check engine 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 1900 of 4264
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 5884022860 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.
Page 1901 of 4264
ENGINE MECHANICAL (6VE1 3.5L) 6A-77
015RS019
Legend
(1) No.1 Compression Ring
(2) No.2 Compression Ring
(3) Oil Ring Side Rail Upper
(4) Oil Ring Side Rail Lower
(5) Piston Front Mark
Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor.
The front marks must be facing the front of the
engine.
Match the numbered caps with the numbers on
the connecting rods. Align the punched marks
on the connecting rods and caps.
Apply engine oil to the threads and seating
faces of the nuts.
Tighten the nuts.
Torque: 54 N
m (5.5 Kg
m/40 lb ft)
After tightening the cap nuts, check to see that
the crankshaft rotates smoothly.
NOTE: Do not apply engine oil to the bearing back
faces.
015RS020
5. Install oil gallery (7) and tighten the bolts in 2
steps, in the order shown.
1st step: 29 N
m (3.0 Kg
m/22 lb ft)
2nd step: 55
65
051RS009
6. Cylinder block side bolts (6)
Tighten all the bolts to the specified torque in
the order shown.
NOTE: Do not apply engine oil to the crank case side
bolts.
Torque: 39 N
m (4.0 Kg
m/29 lb ft)
Page 1904 of 4264
6A-80 ENGINE MECHANICAL (6VE1 3.5L)
5. Remove oil strainer and O-ring (5).
6. Remove oil gallery (6).
7. Remove connecting rod cap with connecting rod
lower bearing (12).
8. Remove piston and connecting rod assembly (7).
NOTE: Before removing piston and connecting rod
assembly, measure thrust clearance.
015RS031
Remove any ridge or carbon build up from the
top end of the cylinder.
9. Remove the piston rings (8) with a piston ring
expander. Arrange the removed piston rings in the
cylinder number order.
015RS022
10. Remove the piston pin (9) using 5884005510
piston pin service set and piston support with a
press.
NOTE: Keep the parts removed from each cylinde
r
separate. All parts must be reinstalled in their original
positions. Heating the connecting rod will permit easy
removal of the piston pin.
015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
11. Piston (10)
12. Connecting rod (11)
Inspection and Repair
Pistons (10)
Carefully clean away all the carbon adhering to the
piston head and the piston ring grooves.
NOTE: Never use a wire brush to clean the pistons.
Damage will result. Visually check each piston fo
r
cracking, scoring, and other signs of excessive wear. If
any of the above conditions are found, the piston must
be replaced.
Piston Diameter
1. Measure the piston outside diameter with
micrometer at the piston grading position and a
right angle to the piston pin.
Piston grading position (from piston head)
Piston grading position : 43.0 mm (1.6929 in)
Page 1907 of 4264
ENGINE MECHANICAL (6VE1 3.5L) 6A-83
3. Insert the new pin into the piston and rotate it. If
the pin rotates smoothly with no backlash, the
clearance is normal. If there is backlash o
r
roughness, measure the clearance. If the
clearance exceeds the specified limit, the piston
must be replaced.
Clearance
Standard : 0.010 mm
0.017 mm
(0.0004 in.
0.0007 in)
Limit : 0.040 mm (0.0016 in)
Connecting Rods (11)
1. Check the connecting rod alignment If either the
bend or the twist exceeds the specified limit, the
connecting rod must be replaced.
Bend per 100 mm (3.937 in)
Limit: 0.15 (0.0059)
Twist per 100 mm (3.937 in)
Limit: 0.20 (0.0078)
015RS030
2. Measure the connecting rod thrust clearance. Use
a feeler gauge to measure the thrust clearance a
t
the large end of the connecting rod If the clearance
exceeds the specified limit, the connecting rod
must be replaced.
Standard : 0.16 mm
0.35 mm
(0.0063 in.
0.0138 in)
Limit : 0.40 mm (0.0157 in)
015RS031
3. Measure the oil clearance between the connecting
rod and the crankshaft.
1. Remove the connecting rod cap nuts and the
rod caps (12).
Arrange the removed rod caps in the cylinder
number order.
2. Clean the rod bearings and the crankshaft pins.
3. Carefully check the rod bearings. If even one
bearing is found to be damaged or badly worn,
the entire bearing assembly must be replaced
as a set. Reinstall the bearings in their original
positions. Apply plastigage to the crank pin.
015RS032
4. Reinstall the rod caps (12) to their original
positions.
Tighten the rod cap nuts.
Torque: 54 N
m (5.5 kg
m/40 lb ft)
Page 1909 of 4264
ENGINE MECHANICAL (6VE1 3.5L) 6A-85
RUW36ASH000501
With 5884005510 Piston pin service set
and a press, press fit the piston pin.
NOTE: Heat the connecting rod small end to a suitable
temperature to ensure smooth installation.
015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
4. Install piston ring with the piston ring expander.
The No.2 compression ring must be set with the
T2 mark (1) facing up.
015RS027
Install piston rings in the following sequence.
1. Oil ring
1. Expander ring
2. Upper side rail
3. Lower side rail
2. 2nd compression ring
The 2nd compression ring must be set with the
T2 mark facing up.
3. 1st compression ring
The compression ring must be set with
direction of origin.
After installation, apply engine oil to the entire
circumference of the piston rings. Check to see
that all the rings rotate smoothly.
015RS038
Page 1912 of 4264
6A-88 ENGINE MECHANICAL (6VE1 3.5L)
Disassembly
1. Remove cylinder head assembly.
2. Remove cylinder head gasket.
3. Remove crankcase with oil pan.
4. Remove oil pipe and O-ring.
5. Remove oil strainer and O-ring.
6. Remove oil pump assembly.
7. Remove crankcase side bolts.
8. Remove oil gallery.
9. Remove piston and connecting rod assembly.
10. Remove flywheel.
11. Remove rear oil seal retainer assembly.
12. Remove main bearing cap.
13. Remove crankshaft.
14. Remove cylinder block.
Inspection and Repair
1. Remove the cylinder head gasket and any other
material adhering to the upper surface of the
cylinder block. Be very careful not to allow any
material to accidentally drop into the cylinder block.
Be very careful not to scratch the cylinder block.
2. Carefully remove the oil pump, rear oil seal
retainer, and crankcase assembly installation
surface seal.
3. Wipe the cylinder block clean.
4. Visually inspect the cylinder block. If necessary,
use a flaw detector to perform a dye penetrate and
hydraulic (or air pressure) test. If cracking or othe
r
damage is discovered, the cylinder block must
either be repaired or replaced.
Flatness
1. Using a straightedge and feeler gauge, check
that the upper surface of the cylinder block is no
t
warped.
NOTE: Be very careful not to allow any material to
accidentally drop into the upper surface of the cylinde
r
block. Be very careful not to scratch the upper surface
of the cylinder block.
2. The cylinder block must be reground or replaced i
f
the warpage exceeds the limit.
Warpage
Limit : 0.15 mm (0.0059 in)
Maximum repairable limit: 0.15 mm (0.0059 in)
012RS004
Cylinder Bore
Use a cylinder gauge to measure the cylinder bore
diameter in both the axial and thrust directions. Each
measurement should be made at six points.
CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
upper surface of the cylinder block.
Cylinder Bore Inside Diameter
Limit : 93.530 mm (3.6823 in)
If the measurement exceed the specified limit, the
cylinder block must be replaced.
Diameter
Grade A : 93.400 mm
93.410 mm
(3.6772 in
3.6776 in)
Grade B : 93.411 mm
93.420 mm
(3.6776 in
3.6779 in)
Grade C : 93.421 mm
93.430 mm
(3.6780 in
3.6783 in)
Page 1914 of 4264
6A-90 ENGINE MECHANICAL (6VE1 3.5L)
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: 25 N
m (2.5 kg
m/18.4 lb ft)
015RW001
4. Install flywheel
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. Holding the crankshaft stationary, tighten the
flywheel bolts in the order shown. Torque: 54 N
m (5.5 kg
m/40 lb ft)
NOTE: Do not reuse the bolts and do not apply oil o
r
thread lock to the bolts.
015RS018
5. Install piston and connecting rod assembly.
Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaf
t
pins.
NOTE: Do not apply engine oil to the bearing back
faces.
Check to see that the piston ring end gaps are
correctly positioned.
015RS019
Legend
(1) No.1 Compression Ring
(2) No.2 Compression Ring
(3) Oil Ring Side Rail Upper
(4) Oil Ring Side Rail Lower
(5) Piston Front Mark
Page 1930 of 4264
6B-6 ENGINE COOLING (6VE1 3.5L)
Draining and Refilling Cooling
System
Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order.
The engine coolant (EC) level should be between the
“ MIN" and “MAX" lines of reserve tank when the engine
is cold. If low, check for leakage and add EC up to the
“ MAX" line.
There should not be any excessive deposit of rust o
r
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening the
drain plug at the bottom of the radiator.
P1010064
2. Remove the radiator cap.
WARNING: To avoid the danger of being burned, do
not remove the cap while the engine and radiato
r
are still hot. Scalding fluid and steam can be blown
out under pressure.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water, then
drain it. Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a
solution that is 50 percent antifreeze.
Procedure for filling with coolant (in case of full change)
Make sure that the engine is cool.
Open radiator cap pour coolant up to filler neck.
Pour coolant into reservoir tank up to “MAX" line.
Tighten radiator cap and start the engine. Afte
r
idling for 2 to 3 minutes, stop the engine and reopen
radiator cap. If the water level is lower, replenish.
WARNING: When the coolant is heated to a high
temperature, be sure not to loosen or remove the
radiator cap. Otherwise you might get scalded by
not vapor or boiling water. To open the radiato
r
cap, put a piece of thick cloth on the cap and
loosen the cap slowly to reduce the pressure when
the coolant has become cooler.
After tightening radiator cap, warm up the engine at
about 2000 rpm. Set heater adjustment to the
highest temperature position, and let the coolan
t
circulate also into heater water system.
Check to see the thermostat has opened through
the needle position of water thermometer, conduct a
5 –minute idling again and stop the engine.
When the engine has been cooled, check filler neck
for water level and replenish if required. Should
extreme shortage of coolant is found, check the
cooling system and reservoir tank hose for leakage.
Pour coolant into the reservoir tank up to “MAX"
line.
Page 1933 of 4264
ENGINE COOLING (6VE1 3.5L) 6B-9
Thermostat
Thermostat and Associated Parts
031RW001
Legend
(1) Thermostat Housing
(2) Thermostat
(3) Outlet Pipe
Removal
1. Disconnect battery ground cable.
2. Drain engine coolant from the radiator and engine.
3. Disconnect radiator hose from the inlet pipe.
4. Remove thermostat housing.
5. Remove thermostat(2).
Inspection
Suspend the thermostat in a water–filled container
using thin wire. Place a thermometer next to the
thermostat.
Do not directly heat the thermostat.
Gradually increase the water temperature. Stir the wate
r
so that the entire water is same temperature.
031RS003
Confirm the temperature when the valve first begins to
open.
Valve opening temperature 74.5
C
78.5
C
(166.1
F
173.3
F)
Confirm the temperature when the valve is fully opened.
Valve full open temperature and lift More than
8.5mm (0.33 in) at 90
C (194
F)
Make necessary repair and parts replacement i
f
extreme wear or damage is found during inspection.
Installation
1. Install thermostat into the outlet pipe(4) making sure
that the air hole is in the up position.
2. Install thermostat housing and tighten bolts to the
specified torque.
Torque: 25 N
m (2.5 kg
m/18 lb ft)
3. Installation rubber hose.
4. Replenish engine coolant (EC).
5. Start engine and check for EC leakage.
Page 1935 of 4264
ENGINE COOLING (6VE1 3.5L) 6B-11
Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug to drain EC.
3. Disconnect oil cooler hose on automatic transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose from the engine.
P1010064
5. Remove fan guide(1), clips(2) on both sides and
the bottom lock, then remove lower fan guide(3)
with fan shroud(4).
RTW46BSH000101
6. Disconnect the reserve tank hose(6) from radiator.
7. Remove bracket(5).
110RW004
8. Lift up and remove the radiator assembly with
hose, taking care not to damage the radiator core
with a fan blade.
Inspection
Radiator Cap
Measure the valve opening pressure of the pressurizing
valve with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside
the standard range.
Valve opening pressure kPa (psi) 93.3
122.7
(13.5
17.8)
Cap tester: 5 –8840 –0277 –0
Adapter: 5 –8840 –2603 –0
Check the condition of the vacuum valve in the cente
r
of the valve seat side of the cap. If considerable rust or
dirt is found, or if the valve seat cannot be moved by
hand, clean or replace the cap.