ISUZU TF SERIES 2004 Workshop Manual

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-78 ENGINE MECHANICAL (6VE1 3.5L)



012RS001
7. Install oil pump assembly (5), refer to “Oil pump" in
this manual.
8. Install oil strainer and O-ring (4).
9. Install oil pipe and O-ring (3) and tighten the bolts.
Torque: 25 N
 m (2.5 Kg
 m/18 lb ft)
10. Install crankcase with oil pan (2).
1. Completely remove all residual sealant,
lubricant and moisture from the sealing
surfaces. The surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TB

1207C or its equivalent) to the contact surfaces
of the oil pan. There must be no gaps in the
bead.
3. The crankcase assembly must be installed
within 5 minutes after sealant application to
prevent premature hardening of the sealant.
4. Tighten the bolts and nuts to the specified
torque.
Torque : 10 N
 m (1.0 Kg
 m/7 lb ft)




013RW010
Legend
(1) Portion Between Bolt Holes
(2) Bolt Hole Portion

11. Install cylinder head assembly, refer to “Cylinder
head" in this manual.

ENGINE MECHANICAL (6VE1 3.5L) 6A-79
Piston and Connecting Rod
Piston, Connecting Rod and Associate Parts




015RW019
Legend
(1) Cylinder Head Assembly
(2) Cylinder Head Gasket
(3) Crankcase with Oil Pan
(4) Oil Pipe and O-Ring
(5) Oil Strainer and O-Ring
(6) Oil Gallery
(7) Piston and Connecting Rod Assembly
(8) Piston Ring
(9) Piston Pin
(10) Piston
(11) Connecting Rod
(12) Connecting Rod Cap


Disassembly
1. Remove cylinder head assembly (1). Refer to
“Cylinder Head Removal" in this manual. 2. Remove cylinder head gasket (2).
3. Remove crankcase with oil pan (3). Refer to ”Oil
Pan and Crankcase" in this manual.
4. Remove oil pipe and O-ring (4).

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-81





015RV014
The size mark (1) for piston outside diameter is
represented as shown in illustration below.
Outside Diameter
Size Mark A : 93.360 mm




93.370 mm
(3.6756 in




3.6760 in)
Size Mark B : 93.371 mm




93.380 mm
(3.6760 in




3.6764 in)
Size Mark C : 93.381 mm




93.390 mm
(3.6764 in




3.6768 in)

015RS025
Measure the cylinder bore inside diameter (refer
to ”Cylinder Block" in this manual).




012RS002
Piston Rings (8)
Any worn or damaged part discovered during engine
overhaul must be replaced with a new one.
1. Ring end gap measurement
 Insert the piston ring into the bore.
 Push the ring by the piston, at a right angle to
the wall, into the point at which the cylinde
r
bore diameter is the smallest.
 Measure the ring end gap.
Compression Ring
1st ring
Standard: 0.300 mm
0.400 mm
(0.0118 in
0.0157 in)
Limit: 1.0 mm (0.0394 in)
2nd ring
Standard: 0.450 mm
0.600 mm
(0.0177 in
0.0236 in)
Limit: 1.2 mm (0.0472 in)
Oil ring
Standard: 0.150 mm
0.450 mm
(0.0059 in
0.0177 in)
Limit: 1.05 mm (0.0413 in)

6A-82 ENGINE MECHANICAL (6VE1 3.5L)





015RS026
 The No.1 compression ring must be set with
direction of origin.
 No.2 compression ring: Positioning mark (1) is
painted as shown in the illustration.




015RS027
2. Measure the clearance between the piston ring
groove and the piston ring with a feeler gauge. I
f
the piston ring groove / piston ring clearance
exceeds the specified limit, the piston must be
replaced.
Compression Ring Clearance
Standard : 0.016 mm




0.038 mm
(0.0006 in.




0.0015 in)
Limit : 0.15mm (0.0059 in)






015RS028
Piston Pin (9)
NOTE: Do not reuse the old piston pin.
1. Use a micrometer to measure the new piston pin
outside diameter in both directions at three
different positions.
2. Measure the inside diameter of the connecting rod
small end. If the fitting interference between the
small end and pin does not conform to the
specified value, the connecting rod must be
replaced.
Standard : 0.023 mm




0.038 mm
(0.0009 in




0.0015 in)







015RS029

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)

6A-84 ENGINE MECHANICAL (6VE1 3.5L)
NOTE: Do not allow the crankshaft to rotate.
5. Remove the rod caps.
6. Measure the width of the plastigage and determine
the oil clearance. If the oil clearance exceeds the
limit, replace the rod bearing as a set.
Standard : 0.019 mm




0.043 mm
(0.0007 in




0.0017 in)
Limit : 0.08 mm (0.003 in)





015RS008
7. Clean the plastigage from the bearings and the
crankshaft pins.
Con




rod Bearing Selection
Select and install the new connecting rod bearings,
paying close attention to the connecting rod big end
diameter size mark (1).
NOTE: Take care not to confuse the alignment mark (2)
and the size mark (1) during the installation procedure.





015RS034


1 Size Mark Big end Bore
Diameter Crankshaft Pin
Diameter Connecting Rod
Bearing Thickness
(Reference) Color of
Size Mark Oil Clearance
(Reference)
A 56.994-57.000
(2.2439-2.2441) 1.512-1.516
(0.0595-0.0597) Yellow 0.025-0.054
(0.0010-0.0021)
B 56.988-56.994
(2.2436-2.2439) 53.922-53.937
(2.1229-2.1235) 1.508-1.512
(0.0594-0.0595) Green 0.027-0.056
(0.0011-0.0022)
C 56.982-56.988
(2.2434-2.2436) 1.504-1.508
(0.0592-0.0594) Pink 0.029-0.058
(0.0011-0.0023)

Reassembly
1. Install connecting rod
2. Install piston
3. Install piston pin

Apply a thin coat of engine oil to the piston pin.
Try to insert the piston pin into the piston pin
hole with normal finger pressure.
NOTE: When changing piston / connecting rod
combinations, do not change the piston / piston pin
combination and do not reuse the old piston pin.

Attach the piston to the connecting rod with the
piston front mark and the connecting rod fron
t
mark on the same side.

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-86 ENGINE MECHANICAL (6VE1 3.5L)
5. Install piston and connecting rod assembly.
 Insert the bearings into the connecting rods and
caps. Apply new engine oil to the bearing faces
and nuts.
 Tighten the connecting rod cap nuts
Torque : 54 N
 m (5.5 kg
 m/40 lb ft)
NOTE: Do not apply engine oil to the bearing back
faces.
6. Oil gallery, refer to “Crankshaft and main bearing"
in this manual.
7. Oil strainer and O-ring.
8. Oil pipe and O-ring.
9. Install crankcase with oil pan, refer to “Oil pan and
Crankcase" in this manual.
10. Install cylinder head gasket.
11. Install Cylinder head assembly.
 Refer to “Cylinder head" in this manual.