ISUZU TF SERIES 2004 Workshop Manual

ENGINE MECHANICAL (6VE1 3.5L) 6A-67
3. Measure the camshaft thrust clearance with a dial
indicator. Replace the camshaft and/or the cylinde
r
head if the camshaft thrust clearance exceeds the
specified limit.
Camshaft thrust Clearance
Standard : 0.03 mm




0.08 mm(0.0012 in




0.0031
in)
Limit : 0.12 mm (0.0047 mm)







014RW035
Reassembly
1. Install camshaft drive gear assembly and tighten
three bolts to specified torque.
Torque: 10 N
 m (1.0 kg
 m/7 lb ft)
2. Tighten sub gear setting bolt.
1. Use 5
8840
2443
0 to turn sub gear to righ
t
direction until the M5 bolt hole aligns between
camshaft driven gear and sub gear.
2. Tighten M5 bolt suitable torque for preven
t
moving the sub gear.



014RW041
3. Install camshaft assembly and camshaft brackets,
tighten twenty bolts on one side bank to the
specified torque.
1.
Apply engine oil to camshaft journal and
bearing surface of camshaft bracket.
2.
Align timing mark on intake camshaft (one dot
for right bank, two dots for left bank) and
exhaust camshaft (one dot for right bank, two
dots for left bank) to timing mark on camshaf
t
drive gear (one dot).








014RW020
Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discerning Mark
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust

6A-68 ENGINE MECHANICAL (6VE1 3.5L)


014RW023
Legend
(1) Right Bank Camshaft Drive Gear
(2) Left Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin

ENGINE MECHANICAL (6VE1 3.5L) 6A-69



014RW024
Legend
(1) Right Bank
(2) Left Bank
(3) Alignment Mark on Camshaft Drive Gear
(4) Alignment Mark on Camshaft
(5) Alignment Mark on Retainer

3. Tighten twenty bolts in numerical order on one
side bank as shown in the illustration.
Torque: 10 N
 m (1.0 kg
 m/7 lb ft)






014RW031
4. If the oil seal requires replacement, use the
5
8840
2445
0 to install the oil seal.






014RW034

6A-70 ENGINE MECHANICAL (6VE1 3.5L)
5. Tighten bolt for camshaft drive gear assembly
pulley to the specified torque using the
5
8840
2447
0 universal holder.
Torque: 98 N
 m (10.0 kg
 m/72 lb ft)




014RW060

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.

6A-72 ENGINE MECHANICAL (6VE1 3.5L)
3. Remove oil pipe and O-ring (3).
4. Remove oil strainer and O-ring (4).
5. Remove oil pump assembly (5).
6. Remove crankcase side bolts (6).
7. Remove oil gallery (7).
8. Remove piston and connecting rod assembly (8).
Refer to “Piston, Piston Ring and Connecting Rod"
in this manual.
9. Remove flywheel (9).
10. Remove rear oil seal retainer (10).
11. Remove main bearing cap (11).
12. Remove crankshaft (12).
Inspection and Repair
1. Crankshaft
Set the dial indicator as shown in the illustration
and measure the crankshaft thrust clearance. I
f
the thrust clearance exceeds the specified limit,
replace the thrust bearings as a set.
Thrust Clearance
Standard : 0.06 mm




0.24 mm
(0.0024 in




0.0094 in)
Limit : 0.30 mm (0.0118 in)




015RS003

Main Bearing Clearance
1. Remove the bearing caps and measure the oil
clearance.
2. Remove the main bearing cap fixing bolts in the
sequence shown in the illustration.

Arrange the removed main bearing caps in the
cylinder number order.
Remove the main bearings.



015RS004
3. Remove the crankshaft. Remove the main
bearings.
4. Clean the upper and lower bearings as well as the
crankshaft main journal.
5. Check the bearings for damage or excessive wear.
The bearings must be replaced as a set if damage
or excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to
their original positions.
Carefully install the crankshaft.
7. Set the lower bearings to the bearing cap original
position.
8.
Apply plastigage to the crankshaft journal unit as
shown in the illustration.
NOTE: Do not set the plastigage on the oil hole.


015RS005
9. Install main bearing caps, oil gallery and crank
case bolts in the order shown, and tighten each
bolt to the specified torque.
NOTE: Do not apply engine oil to the crank case side

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.