ISUZU TF SERIES 2004 Workshop Manual

ENGINE EXHAUST (6VE1 3.5L) 6F-3
CAUTION: The catalytic converter requires the use
of unleaded fuel only.
Periodic maintenance of the exhaust system is no
t
required. If the vehicle is raised for other service, it is
advisable to check the condition of the complete
exhaust system.
A dual bed monolith catalytic converter is used in
combination with three way catalytic converter.
Catalytic Converter Types:
Three way (Reduction/Oxidation) catalyst
The catalyst coating on the three way (reduction)
converter contains platinum and rhodium which lowers
the levels of nitrous oxide (NOx) as well as
hydrocarbons (HC) and carbon monoxide (Co).
Gasket
The gasket must be replaced whenever a new exhaust
pipe, muffler or catalytic converter is installed.

6F-4 ENGINE EXHAUST (6VE1 3.5L)
Three Way Catalytic Converter and Center Exhaust Pipe
Three Way Catalytic Converter and Center Exhaust Pipe and Associated Parts



RTW46FMF000201
Legend (4) Three Way Catalytic Converter LH
(1) Front Exhaust Pipe Fixing Nuts (5) Mounting Rubber
(2) O
2 Sensor (6) Exhaust Pipe Fixing Nuts
(3) Three Way Catalytic Converter RH (7) Center Exhaust Pipe


Removal
1. Disconnect battery ground cable.
2. Lift up the vehicle and support with suitable safety
stands.
3. Disconnect O
2 sensor harness connectors (2).
4. Remove the center exhaust pipe fixing nuts (6) and
the exhaust silencer fixing bolts, then remove the
center exhaust pipe and the mounting rubber.
5. Remove the front exhaust pipe fixing nuts (1) and
the mounting rubber, then remove the three way
catalytic converter (3) (4).
Installation
1. Install the three way catalytic converter (3) (4) and
the mounting rubber, and tighten the fixing nuts (1)
to the specified torque.
Torque : 67 N




m (6.8 kg




m/49 lb ft)
2. Install the center exhaust pipe and the mounting
rubbler, and tighten the fixing nuts (6) and bolts to
the specified torque.
Torque : 43 N




m (4.4 kg




m/32 lb ft)
3. Connect the O
2 sensor connectors (2).

ENGINE EXHAUST (6VE1 3.5L) 6F-5
Exhaust Silencer and Rear Exhaust Pipe
Exhaust Silencer & Tail Pipe and Associated Parts



RTW46FMF000301
Legend (4) Exhaust Silencer Mounting Rubber
(1) Center Exhaust Pipe (5) Exhaust Silencer & Tail Pipe
(2) Exhaust Pipe Fixing Bolts (6) Rear Exhaust Pipe Mounting Rubber
(3) Exhaust Pipe Fixing Nuts


Removal
1. Disconnect battery ground cable.
2. Lift up the vehicle and support with suitable safety
stands.
3. Remove the exhaust pipe fixing nuts (3) and bolts
(2).
4. Remove the silencer and rear exhaust pipe
mounting rubber (4)(6), then remove the exhaus
t
silencer (5) and rear exhaust pipe (6).

Installation
1. Install the exhaust silencer and pipe (5), then install
the exhaust silencer and rear exhaust pipe
mounting rubber (4)(6).
2. Tighten the exhaust pipe fixing nuts (3) and exhaus
t
pipe fixing bolts (2).
Torque: 43 N




m (4.4 kg




m/32 lb ft)

6F-6 ENGINE EXHAUST (6VE1 3.5L)
Main Data and Specifications
Torque Specifications
N




m (kg




m/lb ft)









RTW36FLF000301

ENGINE LUBRICATION (6VE1 3.5L) 6G-1
ENGINE
ENGINE LUBRICATION (6VE1 3.5L)
CONTENTS

Service Precaution................................................. 6G-1
General Description............................................... 6G-2
Oil Pump.................................................................. 6G-3
Oil Pump and Associated Parts........................ 6G-3
Disassembly........................................................ 6G-4
Inspection and Repair........................................ 6G-4
Reassembly......................................................... 6G-5
Oil Pan and Crankcase.......................................... 6G-7
Removal............................................................... 6G-7

Installation............................................................. 6G-7
Oil Pump.................................................................. 6G-9
Removal................................................................ 6G-9
Installation............................................................. 6G-9
Oil Pump Oil Seal.................................................... 6G-11
Removal................................................................ 6G-11
Installation............................................................. 6G-11
Main Data and Specification.................................. 6G-12


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.

6G-2 ENGINE LUBRICATION (6VE1 3.5L)
General Description



C06RW003
Legend (10) Connecting Rod Bearing
(1) Oil Strainer (11) Connecting Rod
(2) Oil Pump (12) Piston
(3) Relief Valve (13) Oil Gallery; Cylinder Head
(4) Oil Pressure Switch (14) Camshaft
(5) Oil Filter (15) Camshaft Journal
(6) Safety Valve (16) Front Journal; Camshaft Drive Gear
(7) Oil Gallery (17) Rear Journal; Camshaft Drive Gear
(8) Crankshaft Bearing (18) Oil Pan

ENGINE LUBRICATION (6VE1 3.5L) 6G-3
Oil Pump
Oil Pump and Associated Parts



051RW005
Legend (8) Relief Valve
(1) Crankshaft Timing Pulley (9) Oil Pump Cover
(2) Crankcase with Oil Pan (10) Driven Gear
(3) Oil Pipe (11) Drive Gear
(4) Oil Strainer (12) Oil Seal
(5) Oil Pump Assembly (13) O-ring
(6) Plug (14) Oil Pump Body

6G-4 ENGINE LUBRICATION (6VE1 3.5L)
Disassembly
1. Remove crankshaft timing pulley.
2. Remove crankcase with oil pan.
3. Remove oil pipe.
4. Remove oil strainer.
5. Remove oil pump assembly.
6. Remove plug.
7. Remove spring.
8. Remove relief valve.
9. Remove oil pump cover.
10. Remove driven gear.
11. Remove drive gear.
12. Remove oil seal.
13. Remove O-ring.
Inspection and Repair
CAUTION: Make necessary correction or parts
replacement if wear, damage or any other abnormal
conditions are found during inspection.
Relief Valve (8)
 Check to see that the relief valve slides freely.
 The oil pump must be replaced if the relief valve
does not slide freely.
 Replace the spring and/or the oil pump assembly
(5) if the spring is damaged or badly worn.





051RS002
Body (14) and Gears (10, 11)
The pump assembly must be replaced if one or more of
the conditions below is discovered during inspection.
 Badly worn or damaged driven gear (10).
 Badly worn drive gear (11) driving face.
 Badly scratched or scored body sliding face (14) o
r
driven gear (10).
 Badly worn or damaged gear teeth.
Measure the clearance between the body and the
driven gear with a feeler gauge.
Standard : 0.10 mm–0.18 mm
(0.0039 in.–0.0070 in)
Limit : 0.20mm (0.0079 in)





051RS004
 Measure the clearance between the drive gear and
driven gear with a feeler gauge.
Standard : 0.11 mm–0.24 mm
(0.0043 in–0.0094 in)
Limit : 0.35mm (0.0138 in)




051RS003

ENGINE LUBRICATION (6VE1 3.5L) 6G-5
 Measure the side clearance with a precision straight
edge and a feeler gauge.
Clearance
Standard : 0.03 mm–0.09 mm
(0.0011 in–0.0035 in)
Limit : 0.15mm (0.0059 in)







051RS005
Oil Strainer
Check the oil strainer for cracking and scoring. If
cracking and scoring are found, the oil strainer must be
replaced.





051RS006

Reassembly
1. Install drive gear (11).
2. Install driven gear (10).
3. Install oil pump cover (9) and first, loosely tighten all
of the attaching screws. Next, tighten the attaching
screws to the specified torque.
Torque : 10 N




m (1.0 kg




m/7 lb ft)
After installation, check that the gear rotates
smoothly.
4. Install relief valve (8) and apply engine oil to the
relief valve and spring (7).
5. Install spring (7).
6. Install the plug (6).
Torque : 8 N




m (0.8 kg




m/6 lb ft)






051RS007
7. Install oil pump assembly (5).
 Carefully remove any oil from the cylinder body
and the pump. Apply sealant (TB–1207B o
r
equivalent) to the pump fitting face as shown in
illustration. Take care that sealant is not applied
to oil port surfaces. The oil pump assembly
must be installed within 5 minutes after sealan
t
application to prevent premature hardening o
f
sealant.
CAUTION: Do not apply an excessive amount o
f
sealant to the contact surface. Applying too much
sealant will overflow the contact surfaces. This
could cause serious damage to the engine.
 Attach oil pump assembly to cylinder body.
 Tighten the oil pump fixing bolts.
Torque : 25 N




m (2.6 kg




m/18 lb ft)

6G-6 ENGINE LUBRICATION (6VE1 3.5L)


051RW002





051RW001
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin


8. Install the new oil seal (12). Apply engine oil to the
oil seal lip before installation then use 5–8840–
2287–0 oil seal Installer, install oil seal.






015RS001
9. Install oil strainer (4) with O-ring (13).
Torque: 25 N




m (2.6 kg




m/18 lb ft)
10. Install oil pipe (3) with O-ring (13).
Torque: 25 N




m (2.6 kg




m/18 lb ft)
11. Install crankcase with oil pan (2).
 Remove oil on crankcase mounting surface and
dry the surface.

Apply a proper 4.5 mm (0.7 in) wide bead of
sealant (TB1207C or equivalent) to the
crankcase mounting surface. The bead must 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/7 lb ft)





013RW010
12. Install crankshaft timing pulley.