engine ISUZU TF SERIES 2004 Workshop 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

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.

ENGINE MECHANICAL (6VE1 3.5L) 6A-45

Tighten nuts to the specified torque.
Torque: 54 N




m (5.5 kg




m/40 lb ft)


After tightening the nuts, make sure that the
crankshaft rotates smoothly.
4. Install rear oil seal retainer.

Remove oil on cylinder block and retainer fitting
surface.


Apply sealant (TB1207B or equivalent) to
retainer fitting surface as shown in illustration.

The oil seal retainer must be installed within 5
minutes after sealant application to preven
t
premature hardening of sealant.




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: 18 N




m (1.8 kg




m/13 lb ft)




015RW001
5. Install flywheel.

Clean tapped holes in the crankshaft.

Remove oil on crankshaft and flywheel fitting
surface.
NOTE:

Do not reuse the bolts.

Do not apply oil or thread lock to the bolts.

Tighten fixing bolts to the specified torque.
Torque: 54 N




m (5.5 kg




m/40 lb ft)


015RS018

6A-46 ENGINE MECHANICAL (6VE1 3.5L)
6. Install oil gallery.

Clean contact surface of oil gallery and main
bearing cap.

Apply engine oil to oil gallery fixing bolts and
tighten the bolts in two steps, in the orde
r
shown.
Torque:
1st step: 29 N




m (3.0 kg




m/21 lb ft)
2nd step: 55
 
 65
 
7. Install cylinder body side bolts and tighten bolts in
order to the specified torque.
Torque: 39 N




m (4.0 kg




m/29 lb ft)
NOTE: Do not apply the oil to the bolts.



012RS007
8. Install oil pump assembly.

Remove oil on cylinder block and oil pump
mounting surface.

Apply sealant (TB1207B or equivalent) to the oil
pump mounting surface.

The oil pump assembly must be installed within
5 minutes after sealant application to preven
t
premature hardening of sealant.

Apply engine oil to oil seal lip.


Install oil pump in the cylinder block and tighten
fixing bolts to the specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft)




051RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin




051RW001
9. Install oil strainer with O-ring, tighten to the
specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft)
10. Install oil pipe with O-ring, tighten fixing bolts to the
specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft)

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.

6A-48 ENGINE MECHANICAL (6VE1 3.5L)
Rear Oil Seal
Removal
1. Remove transmission assembly.

See Transmission section in this manual.
2. Remove flywheel.
3. Remove rear oil seal using a seal remover.
NOTE: Take care not to damage the crankshaft or oil
seal retainer when removing oil seal.
Installation
1. Apply engine oil to oil seal lip and install oil seal
using 5884022860.




015RS017
2. Install flywheel.

Clean tapped holes in the crankshaft.

Remove oil on the crankshaft and flywheel
mounting surface.

Tighten fixing bolts to the specified torque.
NOTE: Do not reuse the bolts and do not apply oil o
r
thread lock to the bolts.
Torque: 54 N




m (5.5 kg




m/40 lb ft)


015RS018
3. Install transmission.

See Transmission section in this manual.
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Take care that dowel positions are different
between the manual transmission and the
automatic transmission. Otherwise, the
transmission may be damaged.






012RS009

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-51
19. Reconnect ground cable between engine and
chassis.
20. Reconnect harness connector to transmission and
install transmission harness bracket on engine lef
t
side.
21. Reconnect three engine harness connectors.
22. Reconnect vacuum booster hose.
23. Reconnect canister vacuum hose.
24. Install air cleaner assembly.
25. Reconnect air duct.
26. Reconnect accelerator cable to throttle valve on
common chamber.
27. Install the ECM.

Tighten the four bolts.
Torque : 10 N




m (1.0 kg




m/7 lb ft)

Connect the two connectors.

Tighten the two ground cable bolts.
28. Install engine hood to the origine position.

Refer to installation procedure for Body section
in this manual.

Install accelerator control cable to accelerato
r
cable bracket.

Rotate the ratchet ring in direction an arrow 90

Confirm marking of outer cap must be uppe
r
side.

Slider the lock in direction B.

Confirm ratchet ring is locked.




RTW46ASH000201
Legend
(1) Cable Bracket
(2) Ratchet ring
(3) Outer Cap
(4) Lock
(5) Paint Mark
(6) Arrow Mark

29. Install the cable clips to accelerator control cable.

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