with that in the
retainer.
 Tighten retainer fixing bolts to the specified
torque.
Torque: 25 N
 m (2.5 kg
 m/18.4 lb ft)




015RW001
4. Install flywheel
1. Thoroughly clean and remove the oil from the
threads of crankshaft.
2. Remove the oil from the crankshaft and
flywheel mounting faces.
3. Mount the flywheel on the crankshaft and then
install the washer.
4. Holding the crankshaft stationary, tighten the
flywheel bolts in the order shown. Torque: 54 N
 m (5.5 kg
 m/40 lb ft)
NOTE: Do not reuse the bolts and do not apply oil o
r
thread lock to the bolts.



015RS018
5. Install piston and connecting rod assembly.
 Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaf
t
pins.
NOTE: Do not apply engine oil to the bearing back
faces.
 Check to see that the piston ring end gaps are
correctly positioned.




015RS019
Legend
(1) No.1 Compression Ring
(2) No.2 Compression Ring
(3) Oil Ring Side Rail Upper
(4) Oil Ring Side Rail Lower
(5) Piston Front Mark