engine ISUZU TF SERIES 2004 Workshop Manual

ENGINE MECHANICAL (6VE1 3.5L) 6A-23
Cylinder Head Cover RH
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner duct assembly.
3. Disconnect ventilation hose from cylinder head
cover.
4. Disconnect three ignition coil connectors from
ignition coils and remove harness bracket bolts on
cylinder head cover then remove ignition coil fixing
bolts on ignition coils and remove ignition coils.
5. Remove heater pipe fixing bolts from the bracket.
6. Disconnect fuel injector harness connector then
remove fuel injector harness bracket bolt.
7. Remove eight fixing bolts then the cylinder head
cover.





010RW002
Installation
1. Install cylinder head cover.

Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.

Apply sealant (TB-1207B or equivalent) of bead
diameter 2‐3 mm at eight place of arched
area of camshaft bracket on front and rea
r
sides.

The cylinder head cover must be installed
within 5 minutes after sealant application to
prevent premature hardening of sealant.

Tighten bolts to the specified torque.
Torque : 9 N




m (0.9 kg




m/7 lb ft)





014RW019
2. Install exhaust gas recirculation pipe and tighten to
specified torque.
Torque :
Exhaust manifold side: 29 N




m (3.0 kg




m/21 lb ft)
Flare nut: 44 N




m (4.5 kg




m/33 lb ft)
Cylinder head side: 20 N




m (2.0 kg




m/14 lb ft)
3. Tighten fuel injector harness bracket bolts to
specified torque then reconnect fuel injecto
r
harness connector.
Torque : 8 N




m (0.8 kg




m/5.7 lb ft)
4. Install heater pipe bolt to the specified torque.
Torque : 20 N




m (2.0 kg




m/14 lb ft)
5. Connect ignition coil connector and tighten ignition
coil fixing bolts to specified torque.
Torque : 4 N




m (0.4 kg




m/3 lb ft)
6. Connect ventilation hose to cylinder head.
7. Install air cleaner duct assembly.

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.

6A-26 ENGINE MECHANICAL (6VE1 3.5L)
Exhaust Manifold LH
Removal
1. Disconnect battery ground cable.
2. Disconnect O
2 sensor connector.
3. Remove torsion bar. Refer to removal procedure in
Front Suspension section.
4. Remove exhaust front pipe three stud nuts from
exhaust side and two nuts from rear end o
f
exhaust front pipe.




RTW36FSH000201
5. Remove heat protector two fixing bolts then the
heat protector.
6. Remove a bolt on engine LH side for ai
r
conditioner (A/C) compressor bracket and loosen
two bolts for A/C compressor then move A/C
compressor to front side.
7. Remove exhaust manifold eight fixing nuts and
remove exhaust manifold from the engine.
Installation
1. Install exhaust manifold and tighten exhaust
manifold fixing nuts to the specified torque with
new nuts.
Torque: 52 N




m (5.3 kg




m/38 lb ft)
2. Install heat protector.
3. Install exhaust front pipe and tighten three stud
nuts and two nuts to the specified torque.
Torque:
Stud nuts: 67 N




m (6.8 kg




m/49 lb ft)
Nuts: 43 N




m (4.4 kg




m/32 lb ft)




RTW36FSH000201
4. Install the torsion bar and readjust the vehicle
height. Refer to installation and vehicle heigh
t
adjustment procedure for front suspension.
5. Set A/C compressor to normal position and tighten
two bolts and a bolt to the specified torque.
Torque : 40 N




m (4.1 kg




m/30 lb ft)
6. Reconnect O
2 sensor connector.
7. Install air cleaner duct assembly.

ENGINE MECHANICAL (6VE1 3.5L) 6A-27
Exhaust Manifold RH
Removal
1. Disconnect battery ground cable.
2. Remove exhaust front pipe three stud nuts and
two nuts then disconnect exhaust front pipe.




RTW36FSH000101
3. Remove steering shaft. Refer to removal
procedure in Steering section.
4. Remove heat protector two fixing bolts then the
heat protector.
5. Remove EGR pipe.
6. Remove exhaust manifold eight fixing nuts then
the exhaust manifold.
Installation
1. Install exhaust manifold and tighten bolts to the
specified torque.
Torque: 52 N




m (5.3 kg




m/38 lb ft)
2. Install EGR pipe.
Torque: 29 N




m (3.0 kg




m/22 lb ft)
3. Install heat protector
4. Install exhaust front pipe and tighten three stud
nuts and two nuts to the specified torque.
Torque:
Stud nuts: 67 N




m (6.8 kg




m/49 lb ft)
Nuts: 43 N




m (4.4 kg




m/32 lb ft)
5. Install steering shaft. Refer to installation
procedure in Steering section.

6A-28 ENGINE MECHANICAL (6VE1 3.5L)
Crankshaft Pulley
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.


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

5. Remove cooling fan assembly four fixing nuts,
then the cooling fan assembly.
6. Remove crankshaft pulley assembly using
5884001330 crankshaft holder, hold crankshaf
t
pulley then remove center bolt and pulley.
Installation
1. Install crankshaft pulley using 5884001330
crankshaft holder, hold the crankshaft pulley and
tighten center bolt to the specified torque.
Torque: 167 N




m (17.0 kg




m/123 lb ft)
2. Install cooling fan assembly and tighten bolts/nuts
to the specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft) for fan pulley
and fan bracket.
Torque: 10 N




m (1.0 kg




m/88.5 lb in) for fan and
clutch assembly.
3. Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
4. Install radiator upper fan shroud.
5. Install air cleaner 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.

6A-30 ENGINE MECHANICAL (6VE1 3.5L)
Installation
For correct belt installation, the letter on the belt must
be able to be read as viewed from the front of the
vehicle.


014RY00042
Legend
(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley
(4) Idle Pulley
(5) LH Bank Camshaft Drive Gear Pulley
(6) Tension Pulley



014RY00043

Legend
(7) Alignment Mark on Oil Pump.
(8) Alignment Mark on Timing Belt
(9)
Alignment Mark (notch) on Crankshaft Timing
Pulley
(10)
Alignment Mark (groove) on Crankshaft Timing
Pulley.







014RW006
Legend
(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side

1. Install timing belt.
1.
Align the mark (notch) of crankshaft timing
pulley (2) with mark on oil pump (1).

Align the mark (groove) on the crankshaft
timing pulley (3) with alignment mark (white
dots line) on the timing belt (4).

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