piston ISUZU TF SERIES 2004 Manual Online

6A-40 ENGINE MECHANICAL (6VE1 3.5L)
Piston, Piston Ring and Connecting Rod
Removal



F06RW011

Legend
(1) Cylinder Head
(2) Crankcase with Oil Pan
(3) Oil Pipe
(4) Oil Strainer
(5) Oil Gallery
(6) Piston with Connecting Rod Assembly


1. Remove cylinder head assembly.

Refer to removal procedure for Cylinder Head
in this manual.
2. Remove crankcase with oil pan.

Refer to removal procedure for Oil Pan and
Crankcase in this manual.

ENGINE MECHANICAL (6VE1 3.5L) 6A-41
3. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.





050RW002
Legend
(1) Oil Pump
(2) Oil Strainer
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter

4. Remove three fixing bolts, oil pipe with O-ring.
5. Remove eight fixing bolts, oil gallery.
6. Remove piston with connecting rod assembly,
before removing the bearing cap, remove carbon
on the top of cylinder bore and push piston with
connecting rod out from the top of cylinder bore.
Installation
1. Install piston with connecting rod assembly.


Apply engine oil to cylinder bore, connecting
rod bearing and crank pin.

When installing the piston, its front mark mus
t
face the engine front side.

The bearing cap number must be the same as
connecting rod number.


Apply engine oil to the thread and seating
surface of each nut.

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.
NOTE: Do not apply engine oil to the bearing back
faces and connecting rod bearing fitting surfaces.





015RW003
Legend
(1) Piston Front Mark
(2) Piston Grade
(3) Connecting Rod Front Mark

2. Install oil gallery and tighten the bolts in two steps,
in the order shown in illustration.
Torque:
1st step: 29 N




m (3.0 kg




m/21 lb ft)
2nd step: 55
 
 65
 



051RS009
3. Install oil pipe with O-ring.
Torque: 10 N




m (1.0 kg




m/7 lb ft)
4. Install oil strainer assembly with O-ring.
Torque: 25 N




m (2.5 kg




m/18 lb ft)
5. Install crankcase with oil pan.

Refer to installation procedure for Oil Pan and
Crankcase in this manual.

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-77



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

 Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor.
The front marks must be facing the front of the
engine.
 Match the numbered caps with the numbers on
the connecting rods. Align the punched marks
on the connecting rods and caps.
 Apply engine oil to the threads and seating
faces of the nuts.
 Tighten the nuts.
Torque: 54 N
 m (5.5 Kg
 m/40 lb ft)

After tightening the cap nuts, check to see that
the crankshaft rotates smoothly.
NOTE: Do not apply engine oil to the bearing back
faces.


015RS020
5. Install oil gallery (7) and tighten the bolts in 2
steps, in the order shown.
1st step: 29 N
 m (3.0 Kg
 m/22 lb ft)
2nd step: 55
  
  65
 




051RS009
6. Cylinder block side bolts (6)
 Tighten all the bolts to the specified torque in
the order shown.
NOTE: Do not apply engine oil to the crank case side
bolts.
Torque: 39 N
 m (4.0 Kg
 m/29 lb ft)

ENGINE MECHANICAL (6VE1 3.5L) 6A-79
Piston and Connecting Rod
Piston, Connecting Rod and Associate Parts




015RW019
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 Gallery
(7) Piston and Connecting Rod Assembly
(8) Piston Ring
(9) Piston Pin
(10) Piston
(11) Connecting Rod
(12) Connecting Rod Cap


Disassembly
1. Remove cylinder head assembly (1). Refer to
“Cylinder Head Removal" in this manual. 2. Remove cylinder head gasket (2).
3. Remove crankcase with oil pan (3). Refer to ”Oil
Pan and Crankcase" in this manual.
4. Remove oil pipe and O-ring (4).

6A-80 ENGINE MECHANICAL (6VE1 3.5L)
5. Remove oil strainer and O-ring (5).
6. Remove oil gallery (6).
7. Remove connecting rod cap with connecting rod
lower bearing (12).
8. Remove piston and connecting rod assembly (7).
NOTE: Before removing piston and connecting rod
assembly, measure thrust clearance.






015RS031
 Remove any ridge or carbon build up from the
top end of the cylinder.
9. Remove the piston rings (8) with a piston ring
expander. Arrange the removed piston rings in the
cylinder number order.

015RS022
10. Remove the piston pin (9) using 5
8840
0551
0
piston pin service set and piston support with a
press.
NOTE: Keep the parts removed from each cylinde
r
separate. All parts must be reinstalled in their original
positions. Heating the connecting rod will permit easy
removal of the piston pin.


015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin

11. Piston (10)
12. Connecting rod (11)
Inspection and Repair
Pistons (10)
Carefully clean away all the carbon adhering to the
piston head and the piston ring grooves.
NOTE: Never use a wire brush to clean the pistons.
Damage will result. Visually check each piston fo
r
cracking, scoring, and other signs of excessive wear. If
any of the above conditions are found, the piston must
be replaced.
Piston Diameter
1. Measure the piston outside diameter with
micrometer at the piston grading position and a
right angle to the piston pin.
Piston grading position (from piston head)
Piston grading position : 43.0 mm (1.6929 in)

ENGINE MECHANICAL (6VE1 3.5L) 6A-81





015RV014
The size mark (1) for piston outside diameter is
represented as shown in illustration below.
Outside Diameter
Size Mark A : 93.360 mm




93.370 mm
(3.6756 in




3.6760 in)
Size Mark B : 93.371 mm




93.380 mm
(3.6760 in




3.6764 in)
Size Mark C : 93.381 mm




93.390 mm
(3.6764 in




3.6768 in)

015RS025
Measure the cylinder bore inside diameter (refer
to ”Cylinder Block" in this manual).




012RS002
Piston Rings (8)
Any worn or damaged part discovered during engine
overhaul must be replaced with a new one.
1. Ring end gap measurement
 Insert the piston ring into the bore.
 Push the ring by the piston, at a right angle to
the wall, into the point at which the cylinde
r
bore diameter is the smallest.
 Measure the ring end gap.
Compression Ring
1st ring
Standard: 0.300 mm
0.400 mm
(0.0118 in
0.0157 in)
Limit: 1.0 mm (0.0394 in)
2nd ring
Standard: 0.450 mm
0.600 mm
(0.0177 in
0.0236 in)
Limit: 1.2 mm (0.0472 in)
Oil ring
Standard: 0.150 mm
0.450 mm
(0.0059 in
0.0177 in)
Limit: 1.05 mm (0.0413 in)

6A-82 ENGINE MECHANICAL (6VE1 3.5L)





015RS026
 The No.1 compression ring must be set with
direction of origin.
 No.2 compression ring: Positioning mark (1) is
painted as shown in the illustration.




015RS027
2. Measure the clearance between the piston ring
groove and the piston ring with a feeler gauge. I
f
the piston ring groove / piston ring clearance
exceeds the specified limit, the piston must be
replaced.
Compression Ring Clearance
Standard : 0.016 mm




0.038 mm
(0.0006 in.




0.0015 in)
Limit : 0.15mm (0.0059 in)






015RS028
Piston Pin (9)
NOTE: Do not reuse the old piston pin.
1. Use a micrometer to measure the new piston pin
outside diameter in both directions at three
different positions.
2. Measure the inside diameter of the connecting rod
small end. If the fitting interference between the
small end and pin does not conform to the
specified value, the connecting rod must be
replaced.
Standard : 0.023 mm




0.038 mm
(0.0009 in




0.0015 in)







015RS029