Timing belt set ISUZU TF SERIES 2004 Workshop Manual

ENGINE MECHANICAL (6VE1 3.5L) 6A-3
General Description
Engine Cleanliness And Care
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, i
t
should be understood that proper cleaning and
protection of machined surfaces and friction areas is
part of the repair procedure. This is considered
standard shop practice even if not specifically stated.


A liberal coating of engine oil should be applied to
all friction areas during assembly to protect and
lubricate the surfaces on initial operation.

Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and
crankshaft journal bearings are removed fo
r
service, they should be retained in order.


At the time of installation, they should be installed
in the same locations and with the same mating
surfaces as when removed.

Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.

The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaf
t
pulley side to flywheel side.
General Information on Engine Service
The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance.

When raising or supporting the engine for any
reason, do not use a jack under the oil pan. Due to
the small clearance between the oil pan and the oil
pump strainer, jacking against the oil pan may
cause damage to the oil pick-up unit.

The 12-volt electrical system is capable o
f
damaging circuits. When performing any work
where electrical terminals could possibly be
grounded, the ground cable of the battery should
be disconnected at the battery.


Any time the intake air duct or air cleaner is
removed, the intake opening should be covered.
This will protect against accidental entrance o
f
foreign material into the cylinder which could
cause extensive damage when the engine is
started.
Cylinder Block
The cylinder block is made of aluminum die-cast casting
for 75Vtype six cylinders. It has a rear plate integrated
structure and employs a deep skirt. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width is differen
t
between No.2, No.3 and No.1, No.4; the width of No.3
bearing on the body side is different in order to suppor
t
the thrust bearing. The bearing cap is made of nodular
cast iron and each bearing cap uses four bolts and two
side bolts.
Cylinder Head
The cylinder head, made of aluminum alloy casting
employs a pent-roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V-type design. The ports are cross-flo
w
type.
Valve Train
Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing
belt. The valves are operated by the camshaft and the
valve clearance is adjusted to select suitable thickness
shim.
Intake Manifold
The intake manifold system is composed of the
aluminum cast common chamber and intake manifold
attached with six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade
that meets the cylinder bore diameter. Each piston has
two compression rings and one oil ring. The piston pin
made of chromium steel is offset 1mm toward the thrus
t
side, and the thrust pressure of piston to the cylinder
wall varies gradually as the piston travels. The
connecting rods are made of forged steel. The
connecting rod bearings are graded for correct size
selection.
Crankshaft and Bearings
The crankshaft is made of Ductile cast-iron. Pins and
journals are graded for correct size selection for thei
r
bearing.
Engine Control Module (ECM)
The ECM location is on the common charmber.

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.