ISUZU TF SERIES 2004 Workshop Manual

ENGINE MECHANICAL (6VE1 3.5L) 6A-87
Cylinder Block
Cylinder Block and Associated Parts



012RW010
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 Pump Assembly
(7) Cylinder Block Side Bolts
(8) Oil Gallery
(9) Piston and Connecting Rod Assembly
(10) Flywheel
(11) Rear Oil Seal Retainer Assembly
(12) Main Bearing Cap
(13) Crankshaft
(14) Cylinder Block

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)

ENGINE MECHANICAL (6VE1 3.5L) 6A-89


012RS005
NOTE: For information on piston diameter, please refer
to the section "Inspection of the Piston and Connecting
Rod Assembly" in this manual.
 The "Grade" mark (1) is stamped at the
position illustrated.





012RS006
Reassembly
1. Install cylinder block.
2. Install crankshaft.
 Install the main bearings to the cylinder block
and the main bearing caps.
 Be sure that they are positioned correctly.

Apply new engine oil to the upper and lower
main bearing faces.
NOTE: Do not apply engine oil to the bearing back
faces.






015RS012
Legend
(1) Number 1 and 4 main bearing upper and lower.
(2) Number 2 and 3 main bearing upper.
(3) Number 2 and 3 main bearing lower.

 Carefully mount the crankshaft.
 Apply engine oil to the thrust washer.
 Assemble the thrust washer to the No. 3
bearing journal. The oil grooves must face the
crankshaft.





015RS013
3. Install rear oil seal retainer.
 Remove oil on cylinder block and retainer fitting
surface.

Apply sealant (TB1207B or equivalent) to
retainer fitting surface as shown in illustration.
 The oil seal retainer must be installed within 5
minutes after sealant application before the
sealant hardens.

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

ENGINE MECHANICAL (6VE1 3.5L) 6A-91
 Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor.
 The front marks (1) must be facing the front o
f
the engine.


015RS020
6. Install oil gallery 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°



012RS007
7. Install cylinder block side bolts (1) and tighten
crankcase bolts in sequence shown in the
illustration.
Torque : 39 N
 m (4.0 kg
 m/29 lb ft)





012RW005
8. Install oil pump assembly. Refer to “Oil Pump" in
this manual.
9. Install oil strainer and O-ring.
10. Install oil pipe and O-ring.
11. Install crankcase with oil pan.
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 crankcase. There must be no gaps in the
bead.
3. The oil pan must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.

6A-92 ENGINE MECHANICAL (6VE1 3.5L)
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 Both Holes
(2) Bolt Hole Portions

12. Install cylinder head gasket.
13. Install cylinder head assembly. Refer to “Cylinde
r
Head" in this manual.

ENGINE MECHANICAL (6VE1 3.5L) 6A-93
Main Data and Specification

General Specification
Item Specifications
Engine type, number of cylinders and arrangement Water cooled, four cycle V6
Form of combustion chamber Pent-roof type
Valve mechanism 4-Cams, 4-Valves, DOHC Gear & Belt Drive
Cylinder liner type Casted in cylinder block
Total piston displacement 3494 cc
Cylinder bore x stroke 93.4mm x 85.0mm

(3.6772 in  3.3465 in)
Compression ratio 8.6
Compression pressure at 300rpm 1.37 MPa (14.0 Kg/cm2)
Engine idling speed rpm Non adjustable (750)
Valve clearance Intake: 0.28 mm (0.11 in)

Exhaust: 0.30mm (0.12 in)
Oil capacity 5.3 liters
Ignition timing
Non adjustable (12 BTDC at idle rpm)
Spark plug PK16PR11, RC10PYP4, K16PR-P11
Plug gap 1.0 mm – 1.1 mm (0.0394 in – 0.0433 in)

6A-94 ENGINE MECHANICAL (6VE1 3.5L)
Torque Specifications
Ignition coil, Spark plug, Crankshaft angle sensor and Under cover
N
 m (kg
 m/ lb ft)







RTW460LF000101

ENGINE MECHANICAL (6VE1 3.5L) 6A-95
Cylinder head cover, Cylinder head, Camshaft bracket, Common chamber, ECM
N
 m (kg
 m/ lb ft)





RTW46ALF000601

6A-96 ENGINE MECHANICAL (6VE1 3.5L)
Crankshaft main bearing, Flywheel, Crankcase, Oil pan, Timing belt tensioner, Timing pulley, timing belt
cover, Oil pump, Oil gallery, Oil strainer and water pump
N
 m (kg
 m/ lb ft)




RTW46ALF000701