Timing ISUZU TF SERIES 2004 Repair 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 1858 of 4264
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.
Page 1859 of 4264
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
Page 1860 of 4264
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.
Page 1861 of 4264
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.
Page 1862 of 4264
6A-38 ENGINE MECHANICAL (6VE1 3.5L)
NOTE: Do not reuse cylinder head bolts.
Do not apply any lubricant to the cylinder head bolts.
Torque:
Temporary: 29 N
m (3.0 kg
m/21 lb ft)
Final: 64 N
m (6.5 kg
m/47 lb ft)
014RW029
2. Install common chamber.
Refer to installation procedure for Common
Chamber in this manual.
3. Install cylinder head cover RH.
Refer to installation procedure for Cylinde
r
Head Cover RH in this manual.
4. Install cylinder head cover LH.
Refer to installation procedure for Cylinde
r
Head Cover LH in this manual.
5. Install timing belt.
Refer to installation procedure for Timing Belt in
this manual. 6. Install crankshaft pulley.
Refer to installation procedure for Crankshaf
t
Pulley in this manual.
Page 1867 of 4264
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
Page 1868 of 4264
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.
Page 1871 of 4264
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.
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 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.