oil ISUZU TF SERIES 2004 Workshop Manual

ENGINE MECHANICAL (6VE1 3.5L) 6A-39
Valve Stem Oil Controller, Valve Spring and Valve Guide
Removal
1. Disconnect battery ground cable.

Drain engine oil.
2. Drain engine coolant.
3. Remove cylinder head assembly.

Refer to removal procedure for Cylinder Head
in this manual.
4. Remove camshaft.

Refer to removal procedure for Camshaft in this
manual.
5. Remove tappets with shim.
NOTE: Do not damage shim surface.
6. Remove valve springs using 5884024460
valve spring compressor and 5884025470
valve spring compressor adapter then remove
upper valve spring seat and lower seat.



014RW042
7. Remove oil controller using 5884006230 oil
controller remover, remove each valve stem oil
controller.
8. Remove valve guide using 5884025490 valve
guide replacer.

Installation
1. Install valve guide using 5884024420 valve
guide installer.
2. Install oil controller using 5884006240 oil
controller installer.
3. Install lower valve spring seat, valve spring and
upper valve spring seat then put split collars on the
upper spring seat, using 5884024420 valve
spring compressor and 5884006240 valve
spring compressor adapter to install the spli
t
collars.



014RW042
4. Install tappet with shim.
5. Install camshaft assembly.

Refer to installation procedure for Camshaft in
this manual.
6. Install cylinder head assembly.

Refer to installation procedure for Cylinde
r
Head in this manual.
7. Fill engine oil until full level.
8. Fill engine coolant.

6A-40 ENGINE MECHANICAL (6VE1 3.5L)
Piston, Piston Ring and Connecting Rod
Removal



F06RW011

Legend
(1) Cylinder Head
(2) Crankcase with Oil Pan
(3) Oil Pipe
(4) Oil Strainer
(5) Oil Gallery
(6) Piston with Connecting Rod Assembly


1. Remove cylinder head assembly.

Refer to removal procedure for Cylinder Head
in this manual.
2. Remove crankcase with oil pan.

Refer to removal procedure for Oil Pan and
Crankcase in this manual.

ENGINE MECHANICAL (6VE1 3.5L) 6A-41
3. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.





050RW002
Legend
(1) Oil Pump
(2) Oil Strainer
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter

4. Remove three fixing bolts, oil pipe with O-ring.
5. Remove eight fixing bolts, oil gallery.
6. Remove piston with connecting rod assembly,
before removing the bearing cap, remove carbon
on the top of cylinder bore and push piston with
connecting rod out from the top of cylinder bore.
Installation
1. Install piston with connecting rod assembly.


Apply engine oil to cylinder bore, connecting
rod bearing and crank pin.

When installing the piston, its front mark mus
t
face the engine front side.

The bearing cap number must be the same as
connecting rod number.


Apply engine oil to the thread and seating
surface of each nut.

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.
NOTE: Do not apply engine oil to the bearing back
faces and connecting rod bearing fitting surfaces.





015RW003
Legend
(1) Piston Front Mark
(2) Piston Grade
(3) Connecting Rod Front Mark

2. Install oil gallery and tighten the bolts in two steps,
in the order shown in illustration.
Torque:
1st step: 29 N




m (3.0 kg




m/21 lb ft)
2nd step: 55
 
 65
 



051RS009
3. Install oil pipe with O-ring.
Torque: 10 N




m (1.0 kg




m/7 lb ft)
4. Install oil strainer assembly with O-ring.
Torque: 25 N




m (2.5 kg




m/18 lb ft)
5. Install crankcase with oil pan.

Refer to installation procedure for Oil Pan and
Crankcase in this manual.

ENGINE MECHANICAL (6VE1 3.5L) 6A-43
Crankshaft and Main Bearings
Removal




F06RW010

Legend
(1) Engine Assembly
(2) Crankshaft Pulley
(3) Timing Belt Cover
(4) Timing Belt
(5) Crankcase with Oil Pan
(6) Oil Pipe
(7) Oil Strainer
(8) Oil Pump Assembly
(9) Cylinder Body Side Bolt
(10) Oil Gallery
(11) Flywheel
(12) Rear Oil Seal Retainer
(13) Connecting Rod Cap
(14) Crankshaft Main Bearing Cap
(15) Crankshaft and Main Bearing

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.

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

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)

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.

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

6A-50 ENGINE MECHANICAL (6VE1 3.5L)





012RS009
1. Install engine assembly. Tighten engine mount
fixing bolts to frame to the specified torque.
Torque: 41 N




m (4.2 kg




m/30 lb ft)
2. Reconnect fuel hose to fuel pipe on engine.
3. Install transmission assembly. Refer to
Transmission section in this manual.
4. Reconnect two heater hoses to engine.
5. Install flywheel dust covers.
6. Install exhaust pipe and temporally tighten two
(each bank) rear exhaust flange nuts then tighten
three stud nuts (each bank) between exhaus
t
manifold and exhaust pipe, finally tighten rear side
stud nuts to the specified torque.
Torque: 67 N




m (6.8 kg




m/49 lb ft)






LTW36FSH000101
7. Reconnect O2 sensor connector.
8. 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/7 lb ft) for fan and
clutch assembly.
9. Install air conditioner compressor to engine and
tighten to the specified torque.
Torque : 43 N




m (4.4 kg




m/32 lb ft)
10. Install power steering pump, tighten fixing bolt to
the specified torque.
Torque :
M8 bolts : 25 N




m (2.5 kg




m/18 lb ft)
M10 bolts : 43 N




m (4.4 kg




m/32 lb ft)
11. Move drive belt tensioner to loose side using
wrench, then install drive belt to normal position.



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

12. Install upper fan shroud.
13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back o
f
right dash panel.