belt ISUZU TF SERIES 2004 Repair Manual

ENGINE MECHANICAL (6VE1 3.5L) 6A-29
Timing Belt
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using
wrench then remove drive belt.


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

5. Remove cooling fan assembly four nuts, then the
cooling fan assembly.
6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.
10. Remove crankshaft pulley assembly using
5884001330 crankshaft holder, hold crankshaf
t
pulley remove center bolt, then the pulley.
11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover 13. Remove pusher.
CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.




014RW011
Legend
(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin

14. Remove timing belt.
CAUTION:
1. Do not bend or twist the belt, otherwise its
core could be damaged. The belt should not be
bent at a radius less than 30 mm.
2. Do not allow oil or other chemical substances
to come in contact with the belt. They will
shorten the life.
3. Do not attempt to pry or stretch the belt with a
screw driver or any other tool during
installation.
4. Store timing belt in a cool and dark place.
Never expose the belt direct sunlight or heat.

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-32 ENGINE MECHANICAL (6VE1 3.5L)
2. Install pusher and tighten bolt to the specified
torque.
Torque: 25 N




m (2.5 Kg




m/18 lb ft)
1. Install the pusher while pushing the tension
pulley to the belt.
2. Pull out pin from the pusher.
NOTE: When reusing the pusher, press the pusher with
approximately 100Kg to retract the rod, and insert a pin
(1.4 mm piano wire).




014RW011
Legend
(1) Up Side
(2) Down Side
(3) Direction for Installation
(4) Locking Pin

3. Remove double clips or equivalent clips, from
timing belt pulleys.
Turn the crankshaft pulley clockwise by two
turns.

3. Install timing belt cover.
Remove crankshaft pulley that was installed in
step 1 item 5.
Tighten bolts to the specified torque.
Torque: 18 N




m (1.8 kg




m/13 lb ft)


020RW004
Legend
(1) Timing Belt Cover RH
(2) Timing Belt Cover LH
(3) Timing Belt Cover Lower


020RW003
Legend
(1) Timing Belt Cover
(2) Rubber Bushing
(3) Sealing Rubber
(4) Cylinder Body

ENGINE MECHANICAL (6VE1 3.5L) 6A-33
4. Install crankshaft pulley using 5-8840-0133-0, hold
the crankshaft pulley and tighten center bolt to the
specified torque.
Torque: 167 N




m (17.0 kg




m/123 lb ft)
5. Install fan pulley bracket and tighten fixing bolts to
the specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft)
6. Install power steering pump assembly and tighten
to the specified torque.
Torque:
M8 bolt: 25 N




m (2.5 kg




m/18 lb ft)
M10 bolt: 43 N




m (4.4 kg




m/32 lb ft)
7. 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.
8. 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

9. Install radiator upper fan shroud.
10. Install air cleaner assembly.

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.

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.

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.

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