lock ISUZU TF SERIES 2004 Workshop Manual

6A-46 ENGINE MECHANICAL (6VE1 3.5L)
6. Install oil gallery.

Clean contact surface of oil gallery and main
bearing cap.

Apply engine oil to oil gallery fixing bolts and
tighten the bolts in two steps, in the orde
r
shown.
Torque:
1st step: 29 N




m (3.0 kg




m/21 lb ft)
2nd step: 55
 
 65
 
7. Install cylinder body side bolts and tighten bolts in
order to the specified torque.
Torque: 39 N




m (4.0 kg




m/29 lb ft)
NOTE: Do not apply the oil to the bolts.



012RS007
8. Install oil pump assembly.

Remove oil on cylinder block and oil pump
mounting surface.

Apply sealant (TB1207B or equivalent) to the oil
pump mounting surface.

The oil pump assembly must be installed within
5 minutes after sealant application to preven
t
premature hardening of sealant.

Apply engine oil to oil seal lip.


Install oil pump in the cylinder block and tighten
fixing bolts to the specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft)




051RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin




051RW001
9. Install oil strainer with O-ring, tighten to the
specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft)
10. Install oil pipe with O-ring, tighten fixing bolts to the
specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft)

6A-48 ENGINE MECHANICAL (6VE1 3.5L)
Rear Oil Seal
Removal
1. Remove transmission assembly.

See Transmission section in this manual.
2. Remove flywheel.
3. Remove rear oil seal using a seal remover.
NOTE: Take care not to damage the crankshaft or oil
seal retainer when removing oil seal.
Installation
1. Apply engine oil to oil seal lip and install oil seal
using 5884022860.




015RS017
2. Install flywheel.

Clean tapped holes in the crankshaft.

Remove oil on the crankshaft and flywheel
mounting surface.

Tighten fixing bolts to the specified torque.
NOTE: Do not reuse the bolts and do not apply oil o
r
thread lock to the bolts.
Torque: 54 N




m (5.5 kg




m/40 lb ft)


015RS018
3. Install transmission.

See Transmission section in this manual.
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Take care that dowel positions are different
between the manual transmission and the
automatic transmission. Otherwise, the
transmission may be damaged.






012RS009

ENGINE MECHANICAL (6VE1 3.5L) 6A-51
19. Reconnect ground cable between engine and
chassis.
20. Reconnect harness connector to transmission and
install transmission harness bracket on engine lef
t
side.
21. Reconnect three engine harness connectors.
22. Reconnect vacuum booster hose.
23. Reconnect canister vacuum hose.
24. Install air cleaner assembly.
25. Reconnect air duct.
26. Reconnect accelerator cable to throttle valve on
common chamber.
27. 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.
28. Install engine hood to the origine position.

Refer to installation procedure for Body section
in this manual.

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 in direction B.

Confirm ratchet ring is locked.




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

29. Install the cable clips to accelerator control cable.

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-66 ENGINE MECHANICAL (6VE1 3.5L)
3. Place the camshaft on V
blocks.
Slowly rotate the camshaft and measure the
runout with a dial indicator.
Replace the camshaft if the runout exceeds the
specified limit.
Run out
Limit: 0.1 mm (0.0039 in)






014RW044
4. Measure the camshaft journal oil clearance.
1. Measure the camshaft bracket housing inside
diameter.
NOTE: Tighten camshaft bracket (2) to specified torque
before measuring the camshaft bracket inside diameter.
Torque : 10 N
 m (1.0 kg
 m/7 lb ft)






014RW031
2. Subtract the camshaft outside diameter from the
camshaft bracket housing inside diameter.
Oil Clearance
Standard : 0.027 mm




0.078 mm(0.0011 in




0.0031
in)
Limit : 0.11 mm (0.0043 in)







014RW037
5. Replace the cylinder head and/or camshaft if the
measured oil clearance exceeds the specified
limit.
1. Carefully clean the camshaft journal, the
camshaft bracket, and the cylinder head.
2. Install camshaft assembly and camshaf
t
brackets (2), tighten twenty bolts (1) on one
side bank to the specified torque.
Torque: 10 N
 m (1.0 kg
 m/7 lb ft)






014RW031

ENGINE MECHANICAL (6VE1 3.5L) 6A-71
Crankshaft
Crankshaft and Associated Parts



013RW009
Legend
(1) Cylinder Head Assembly
(2) Crankcase with Oil Pan
(3) Oil Pipe and O-Ring
(4) Oil Strainer and O-Ring
(5) Oil Pump Assembly
(6) Cylinder Block Side Bolts
(7) Oil Gallery
(8) Piston and Connecting Rod Assembly
(9) Flywheel
(10) Rear Oil Seal Retainer and Oil Seal
(11) Main Bearing Cap
(12) Crankshaft
(13) Main Bearing Cap Fixing Bolts
(14) Oil Gallery Fixing Bolts

Disassembly
1. Remove cylinder head assembly (1). Refer to
“Head" in this manual. 2. Remove crankcase with oil pan (2). Refer to “Oil
Pan and Crankcase" in this manual.
CAUTION: Take care not to damage or deform the
sealing flange surface of crankcase.

ENGINE MECHANICAL (6VE1 3.5L) 6A-73
bolts.
Main bearing cap bolts.
Torque: 39 N
 m (4.0 Kg
 m/29 lb ft)
Oil gallery fixing bolts.
Torque:
1st step: 29 N
 m (3.0 Kg
 m/21 lb ft)
2nd step 55
  
  65
 
Crank case side bolts
Torque : 39 N
 m (4.0 Kg
 m/29 lb ft)
NOTE: Do not allow the crankshaft to rotate.




015RS006
10. Remove the main bearing caps in the sequence
shown in the illustration.




015RS004
11. Measure the plastigage width and determine the
oil clearance. If the oil clearance exceeds the
specified limit, replace the main bearings as a se
t
and/or replace the crankshaft.
Standard : 0.019 mm




0.043 mm
(0.0007 in




0.0017 in)
Limit : 0.08 mm (0.0031 in)





015RS008
12. Clean the plastigage from the bearings and the
crankshaft.
Remove the crankshaft and the bearings.
Crankshaft (12) Inspection
Inspect the surface of the crankshaft journal and crank
pins for excessive wear and damage. Inspect the oil
seal fitting surfaces for excessive wear and damage.
Inspect the oil ports for obstructions.
Inspection and Repair
1. Carefully set the crankshaft on the V
blocks.
Slowly rotate the crankshaft and measure the
runout. If the crankshaft runout exceeds the
specified limit, the crankshaft must be replaced.
Runout : 0.04 mm (0.0016 in)






015RS007

6A-74 ENGINE MECHANICAL (6VE1 3.5L)
2. Measure the diameter and the uneven wear of
main journal and crank pin. If the crankshaft wear
exceeds the specified limit, crankshaft must be
replaced.
Main journal diameter : 63.918 mm




63.933 mm
(2.5165 in.




2.5170 in.)
Crank pin diameter : 53.922 mm




53.937 mm
(2.1229 in.




2.1235 in.)
Uneven wear limit : 0.005 mm (0.0002 in)






015RS009
Crankshaft Bearing Selection
Crankshaft bearing selection is based on the measured
diameters of the crankshaft journals and the bearing
inserts.
1. The grade mark (1) for cylinder block journal are
stamped on the lower face of cylinder block as
shown in the illustration.





RTW31BSH000701
2. The crankshaft journal diameter grade mark (1)
are stamped on the No.1 crankshaft balancer (2)
as shown in the illustration.




015R200005
3. Match the cylinder block journal grade marks and
the crankshaft journal grade marks in the table
below to determine the correct crankshaft bearing
size.
The size color code is painted to side of the
crankshaft bearings.




RTW31BSH000601

ENGINE MECHANICAL (6VE1 3.5L) 6A-75

Grade
Mark
Cylinder Block
Journal
Crank Shaft Journal
Diameter
Grade
Mark
Color Code
Oil Clearance
(Reference)
1 68.994-69.000
(2.7163-2.7165) 63.918-63.925
(2.5165-2.5167) 2 Blue 0.024-0.043
(0.0009-0.0017)
63.926-63.933
(2.5168-2.5170) 1 Brown 0.022-0.041
(0.0009-0.0016)
2 68.987-68.993
(2.7160-2.7163) 63.918-63.925
(2.5165-2.5167) 2 0.023-0.042
(0.0009-0.0016)
63.926-63.933
(2.5168-2.5170) 1 Green 0.021-0.040
(0.0008-0.0016)
3 68.980-68.986
(2.7157-2.7160) 63.918-63.925
(2.5165-2.5167) 2 0.022-0.041
(0.0009-0.0016)
63.926-63.933
(2.5168-2.5170) 1 Yellow 0.020-0.039
(0.0008-0.0015)

Reassembly
1. Crankshaft (12)
 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 main bearing back
faces.






015RS012
Legend
(1) Numver 1 and 4 main bearing upper and lower
(2) Numver 2 and 3 main bearing upper
(3) Numver 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
2. Rear oil seal (10)
 Remove the oil from the cylinder block and the
retainer mounting surface.
 Apply sealant (TB
1207B or equivalent) to the
retainer mounting surface, following the pattern
shown in the illustration.
The retainer must be installed within 5 minutes
after sealant application before the sealan
t
hardens.

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.