Camshaft ISUZU TF SERIES 2004 Owner's Guide

6A-14 ENGINE MECHANICAL (6VE1 3.5L)
Troubleshooting Procedure
The slapping sound stops when spark plug on bad
cylinder is shorted out.

Symptom Possible Cause Action
Timing belt noise Timing belt tension is incorrect Replace pusher or adjust the tension
pulley or replace timing belt
Tensioner bearing defective Replace
Timing belt defective Replace
Timing pulley defective Replace
Timing belt comes in contact with
timing cover Replace timing belt and timing cover
Valve noise Valve clearance incorrect Replace adjusting shim
Valve and valve guide seized Replace valve and valve guide
Valve spring broken or weakened Replace
Valve seat off–positioned Correct
Camshaft worn out Replace
Crankshaft noise Crankshaft end play excessive (noise
occurs when clutch is engaged) Replace thrust bearing
Engine knocking Preignition due to use of spark plugs
of inadequate heat range Install Spark Plugs of adequate heat
range
Carbon deposits in combustion
chambers Clean
Fuel too low in octane rating Replace fuel
Wide Open Throttle enrichment
system failure Refer to Section 6E
Selection of transmission gear
incorrect Caution operator of incorrect gear
selection
Engine overheating Refer to “Engine Lacks Power"
Others Water pump defective Replace
Drive belt slipping Replace auto tentioner or drive belt

ENGINE MECHANICAL (6VE1 3.5L) 6A-21
Cylinder Head Cover LH
Removal
1. Disconnect battery ground cable.
2. Disconnect positive crankcase ventilation hose.
3. Remove camshaft angle sensor connector.
4. Remove ground cable fixing bolt on cylinder head
cover.
5. Ignition coil connector and ignition coil.

Disconnect the three connectors from the
ignition coils.

Remove harness bracket bolt on cylinder head
cover.

Remove fixing bolts on ignition coils.









060RW078
Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assemblies

6. Remove fixing bolt for fuel injector harness
bracket.

7. Remove eight fixing bolts, then the cylinder head
cover.






010RW001
Installation
1. Install cylinder head cover.

Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.

Apply sealant (TB-1207B or equivalent) of bead
diameter 2-3 mm at eight place of arched area
of camshaft bracket on front and rear sides.

The cylinder head cover must be installed with
in 5 minutes after sealant application to preven
t
hardening of sealant.

Tighten bolts to the specified torque.
Torque : 9 N




m (0.9 kg




m/7 lb ft)




010RW006

6A-22 ENGINE MECHANICAL (6VE1 3.5L)
2. Install fuel injection harness bracket and tighten
bolt to the specified torque.
Torque : 8 N




m (0.8 kg




m/8 lb ft)
3. Connect ignition coil connector and ignition coil,
then tighten bolt to the specified torque.
Torque : 4 N




m (0.4 kg




m/3 lb ft)


060RW078
Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assembly

4. Connect ground cable and tighten bolts to the
specified torque.
Torque : 8 N




m (0.8 kg




m/6 lb ft)
5. Connect camshaft angle sensor connector.
6. Install positive crankcase ventilation hose.

ENGINE MECHANICAL (6VE1 3.5L) 6A-23
Cylinder Head Cover RH
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner duct assembly.
3. Disconnect ventilation hose from cylinder head
cover.
4. Disconnect three ignition coil connectors from
ignition coils and remove harness bracket bolts on
cylinder head cover then remove ignition coil fixing
bolts on ignition coils and remove ignition coils.
5. Remove heater pipe fixing bolts from the bracket.
6. Disconnect fuel injector harness connector then
remove fuel injector harness bracket bolt.
7. Remove eight fixing bolts then the cylinder head
cover.





010RW002
Installation
1. Install cylinder head cover.

Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.

Apply sealant (TB-1207B or equivalent) of bead
diameter 2‐3 mm at eight place of arched
area of camshaft bracket on front and rea
r
sides.

The cylinder head cover must be installed
within 5 minutes after sealant application to
prevent premature hardening of sealant.

Tighten bolts to the specified torque.
Torque : 9 N




m (0.9 kg




m/7 lb ft)





014RW019
2. Install exhaust gas recirculation pipe and tighten to
specified torque.
Torque :
Exhaust manifold side: 29 N




m (3.0 kg




m/21 lb ft)
Flare nut: 44 N




m (4.5 kg




m/33 lb ft)
Cylinder head side: 20 N




m (2.0 kg




m/14 lb ft)
3. Tighten fuel injector harness bracket bolts to
specified torque then reconnect fuel injecto
r
harness connector.
Torque : 8 N




m (0.8 kg




m/5.7 lb ft)
4. Install heater pipe bolt to the specified torque.
Torque : 20 N




m (2.0 kg




m/14 lb ft)
5. Connect ignition coil connector and tighten ignition
coil fixing bolts to specified torque.
Torque : 4 N




m (0.4 kg




m/3 lb ft)
6. Connect ventilation hose to cylinder head.
7. Install air cleaner duct assembly.

6A-30 ENGINE MECHANICAL (6VE1 3.5L)
Installation
For correct belt installation, the letter on the belt must
be able to be read as viewed from the front of the
vehicle.


014RY00042
Legend
(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley
(4) Idle Pulley
(5) LH Bank Camshaft Drive Gear Pulley
(6) Tension Pulley



014RY00043

Legend
(7) Alignment Mark on Oil Pump.
(8) Alignment Mark on Timing Belt
(9)
Alignment Mark (notch) on Crankshaft Timing
Pulley
(10)
Alignment Mark (groove) on Crankshaft Timing
Pulley.







014RW006
Legend
(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side

1. Install timing belt.
1.
Align the mark (notch) of crankshaft timing
pulley (2) with mark on oil pump (1).

Align the mark (groove) on the crankshaft
timing pulley (3) with alignment mark (white
dots line) on the timing belt (4).

ENGINE MECHANICAL (6VE1 3.5L) 6A-31
NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.




014RW003
Legend
(1) Alignment Mark on Oil Pump
(2) Groove on Crankshaft Timing Pulley
(3) Alignment Mark on Crankshaft Timing Pulley
(4) Alignment Mark on Timing Belt

2. Align the alignment mark on the RH bank
camshaft drive gear pulley (2) to the alignmen
t
mark of the cylinder head cover RH (3).
3.
Align the alignment mark (white line) on the
timing belt (1) with alignment mark on the RH
bank camshaft drive gear pulley (2) (on the left
side as viewed from the front of the vehicle)
and put the timing belt on the camshaft drive
gear pulley.
Secure the belt with a double clip or equivalen
t
clip.


014RW00004

Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear Pulley.
(3) Alignemnt Mark on Cylinder Head Cover RH.

4. Align the alignment mark on the LH bank
camshaft drive gear pulley (2) to the alignmen
t
mark of the cylinder head cover LH (3).
5.
Align the alignment mark (white line) on the
timing belt (1) with the alignment mark on the
LH bank camshaft drive gear pulley (2).
When aligning the timing marks, use a wrench
to turn the camshaft drive gear pulley, then se
t
the timing mark between timing belt and
camshaft drive gear pulley and put the timing
belt on the camshaft drive gear pulley.
Secure the belt with a double clip or equivalen
t
clip.
NOTE: It is recommended for easy installation that the
belt be secured with a double clip or equivalent clip afte
r
it is installed the timing belt to each pulley.


014RW00005
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear Pulley.
(3) Alignemnt Mark on Cylinder Head Cover LH.

6. Install crankshaft pulley temporarily and tighten
center bolt by hand (do not use a wrench).
Turn the crankshaft pulley clockwise to give
some belt slack between the crankshaft timing
pulley and the RH bank camshaft drive gea
r
pulley.

6A-34 ENGINE MECHANICAL (6VE1 3.5L)
Camshaft
Removal
1. Disconnect battery ground cable.
2. Remove crankshaft pulley.

Refer to removal procedure for Crankshaf
t
Pulley in this manual.
3. Remove timing belt.

Refer to removal procedure for Timing Belt in
this manual.
4. Remove cylinder head cover LH.

Refer to removal procedure for Cylinder Head
Cover LH in this manual.
5. Remove cylinder head cover RH.

Refer to removal procedure for Cylinder Head
Cover RH in this manual.
6. Remove twenty fixing bolts from inlet and exhaus
t
camshaft bracket on one side bank, then camshaft
brackets.





014RW027
7. Remove camshaft assembly.
8. Remove fixing bolt for camshaft drive gear pulley.
9. Remove three fixing bolts from camshaft drive
gear retainer, then camshaft drive gear assembly.






014RW026
Legend
(1) Right Bank
(2) Left Bank
(3) Timing Mark on Retainer

Installation
1. Install camshaft drive gear assembly and tighten
three bolts to the specified torque.
Torque: 10 N




m (1.0 kg




m/7 lb ft)
2. Tighten bolt for camshaft drive gear assembly
pulley to the specified torque.
Torque: 98 N




m (10.0 kg




m/72 lb ft)
3. Tighten sub gear setting bolt.
1. Use 5884024430 to turn sub gear to righ
t
direction until it aligns with the M5 bolt hole
between camshaft driven gear and sub gear.
2. Tighten the M5 bolt to a suitable torque to
prevent the sub gear from moving.

ENGINE MECHANICAL (6VE1 3.5L) 6A-35

014RW041
4. 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 dot 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) Discrimination Mark
(LI: Left bank intake, RI: Right bank intake)
(LE: Left bank exhaust, RE: Right bank exhaust)




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

6A-36 ENGINE MECHANICAL (6VE1 3.5L)



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 on numerical order an one
side bank as shown in the illustration.
Torque : 10 N




m (1.0 kg




m/7 lb ft)




014RW031
5. Install cylinder head cover RH.

Refer to installation procedure for CYLINDER
HEAD COVER RH in this manual.
6. Install cylinder head cover LH.

Refer to installation procedure for CYLINDER
HEAD COVER LH in this manual.
7. Install timing belt.

Refer to installation procedure for TIMING
BELT in this manual. 8. Install crankshaft pulley.

Refer to installation procedure fo
r
CRANKSHAFT PULLEY in this manual.

ENGINE MECHANICAL (6VE1 3.5L) 6A-37
Cylinder Head
Removal
1. Remove engine hood.
2. Disconnect battery ground cable.
3. Drain radiator coolant.
4. Drain engine oil.
5. Remove crankshaft pulley.

Refer to removal procedure for Crankshaf
t
Pulley in this manual.
6. Remove timing belt.

Refer to removal procedure for Timing Belt in
this manual.
7. Remove cylinder head cover LH.

Refer to removal procedure for Cylinder Head
Cover LH in this manual.
8. Remove cylinder head cover RH.

Refer to removal procedure for Cylinder Head
Cover RH in this manual.
9. Remove common chamber.

Refer to removal procedure for Common
Chamber in this manual.
10. Remove cylinder head assembly.
1. Loosen eights bolts for tight cylinder head.
2. Remove cylinder head assembly.



014RW028
Legend
(1) Cylinder Head
(2) Cylinder Head Bolt
(3) Camshaft


Installation
1. Install cylinder head assembly to cylinder block.
1. Put cylinder head gasket on the cylinder block.
NOTE: There is discrimination mark “R" for righ
t
bank and “L" for left bank on the cylinder head
gasket as shown in the illustration.
Do not reuse cylinder head gasket.


011RW005
2. Align dowel pin hole to dowel pin on the
cylinder block.
3. Tighten two bolts temporarily by hand to
prevent the cylinder head assembly from
moving.
4. Using 9851142090 cylinder head bol
t
wrench, tighten bolts in numerical order as
shown in the illustration to the specified torque.