wheel bolts ISUZU TF SERIES 2004 Service Manual

ENGINE MECHANICAL (6VE1 3.5L) 6A-49
Engine Assembly
Removal

P1010068
1. Disconnect battery ground and positive cable.
2. Remove battery.
3. Make alignment mark on the engine hood and
hinges before removal in order to return the hood
to original position exactly.
4. Remove engine hood.
5. Drain radiator coolant.
6. Disconnect accelerator cable and automatic cruise
control cable from throttle valve on common
chamber.
7. Remove the ECM.

Disconnect the two connectors from the ECM.

. Remove fixing bolts on the common chamber.

Remove fixing bolts for ground cable.
8. Disconnect air duct with air cleaner cover.
9. Remove air cleaner assembly.
10. Disconnect canister vacuum hose.
11. Disconnect vacuum booster hose.
12. Disconnect three engine harness connectors.
13. Disconnect harness connector to transmission (lef
t
front side of engine compartment), disconnect shift
on the fly harness connector from front side o
f
front axle and remove transmission harness
bracket from engine left side.
14. Disconnect ground cable between engine and
frame.
15. Disconnect bonding cable connector on the back
of right dash panel.
16. Disconnect bonding cable terminal on the lef
t
bank.

17. Disconnect starter harness connector from starter.
18. Disconnect generator harness connector from
generator.
19. Disconnect coolant reserve tank hose from
radiator.
20. Remove radiator upper and lower hoses.
21. Remove upper fan shroud.
22. Remove cooling fan assembly four fixing nuts,
then the cooling fan assembly.
23. Move drive belt tensioner to loose side using
wrench then remove drive belt.
24. Remove power steering pump fixing bolts, then
power steering pump. Place the power steering
pump along with piping on the body side.
25. Remove air conditioning compressor fixing bolts
from bracket and place the compressor along with
piping on the body side.
26. Remove four O2 sensor harness connectors (two
each bank) from exhaust front pipe.
27. Remove three exhaust pipe fixing nuts from each
bank.
28. Remove two exhaust pipe fixing nuts from each
exhaust pipe, then move exhaust pipe to rear side
of vehicle.
29. Remove flywheel dust covers.
30. Disconnect two heater hoses from engine.
31. Disconnect fuel hose from right side o
f
transmission.
CAUTION: Plug fuel pipe on engine side and fuel
hose from fuel tank.
32. Remove transmission assembly. Refer to
Transmission section in this manual.
33. Support the engine by engine hoist.
34. Remove two left side engine mount fixing bolts
from engine mount on chassis side.
35. Remove two right side engine mount fixing bolts
from engine mount on chassis side.
36. Remove engine assembly.
Installation
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Also take care that dowel positions are
different between the manual transmission and the
automatic transmission. Otherweise, the
transmission may be damaged.

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.

ENGINE MECHANICAL (6VE1 3.5L) 6A-71
Crankshaft
Crankshaft and Associated Parts



013RW009
Legend
(1) Cylinder Head Assembly
(2) Crankcase with Oil Pan
(3) Oil Pipe and O-Ring
(4) Oil Strainer and O-Ring
(5) Oil Pump Assembly
(6) Cylinder Block Side Bolts
(7) Oil Gallery
(8) Piston and Connecting Rod Assembly
(9) Flywheel
(10) Rear Oil Seal Retainer and Oil Seal
(11) Main Bearing Cap
(12) Crankshaft
(13) Main Bearing Cap Fixing Bolts
(14) Oil Gallery Fixing Bolts

Disassembly
1. Remove cylinder head assembly (1). Refer to
“Head" in this manual. 2. Remove crankcase with oil pan (2). Refer to “Oil
Pan and Crankcase" in this manual.
CAUTION: Take care not to damage or deform the
sealing flange surface of crankcase.

6A-72 ENGINE MECHANICAL (6VE1 3.5L)
3. Remove oil pipe and O-ring (3).
4. Remove oil strainer and O-ring (4).
5. Remove oil pump assembly (5).
6. Remove crankcase side bolts (6).
7. Remove oil gallery (7).
8. Remove piston and connecting rod assembly (8).
Refer to “Piston, Piston Ring and Connecting Rod"
in this manual.
9. Remove flywheel (9).
10. Remove rear oil seal retainer (10).
11. Remove main bearing cap (11).
12. Remove crankshaft (12).
Inspection and Repair
1. Crankshaft
Set the dial indicator as shown in the illustration
and measure the crankshaft thrust clearance. I
f
the thrust clearance exceeds the specified limit,
replace the thrust bearings as a set.
Thrust Clearance
Standard : 0.06 mm




0.24 mm
(0.0024 in




0.0094 in)
Limit : 0.30 mm (0.0118 in)




015RS003

Main Bearing Clearance
1. Remove the bearing caps and measure the oil
clearance.
2. Remove the main bearing cap fixing bolts in the
sequence shown in the illustration.

Arrange the removed main bearing caps in the
cylinder number order.
Remove the main bearings.



015RS004
3. Remove the crankshaft. Remove the main
bearings.
4. Clean the upper and lower bearings as well as the
crankshaft main journal.
5. Check the bearings for damage or excessive wear.
The bearings must be replaced as a set if damage
or excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to
their original positions.
Carefully install the crankshaft.
7. Set the lower bearings to the bearing cap original
position.
8.
Apply plastigage to the crankshaft journal unit as
shown in the illustration.
NOTE: Do not set the plastigage on the oil hole.


015RS005
9. Install main bearing caps, oil gallery and crank
case bolts in the order shown, and tighten each
bolt to the specified torque.
NOTE: Do not apply engine oil to the crank case side

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 5
8840
2286
0 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.

ENGINE MECHANICAL (6VE1 3.5L) 6A-87
Cylinder Block
Cylinder Block and Associated Parts



012RW010
Legend
(1) Cylinder Head Assembly
(2) Cylinder Head Gasket
(3) Crankcase with Oil Pan
(4) Oil Pipe and O-Ring
(5) Oil Strainer and O-Ring
(6) Oil Pump Assembly
(7) Cylinder Block Side Bolts
(8) Oil Gallery
(9) Piston and Connecting Rod Assembly
(10) Flywheel
(11) Rear Oil Seal Retainer Assembly
(12) Main Bearing Cap
(13) Crankshaft
(14) Cylinder Block

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 straight
edge 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)

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

ENGINE LUBRICATION (6VE1 3.5L) 6G-7
Oil Pan and Crankcase
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Lift vehicle by supporting the frame.
4. Remove front wheels.
5. Remove oil level dipstick from level gauge tube.
6. Remove stone guard.
7. Remove radiator under fan shroud.
NOTE: For 4WD model, remove front axle housing
assembly from chassis (steps 8 to 10).
8. Remove suspension cross member fixing bolts, 2
pcs each per side and remove suspension cross
member.
9. Remove pitman arm and relay lever assembly,
using the 5–8840–2005–0 remover, remove pitman
arm from the steering unit and remove four fixing
bolts for relay lever assembly.
10. Remove axle housing assembly four fixing bolts
from housing isolator side and mounting bolts from
wheel side. At this time support the axle with a
garage jack and remove axle housing assembly.
11. Remove oil pan fixing bolts.
12. Remove oil pan, using 5–8840–2153–0 seale
r
cutter, remove oil pan.



013RS003
13. Remove crankcase fixing bolts.
14. Remove crankcase, using 5–8840–2153–0 seale
r
cutter, remove crankcase.

NOTE: Do not deform or damage the flange of oil pan
and crankcase.
Replace the oil pan and/or crankcase if deformed o
r
damaged.



013RS003
Installation
1. Install crankcase.
1. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
2. Properly apply a 4.5 mm (0.7 in) wide bead o
f
sealant (TB-1207C or equivalent) to mounting
surface of crankcase.
Sealant beat must be continuous.
 The crankcase must be installed within 5
minutes after sealant application before the
sealant hardens.





013RW010

6A-46 ENGINE MECHANICAL (C24SE)





Inspection
Check contact pattern (I
) on valve seat and in cylinder head.

Clean
Valves, valve guides, cylinder head.

Flywheel

Removal
1. Remove transmission and clutch.
2. Remove flywheel while locking with 5-88400-446-0.







Torque - Angle Method
Flywheel to crankshaft - 65 Nm/6.5 kgf

m.+30
to 45


Important!
Use new bolts.
Do not apply grease to the thread.

Installation
1. Install clutch and transmission.



Component Parts
Flywheel and Ring gear. (Manual Transmission)