Camshaft ISUZU TF SERIES 2004 Service 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 1863 of 4264
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.
Page 1876 of 4264
6A-52 ENGINE MECHANICAL (6VE1 3.5L)
Cylinder Head
Cylinder Head and Associated Parts
011RW008
Legend
(1) Spark Plug
(2) Cylinder Head Bolt
(3) Camshaft Drive Gear Pulley Fixing Bolt
(4) Camshaft Drive Gear Pulley
(5) Camshaft Drive Gear Pulley
(6) Camshaft Bracket
(7) Camshaft Exhaust
(8) Camshaft Intake
(9) Retainer Fixing Bolt
(10) Retainer Assembly
(11) Tappet with Shim
(12) Split Collar
(13) Valve Spring and Spring Upper Seat
(14) Valve
Page 1877 of 4264
ENGINE MECHANICAL (6VE1 3.5L) 6A-53
Disassembly
NOTE:
During disassembly, be sure that the valve train
components are kept together and identified so
that they can be reinstalled in their original
locations.
Before removing the cylinder head from the engine
and before disassembling the valve mechanism,
perform a compression test and note the results.
1. Remove camshaft drive gear pulley fixing bolt (3),
then pulley (4).
2. Remove camshaft bracket fixing bolt (5), camshaf
t
bracket (6), then camshaft exhaust (7), and intake
side (8).
3. Remove tappet with shim (11).
4. Use the 5884024460 valve spring compresso
r
and 5884025470 valve spring compressor
adapter to remove the split collar (12), valve spring
with upper seat (13) and valve (14).
014RW042
5. Remove spark plug (1).
CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use a motorized wire brush on any
gasket sealing surface.
Inspection and Repair
1. Cylinder head gasket and mating surfaces for
leaks, corrosion and blow-by. If the gasket has
failed, determine the cause.
Insufficient torque on head bolts
Improper installation
Loose or warped cylinder head
Missing dowel pins
Warped case surface
2. Cylinder head for cracks, especially between valve
seats and in the exhaust ports.
3. Cylinder head deck for corrosion, sand particles in
head and porosity.
CAUTION:
Do not attempt to weld the cylinder head.
Replace it.
Do not reuse cylinder head bolts.
4. Cylinder head deck, common chamber and
exhaust manifold mating surfaces for flatness.
These surfaces may be reconditioned by milling. I
f
the surfaces are “out of flat" by more than
specification, the surface should be ground to
within specifications. Replace the head if i
t
requires machining beyond the repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362
in)
011RW019
Page 1878 of 4264
6A-54 ENGINE MECHANICAL (6VE1 3.5L)
5. Water jacket sealing plugs seating surfaces.
Reassembly
1. Install spark plug and tighten all the spark plugs to
specified torque.
Torque: 18 Nm (1.8 kgm/13 lb ft)
2. Tighten sub gear setting bolt.
1. Use 5884024430 gear spring lever to turn
sub gear to right direction until the M5 bol
t
aligns with the hole between camshaft driven
gear and sub gear.
2. Tighten the M5 bolt to a suitable torque to
prevent the sub gear from moving.
014RW041
3. Install camshaft drive gear assembly and tighten
three bolts to the specified torque.
Torque: 10 N
m (1.0 kg
m/7 lb ft)
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 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) 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
Page 1879 of 4264
ENGINE MECHANICAL (6VE1 3.5L) 6A-55
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 each
bank as shown in the illustration.
Torque: 10 N
m (1.0 kg
m/7 lb ft)
014RW031
5. Tighten bolt for camshaft drive gear assembly
pulley to the specified torque.
Torque: 98 N
m (10.0 kg
m/72 lb ft)
Page 1880 of 4264
6A-56 ENGINE MECHANICAL (6VE1 3.5L)
Valve Spring, Oil Controller, Valve, Valve Guide
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts
014RW039
Legend
(1) Camshaft Bracket Fixing Bolts
(2) Camshaft Assembly Inlet
(3) Camshaft Assembly Exhaust
(4) Shim
(5) Tappet
(6) Split Collar
(7) Spring Upper Seat
(8) Valve Spring
(9) Oil Controller
(10) Spring Lower Seat
(11) Valve Guide
(12) Valve
Page 1881 of 4264
ENGINE MECHANICAL (6VE1 3.5L) 6A-57
Disassembly
1. Remove camshaft bracket fixing bolts (1).
2. Remove camshaft assembly (intake).
3. Remove camshaft assembly (Exhaust side).
4. Remove shim (4) and tappet (5).
5. Use the 5884024460 valve spring compresso
r
and 5884025470 valve spring compressor
adapter to remove split collar.
014RW042
6. Remove valve spring.
7. Remove valve.
8. Remove oil controller and spring lower seat.
9. Remove the valve guide using the 5884024420
valve guide replacer.
Inspection and Repair
Valve Spring
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is
evident.
1. Measure the free height of the springs. The
springs must be replaced if the free height is belo
w
the specified limit.
Standard: 44.6 mm (1.756 in)
Limit: 43.6 mm (1.717 in)
014RS004
2. Measure the valve spring squareness with a steel
square and replace the valve springs if the
measured value exceeds the specified limit.
Limit: 2 mm (0.079 in)
014RS005
3. Using a spring tester to compress the springs to
the installed height, measure the compressed
spring tension, and replace the springs if the
measured tension is below the specified limit.
At installed height: 35.0 mm (1.38 in)
Standard: 196 N (44 lb)
Limit: Less than 181 N (41 lb)
Page 1883 of 4264
ENGINE MECHANICAL (6VE1 3.5L) 6A-59
Valve Guide Replacement
1. Using Valve guide replacer: 5884024420,
drive out the valve guide from the combustion
chamber side.
014RS008
2. Apply engine oil to the outside of the valve guide.
Using valve guide replacer 5884024420,
drive in a new valve guide from the camshaft side,
and check the valve guide height.
Valve guide upper end height: 13.0 mm (0.5118
in)
(Measured from the cylinder head upper face)
014RW046
3. Check the clearance. If the clearance is less than
the specified value, ream the inside diameter o
f
valve guide. Using a sharp 6 mm reamer, ream the
valve guide to obtain the specified clearance.
Valve Seat
1. Measure the protrusion of the valve stem when a
new valve is installed in the cylinder head. If the
protrusion of the valve stem exceeds the limit,
replace the valve seat insert or the cylinder head
assembly.
Protrusion of valve stem
Intake
Standard: 39.32 mm (1.5480 in)
Limit: 39.47 mm (1.5539 in)
Exhaust
Standard: 39.30 mm (1.5472 in)
Limit: 39.45 mm (1.5531 in)
014RW047
Page 1885 of 4264
ENGINE MECHANICAL (6VE1 3.5L) 6A-61
Valve Seat Insert Replacement
1. Arc weld the rod at several points. Be careful not
to damage the aluminum section.
2.
Allow the rod to cool for a few minutes. This will
cause the valve seat to shrink.
3. Strike the rod and pull it out.
014RS015
4. Carefully clean the valve seat pressfit section on
the cylinder head side.
5. Heat the pressfit section with steam or some
other means to cause expansion. Cool the valve
seat with dry ice or some other means.
6. Insert the pressfit section into the valve sea
t
horizontally.
Standard fitting interference: 0.14 mm
0.09 mm
(0.0055 in
0.0035 in)
7.
After insertion, use a seat grinder to grind finish
the seating face. Carefully note the seating angle,
the contact width, and the depression.
8. Lap the valve and the seat.
Reassembly
1. Install valve guide (1) to cylinder head. Apply
engine oil to the outside of the valve guide. Using
valve guide replacer 5884024420, drive in a
new valve guide from the camshaft side.
2. Install oil controller (3) and spring lower seat (2).
Using oil controller replacer 5884006230, drive
in a new oil controller.
014RW058
3. Install valve to valve guide. Before install valve
guide apply engine oil to the outside of the valve
stem.
4. Install valve spring to cylinder head. Attach the
valve spring to the lower spring seat. The painted
area of the valve spring should be facing
downward.
014RS020
Page 1886 of 4264
6A-62 ENGINE MECHANICAL (6VE1 3.5L)
5. Install lower valve spring seat, valve spring and
upper valve spring seat then put split collars on the
upper spring seat, using the 5884024460 valve
spring compresor and 5884025470 valve
spring compressor adapter to install the spli
t
collars.
014RW042
6. Install tappet with shim.
7. Install camshaft assembly.
Refer to installation procedure for Camshaft in
this manual.
Valve Clearance Adjustments
NOTE: To adjust valve clearance, apply engine oil to
the cam as well as to the adjusting shim (2) with the
cylinder head built on the cylinder block, give a fe
w
turns to the camshaft by means of timing pulley
tightening bolt, and measure valve clearance when the
nose of cam is just opposite to maximum cam lift (1) as
shown in illustration below.
014RW081
Legend
(1) Cam
(2) Shim
(3) Tappet
Valve Clearance Standard Value (cold)
Intake: 0.23 mm
0.33 mm
(0.0091 in
0.0130 in)
Exhaust: 0.25 mm
0.35 mm
(0.0098 in
0.0138 in)
Selection of Adjusting Shim
Shim to be selected = (Thickness of removed
shim) + (Valve clearance measurement Standard
value) Based on the above formula, the best suited
shim should be selected from 41 sorts of shim
(differently thick at 0.02mm (0.0008 in) intervals from
2.40mm (0.0945 in) through 3.2mm (0.1260 in) thick).
Install the shim and check valve clearance.