2004 ISUZU TF SERIES Workshop Manual

clock setting service interval cooling manual radio set oil type wheel torque

Page 1873 of 4264

ISUZU TF SERIES 2004 Workshop Manual 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
h

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.

Page 1874 of 4264

ISUZU TF SERIES 2004 Workshop Manual 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)

Page 1875 of 4264

ISUZU TF SERIES 2004 Workshop Manual 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
s

Page 1876 of 4264

ISUZU TF SERIES 2004 Workshop Manual 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 B

Page 1877 of 4264

ISUZU TF SERIES 2004 Workshop Manual ENGINE MECHANICAL (6VE1 3.5L) 6A-53
Disassembly
NOTE:
During disassembly, be sure that the valve train
components are kept together and identified so
that they can be reinstalled in their origin

ENGINE MECHANICAL (6VE1 3.5L) 6A-53
Disassembly
NOTE:
During disassembly, be sure that the valve train
components are kept together and identified so
that they can be reinstalled in their original
locations.
Before removing the cylinder head from the engine
and before disassembling the valve mechanism,
perform a compression test and note the results.
1. Remove camshaft drive gear pulley fixing bolt (3),
then pulley (4).
2. Remove camshaft bracket fixing bolt (5), camshaf
t
bracket (6), then camshaft exhaust (7), and intake
side (8).
3. Remove tappet with shim (11).
4. Use the 5884024460 valve spring compresso
r
and 5884025470 valve spring compressor
adapter to remove the split collar (12), valve spring
with upper seat (13) and valve (14).

014RW042
5. Remove spark plug (1).
CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use a motorized wire brush on any
gasket sealing surface.

Inspection and Repair
1. Cylinder head gasket and mating surfaces for
leaks, corrosion and blow-by. If the gasket has
failed, determine the cause.
Insufficient torque on head bolts
Improper installation
Loose or warped cylinder head
Missing dowel pins
Warped case surface
2. Cylinder head for cracks, especially between valve
seats and in the exhaust ports.
3. Cylinder head deck for corrosion, sand particles in
head and porosity.
CAUTION:

Do not attempt to weld the cylinder head.
Replace it.

Do not reuse cylinder head bolts.
4. Cylinder head deck, common chamber and
exhaust manifold mating surfaces for flatness.
These surfaces may be reconditioned by milling. I
f
the surfaces are “out of flat" by more than
specification, the surface should be ground to
within specifications. Replace the head if i
t
requires machining beyond the repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362
in)

011RW019

Page 1878 of 4264

ISUZU TF SERIES 2004 Workshop Manual 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

Page 1879 of 4264

ISUZU TF SERIES 2004 Workshop Manual ENGINE MECHANICAL (6VE1 3.5L) 6A-55

014RW024

Legend
(1) Right Bank
(2) Left Bank
(3) Alignment Mark on Camshaft Drive Gear
(4) Alignment Mark on Camshaft
(5) Alignment Mark on R

Page 1880 of 4264

ISUZU TF SERIES 2004 Workshop Manual 6A-56 ENGINE MECHANICAL (6VE1 3.5L)
Valve Spring, Oil Controller, Valve, Valve Guide
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts

014RW039

Legend
(1) C

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