engine remove ISUZU TF SERIES 2004 Workshop Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2004, Model line: TF SERIES, Model: ISUZU TF SERIES 2004Pages: 4264, PDF Size: 72.63 MB
Page 1868 of 4264
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.
Page 1869 of 4264
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
Page 1870 of 4264
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)
Page 1871 of 4264
ENGINE MECHANICAL (6VE1 3.5L) 6A-47
11. Install crankcase.
Remove oil on crankcase mounting surface
and dry the surface.
Properly apply a 4.5 mm (0.7 in) wide bead o
f
sealant (TB1207C or equivalent) to the
crankcase mounting surface. The bead mus
t
be continuous.
The crankcase must be installed within 5
minutes after sealant application to preven
t
premature hardening of sealant.
Tighten fixing bolts to the specified torque.
Torque: 10 N
m (1.0 kg
m/1 lb ft)
013RW010
013RW004
12. Install oil pan
Remove oil on oil pan mounting surface and
dry the surface.
Properly apply a 4.5 mm (0.7 in) wide bead o
f
sealant (TB1207C or equivalent) to the oil pan
mounting surface. The bead must be
continuous.
The oil pan must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.
Tighten fixing bolts to the specified torque.
Torque: 25 N
m (2.5 kg
m/18 lb ft)
013RW003
013RW002
13. Install timing belt.
Refer to installation procedure for Timing Belt in
this manual.
14. Install engine assembly.
Refer to installation procedure for Engine
Assembly in this manual.
Page 1872 of 4264
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
Page 1873 of 4264
ENGINE MECHANICAL (6VE1 3.5L) 6A-49
Engine Assembly
Removal
P1010068
1. Disconnect battery ground and positive cable.
2. Remove battery.
3. Make alignment mark on the engine hood and
hinges before removal in order to return the hood
to original position exactly.
4. Remove engine hood.
5. Drain radiator coolant.
6. Disconnect accelerator cable and automatic cruise
control cable from throttle valve on common
chamber.
7. Remove the ECM.
Disconnect the two connectors from the ECM.
. Remove fixing bolts on the common chamber.
Remove fixing bolts for ground cable.
8. Disconnect air duct with air cleaner cover.
9. Remove air cleaner assembly.
10. Disconnect canister vacuum hose.
11. Disconnect vacuum booster hose.
12. Disconnect three engine harness connectors.
13. Disconnect harness connector to transmission (lef
t
front side of engine compartment), disconnect shift
on the fly harness connector from front side o
f
front axle and remove transmission harness
bracket from engine left side.
14. Disconnect ground cable between engine and
frame.
15. Disconnect bonding cable connector on the back
of right dash panel.
16. Disconnect bonding cable terminal on the lef
t
bank.
17. Disconnect starter harness connector from starter.
18. Disconnect generator harness connector from
generator.
19. Disconnect coolant reserve tank hose from
radiator.
20. Remove radiator upper and lower hoses.
21. Remove upper fan shroud.
22. Remove cooling fan assembly four fixing nuts,
then the cooling fan assembly.
23. Move drive belt tensioner to loose side using
wrench then remove drive belt.
24. Remove power steering pump fixing bolts, then
power steering pump. Place the power steering
pump along with piping on the body side.
25. Remove air conditioning compressor fixing bolts
from bracket and place the compressor along with
piping on the body side.
26. Remove four O2 sensor harness connectors (two
each bank) from exhaust front pipe.
27. Remove three exhaust pipe fixing nuts from each
bank.
28. Remove two exhaust pipe fixing nuts from each
exhaust pipe, then move exhaust pipe to rear side
of vehicle.
29. Remove flywheel dust covers.
30. Disconnect two heater hoses from engine.
31. Disconnect fuel hose from right side o
f
transmission.
CAUTION: Plug fuel pipe on engine side and fuel
hose from fuel tank.
32. Remove transmission assembly. Refer to
Transmission section in this manual.
33. Support the engine by engine hoist.
34. Remove two left side engine mount fixing bolts
from engine mount on chassis side.
35. Remove two right side engine mount fixing bolts
from engine mount on chassis side.
36. Remove engine assembly.
Installation
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Also take care that dowel positions are
different between the manual transmission and the
automatic transmission. Otherweise, the
transmission may be damaged.
Page 1877 of 4264
ENGINE MECHANICAL (6VE1 3.5L) 6A-53
Disassembly
NOTE:
During disassembly, be sure that the valve train
components are kept together and identified so
that they can be reinstalled in their original
locations.
Before removing the cylinder head from the engine
and before disassembling the valve mechanism,
perform a compression test and note the results.
1. Remove camshaft drive gear pulley fixing bolt (3),
then pulley (4).
2. Remove camshaft bracket fixing bolt (5), camshaf
t
bracket (6), then camshaft exhaust (7), and intake
side (8).
3. Remove tappet with shim (11).
4. Use the 5884024460 valve spring compresso
r
and 5884025470 valve spring compressor
adapter to remove the split collar (12), valve spring
with upper seat (13) and valve (14).
014RW042
5. Remove spark plug (1).
CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use a motorized wire brush on any
gasket sealing surface.
Inspection and Repair
1. Cylinder head gasket and mating surfaces for
leaks, corrosion and blow-by. If the gasket has
failed, determine the cause.
Insufficient torque on head bolts
Improper installation
Loose or warped cylinder head
Missing dowel pins
Warped case surface
2. Cylinder head for cracks, especially between valve
seats and in the exhaust ports.
3. Cylinder head deck for corrosion, sand particles in
head and porosity.
CAUTION:
Do not attempt to weld the cylinder head.
Replace it.
Do not reuse cylinder head bolts.
4. Cylinder head deck, common chamber and
exhaust manifold mating surfaces for flatness.
These surfaces may be reconditioned by milling. I
f
the surfaces are “out of flat" by more than
specification, the surface should be ground to
within specifications. Replace the head if i
t
requires machining beyond the repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362
in)
011RW019
Page 1881 of 4264
ENGINE MECHANICAL (6VE1 3.5L) 6A-57
Disassembly
1. Remove camshaft bracket fixing bolts (1).
2. Remove camshaft assembly (intake).
3. Remove camshaft assembly (Exhaust side).
4. Remove shim (4) and tappet (5).
5. Use the 5884024460 valve spring compresso
r
and 5884025470 valve spring compressor
adapter to remove split collar.
014RW042
6. Remove valve spring.
7. Remove valve.
8. Remove oil controller and spring lower seat.
9. Remove the valve guide using the 5884024420
valve guide replacer.
Inspection and Repair
Valve Spring
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is
evident.
1. Measure the free height of the springs. The
springs must be replaced if the free height is belo
w
the specified limit.
Standard: 44.6 mm (1.756 in)
Limit: 43.6 mm (1.717 in)
014RS004
2. Measure the valve spring squareness with a steel
square and replace the valve springs if the
measured value exceeds the specified limit.
Limit: 2 mm (0.079 in)
014RS005
3. Using a spring tester to compress the springs to
the installed height, measure the compressed
spring tension, and replace the springs if the
measured tension is below the specified limit.
At installed height: 35.0 mm (1.38 in)
Standard: 196 N (44 lb)
Limit: Less than 181 N (41 lb)
Page 1884 of 4264
6A-60 ENGINE MECHANICAL (6VE1 3.5L)
2. Measure the valve seat contact width. Make the
necessary corrections if the seat contact surface is
damaged or rough or if the contact width wea
r
exceeds the limit.
Valve seat contact width
Standard: 1.1 mm (0.0433 in)
Limit: 1.7 mm (0.0669 in)
014RS011
Contact Surface Angle on Valve Seat on
Valve
1. Measure contact surface angle on valve seat.
2. If the measured value exceeds the limit, replace
valve, valve guide and valve seat as a set.
Valve contact surface angle: 45
014RS012
Valve Seat Insert Correction
1. Remove the carbon from the valve seat insert
surface.
2. Use a valve cutter to minimize scratches and othe
r
rough areas. This will bring the contact width back
to the standard value. Remove only the scratches
and rough areas. Do not cut away too much. Take
care not to cut away unblemished areas of the
valve seat surface.
Valve seat angle degree: 90
014RW059
3. Apply abrasive compound to the valve seat insert
surface.
4. Insert the valve into the valve guide.
5. Turn the valve while lapping it to fit the valve sea
t
insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in
contact with the entire circumference of the valve.
014RS014
Page 1886 of 4264
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 5884024460 valve
spring compresor and 5884025470 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.