lock ISUZU TF SERIES 2004 Workshop Manual

6A-2 ENGINE MECHANICAL (6VE1 3.5L)
Crankshaft............................................................... 6A-71
Crankshaft and Associated Parts..................... 6A-71
Disassembly........................................................ 6A-71
Inspection and Repair........................................ 6A-73
Reassembly......................................................... 6A-75
Piston and Connecting Rod.................................. 6A-79
Piston, Connecting Rod and Associate
Parts.................................................................... 6A-79
Disassembly........................................................ 6A-79
Inspection and Repair........................................ 6A-80
Reassembly......................................................... 6A-84
Cylinder Block......................................................... 6A-87
Cylinder Block and Associated Parts............... 6A-87
Disassembly........................................................ 6A-88
Inspection and Repair........................................ 6A-88
Reassembly......................................................... 6A-89
Main Data and Specification................................. 6A-93
Special Tool......................................................... 6A-99


Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.


CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners o
r
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

ENGINE MECHANICAL (6VE1 3.5L) 6A-3
General Description
Engine Cleanliness And Care
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, i
t
should be understood that proper cleaning and
protection of machined surfaces and friction areas is
part of the repair procedure. This is considered
standard shop practice even if not specifically stated.


A liberal coating of engine oil should be applied to
all friction areas during assembly to protect and
lubricate the surfaces on initial operation.

Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and
crankshaft journal bearings are removed fo
r
service, they should be retained in order.


At the time of installation, they should be installed
in the same locations and with the same mating
surfaces as when removed.

Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.

The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaf
t
pulley side to flywheel side.
General Information on Engine Service
The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance.

When raising or supporting the engine for any
reason, do not use a jack under the oil pan. Due to
the small clearance between the oil pan and the oil
pump strainer, jacking against the oil pan may
cause damage to the oil pick-up unit.

The 12-volt electrical system is capable o
f
damaging circuits. When performing any work
where electrical terminals could possibly be
grounded, the ground cable of the battery should
be disconnected at the battery.


Any time the intake air duct or air cleaner is
removed, the intake opening should be covered.
This will protect against accidental entrance o
f
foreign material into the cylinder which could
cause extensive damage when the engine is
started.
Cylinder Block
The cylinder block is made of aluminum die-cast casting
for 75Vtype six cylinders. It has a rear plate integrated
structure and employs a deep skirt. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width is differen
t
between No.2, No.3 and No.1, No.4; the width of No.3
bearing on the body side is different in order to suppor
t
the thrust bearing. The bearing cap is made of nodular
cast iron and each bearing cap uses four bolts and two
side bolts.
Cylinder Head
The cylinder head, made of aluminum alloy casting
employs a pent-roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V-type design. The ports are cross-flo
w
type.
Valve Train
Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing
belt. The valves are operated by the camshaft and the
valve clearance is adjusted to select suitable thickness
shim.
Intake Manifold
The intake manifold system is composed of the
aluminum cast common chamber and intake manifold
attached with six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade
that meets the cylinder bore diameter. Each piston has
two compression rings and one oil ring. The piston pin
made of chromium steel is offset 1mm toward the thrus
t
side, and the thrust pressure of piston to the cylinder
wall varies gradually as the piston travels. The
connecting rods are made of forged steel. The
connecting rod bearings are graded for correct size
selection.
Crankshaft and Bearings
The crankshaft is made of Ductile cast-iron. Pins and
journals are graded for correct size selection for thei
r
bearing.
Engine Control Module (ECM)
The ECM location is on the common charmber.

6A-24 ENGINE MECHANICAL (6VE1 3.5L)
Common Chamber
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner duct assembly.
3. Remove the ECM.

Disconnect the two connectors from the ECM.

Remove fixing bolts on the common chamber.

Remove fixing bolts for ground cable.




060RW025
4. Remove the accelerator control cable from
accelerator control cable bracket.

Slide the lock in direction A

Rotate the ratchet ring in indirection an arro
w
90




RTW46ASH000201
Legend
(1) Cable Bracket
(2) Ratchet ring
(3) Outer Cap
(4) Lock
(5) Paint Mark
(6) Arrow Mark

5. Remove the accelerator control cable from the
throttle.
6. Disconnect vacuum booster hose from common
chamber.
7. Disconnect connector from manifold absolute
pressure sensor, idle air control valve, throttle
position sensor, solenoid valve, electric vacuum
sensing valve.
8. Disconnect vacuum hose on canister VSV and
positive crankcase ventilation hose, fuel rail
assembly with pressure control valve bracket.
9. Remove ventilation hose from throttle valve and
intake duct and remove water hose.
10. Remove exhaust gas recirculation valve assembly
fixing bolt and nut on common chamber.
11. Remove two bolts from common chamber rea
r
side for remove fuel hose bracket.
12. Remove common chamber four bolts and fou
r
nuts then remove the common chamber.



025RW001
Legend
(1) Common Chamber
(2) Throttle Valve Assembly
(3) Bolt

13. Remove the four throttle body fixing bolts.

ENGINE MECHANICAL (6VE1 3.5L) 6A-25
Installation
1. Install throttle body and tighten bolts to the
specified torque.
Torque : 25 N




m (2.5 kg




m/18 lb ft)
2. Install common chamber and tighten bolts and
nuts to the specified torque.
Torque :
Bolt : 18 N




m (1.8 kg




m/13 lb ft)
Nut : 18 N




m (1.8 kg




m/13 lb ft)
3. Install fuel hose bracket and tighten bolts to
specified torque.
Torque : 10 N




m (1.0 kg




m/89 lb in)
4. Install ventilating hose to throttle valve and intake
duct.
5. Connect vacuum hoses on canister VSV and
positive crankcase ventilation hose. Tighten bolts
for fuel rail assembly with pressure control valve
bracket.
Torque : 25 N




m (2.5 kg




m/18 lb ft)
6. Connect each connector without fail.
7. Connect vacuum booster hose.
8. Install the ECM.

Tighten the four bolts.
Torque : 10 N




m (1.0 kg




m/7 lb ft)

Connect the two connectors.

Tighten the two ground cable bolts.
9. Install accelerator control cable to accelerato
r
cable bracket.

Rotate the ratchet ring in direction an arrow 90

Confirm marking of outer cap must be uppe
r
side.

Slider the lock of outer cap must be upper side.

Confirm ratchet ring is locked.



060RW093
Legend
(1) Cable Bracket
(2) Ratchet ring
(3) Outer Cap
(4) Lock
(5) Paint Mark
(6) Arrow Mark

10. Install the cable clips to accelerator control cable.
11. Install air cleaner duct assembly.

ENGINE MECHANICAL (6VE1 3.5L) 6A-29
Timing Belt
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using
wrench then remove drive belt.


850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt

5. Remove cooling fan assembly four nuts, then the
cooling fan assembly.
6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.
10. Remove crankshaft pulley assembly using
5884001330 crankshaft holder, hold crankshaf
t
pulley remove center bolt, then the pulley.
11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover 13. Remove pusher.
CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.




014RW011
Legend
(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin

14. Remove timing belt.
CAUTION:
1. Do not bend or twist the belt, otherwise its
core could be damaged. The belt should not be
bent at a radius less than 30 mm.
2. Do not allow oil or other chemical substances
to come in contact with the belt. They will
shorten the life.
3. Do not attempt to pry or stretch the belt with a
screw driver or any other tool during
installation.
4. Store timing belt in a cool and dark place.
Never expose the belt direct sunlight or heat.

ENGINE MECHANICAL (6VE1 3.5L) 6A-31
NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.




014RW003
Legend
(1) Alignment Mark on Oil Pump
(2) Groove on Crankshaft Timing Pulley
(3) Alignment Mark on Crankshaft Timing Pulley
(4) Alignment Mark on Timing Belt

2. Align the alignment mark on the RH bank
camshaft drive gear pulley (2) to the alignmen
t
mark of the cylinder head cover RH (3).
3.
Align the alignment mark (white line) on the
timing belt (1) with alignment mark on the RH
bank camshaft drive gear pulley (2) (on the left
side as viewed from the front of the vehicle)
and put the timing belt on the camshaft drive
gear pulley.
Secure the belt with a double clip or equivalen
t
clip.


014RW00004

Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear Pulley.
(3) Alignemnt Mark on Cylinder Head Cover RH.

4. Align the alignment mark on the LH bank
camshaft drive gear pulley (2) to the alignmen
t
mark of the cylinder head cover LH (3).
5.
Align the alignment mark (white line) on the
timing belt (1) with the alignment mark on the
LH bank camshaft drive gear pulley (2).
When aligning the timing marks, use a wrench
to turn the camshaft drive gear pulley, then se
t
the timing mark between timing belt and
camshaft drive gear pulley and put the timing
belt on the camshaft drive gear pulley.
Secure the belt with a double clip or equivalen
t
clip.
NOTE: It is recommended for easy installation that the
belt be secured with a double clip or equivalent clip afte
r
it is installed the timing belt to each pulley.


014RW00005
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear Pulley.
(3) Alignemnt Mark on Cylinder Head Cover LH.

6. Install crankshaft pulley temporarily and tighten
center bolt by hand (do not use a wrench).
Turn the crankshaft pulley clockwise to give
some belt slack between the crankshaft timing
pulley and the RH bank camshaft drive gea
r
pulley.

6A-32 ENGINE MECHANICAL (6VE1 3.5L)
2. Install pusher and tighten bolt to the specified
torque.
Torque: 25 N




m (2.5 Kg




m/18 lb ft)
1. Install the pusher while pushing the tension
pulley to the belt.
2. Pull out pin from the pusher.
NOTE: When reusing the pusher, press the pusher with
approximately 100Kg to retract the rod, and insert a pin
(1.4 mm piano wire).




014RW011
Legend
(1) Up Side
(2) Down Side
(3) Direction for Installation
(4) Locking Pin

3. Remove double clips or equivalent clips, from
timing belt pulleys.
Turn the crankshaft pulley clockwise by two
turns.

3. Install timing belt cover.
Remove crankshaft pulley that was installed in
step 1 item 5.
Tighten bolts to the specified torque.
Torque: 18 N




m (1.8 kg




m/13 lb ft)


020RW004
Legend
(1) Timing Belt Cover RH
(2) Timing Belt Cover LH
(3) Timing Belt Cover Lower


020RW003
Legend
(1) Timing Belt Cover
(2) Rubber Bushing
(3) Sealing Rubber
(4) Cylinder Body

ENGINE MECHANICAL (6VE1 3.5L) 6A-37
Cylinder Head
Removal
1. Remove engine hood.
2. Disconnect battery ground cable.
3. Drain radiator coolant.
4. Drain engine oil.
5. Remove crankshaft pulley.

Refer to removal procedure for Crankshaf
t
Pulley in this manual.
6. Remove timing belt.

Refer to removal procedure for Timing Belt in
this manual.
7. Remove cylinder head cover LH.

Refer to removal procedure for Cylinder Head
Cover LH in this manual.
8. Remove cylinder head cover RH.

Refer to removal procedure for Cylinder Head
Cover RH in this manual.
9. Remove common chamber.

Refer to removal procedure for Common
Chamber in this manual.
10. Remove cylinder head assembly.
1. Loosen eights bolts for tight cylinder head.
2. Remove cylinder head assembly.



014RW028
Legend
(1) Cylinder Head
(2) Cylinder Head Bolt
(3) Camshaft


Installation
1. Install cylinder head assembly to cylinder block.
1. Put cylinder head gasket on the cylinder block.
NOTE: There is discrimination mark “R" for righ
t
bank and “L" for left bank on the cylinder head
gasket as shown in the illustration.
Do not reuse cylinder head gasket.


011RW005
2. Align dowel pin hole to dowel pin on the
cylinder block.
3. Tighten two bolts temporarily by hand to
prevent the cylinder head assembly from
moving.
4. Using 9851142090 cylinder head bol
t
wrench, tighten bolts in numerical order as
shown in the illustration to the specified torque.

6A-44 ENGINE MECHANICAL (6VE1 3.5L)
1. Remove engine assembly.

Refer to removal procedure for Engine
Assembly in this manual.
2. Remove timing belt.

Refer to removal procedure for Timing Belt in
this manual.
3. Remove oil pan and crankcase.

Refer to removal procedure for Oil Pan and
Crankcase in this manual.
4. Remove oil pipe with O-ring.
5. Remove oil strainer assembly with O-ring.
6. Remove oil pump assembly.

Refer to removal procedure for Oil Pump in this
manual.
7. Remove cylinder body side bolts.
8. Remove oil gallery.
9. Remove flywheel.
10. Remove rear oil seal retainer.

Refer to removal procedure for Rear Oil Seal in
this manual.
11. Remove connecting rod caps.
12. Remove crankshaft main bearing caps.
13. Remove crankshaft and main bearings.
Installation
1. Install crankshaft and main bearings.

Install main bearing in the cylinder block and
main bearing cap respectively.

Apply new engine oil to upper and lower main
bearings.
NOTE:

Do not apply engine oil to the bearing back faces.

Make sure that main bearings are in correc
t
position.

Install crankshaft with care.

Apply engine oil to the thrust washer.

Install thrust washer on No.3 journal.

Oil grooves in thrust washer must face the
crankshaft.





015RS012



015RS013
2. Install crankshaft main bearing caps.


Apply engine oil to the thread and seating
surface of each bearing cap fixing bolt.
NOTE:

Do not apply engine oil to the bearing back faces.

Install bearing caps in the order of numbers,
starting with cylinder block front side.

Tighten main bearing fixing bolts to the specified
torque.
Torque: 39 N




m (4.0 kg




m/29 lb ft)


After tightening the bolts, make sure that the
crankshaft rotates smoothly.
3. Install connecting rod caps.

The cap number must be same as connecting
rod number.


Apply engine oil to the thread and seating
surface of each nut.

ENGINE MECHANICAL (6VE1 3.5L) 6A-45

Tighten nuts to the specified torque.
Torque: 54 N




m (5.5 kg




m/40 lb ft)


After tightening the nuts, make sure that the
crankshaft rotates smoothly.
4. 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 to preven
t
premature hardening of sealant.




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: 18 N




m (1.8 kg




m/13 lb ft)




015RW001
5. Install flywheel.

Clean tapped holes in the crankshaft.

Remove oil on crankshaft and flywheel fitting
surface.
NOTE:

Do not reuse the bolts.

Do not apply oil or thread lock to the bolts.

Tighten fixing bolts to the specified torque.
Torque: 54 N




m (5.5 kg




m/40 lb ft)


015RS018