2004 ISUZU TF SERIES Workshop Manual

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Page 1905 of 4264

ISUZU TF SERIES 2004 Workshop Manual 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
9

Page 1906 of 4264

ISUZU TF SERIES 2004 Workshop Manual 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 il

Page 1907 of 4264

ISUZU TF SERIES 2004 Workshop Manual ENGINE MECHANICAL (6VE1 3.5L) 6A-83
3. Insert the new pin into the piston and rotate it. If
the pin rotates smoothly with no backlash, the
clearance is normal. If there is backlash o
r
roughness, me

Page 1908 of 4264

ISUZU TF SERIES 2004 Workshop Manual 6A-84 ENGINE MECHANICAL (6VE1 3.5L)
NOTE: Do not allow the crankshaft to rotate.
5. Remove the rod caps.
6. Measure the width of the plastigage and determine
the oil clearance. If the oil clearanc

Page 1909 of 4264

ISUZU TF SERIES 2004 Workshop Manual ENGINE MECHANICAL (6VE1 3.5L) 6A-85

RUW36ASH000501
With 5884005510 Piston pin service set
and a press, press fit the piston pin.
NOTE: Heat the connecting rod small end to a suitable
te

Page 1910 of 4264

ISUZU TF SERIES 2004 Workshop Manual 6A-86 ENGINE MECHANICAL (6VE1 3.5L)
5. Install piston and connecting rod assembly.
Insert the bearings into the connecting rods and
caps. Apply new engine oil to the bearing faces
and nuts.
T

Page 1911 of 4264

ISUZU TF SERIES 2004 Workshop Manual ENGINE MECHANICAL (6VE1 3.5L) 6A-87
Cylinder Block
Cylinder Block and Associated Parts

012RW010
Legend
(1) Cylinder Head Assembly
(2) Cylinder Head Gasket
(3) Crankcase with Oil Pan

Page 1912 of 4264

ISUZU TF SERIES 2004 Workshop Manual 6A-88 ENGINE MECHANICAL (6VE1 3.5L)
Disassembly
1. Remove cylinder head assembly.
2. Remove cylinder head gasket.
3. Remove crankcase with oil pan.
4. Remove oil pipe and O-ring.
5. Remove oil

6A-88 ENGINE MECHANICAL (6VE1 3.5L)
Disassembly
1. Remove cylinder head assembly.
2. Remove cylinder head gasket.
3. Remove crankcase with oil pan.
4. Remove oil pipe and O-ring.
5. Remove oil strainer and O-ring.
6. Remove oil pump assembly.
7. Remove crankcase side bolts.
8. Remove oil gallery.
9. Remove piston and connecting rod assembly.
10. Remove flywheel.
11. Remove rear oil seal retainer assembly.
12. Remove main bearing cap.
13. Remove crankshaft.
14. Remove cylinder block.
Inspection and Repair
1. Remove the cylinder head gasket and any other
material adhering to the upper surface of the
cylinder block. Be very careful not to allow any
material to accidentally drop into the cylinder block.
Be very careful not to scratch the cylinder block.
2. Carefully remove the oil pump, rear oil seal
retainer, and crankcase assembly installation
surface seal.
3. Wipe the cylinder block clean.
4. Visually inspect the cylinder block. If necessary,
use a flaw detector to perform a dye penetrate and
hydraulic (or air pressure) test. If cracking or othe
r
damage is discovered, the cylinder block must
either be repaired or replaced.
Flatness
1. Using a straightedge and feeler gauge, check
that the upper surface of the cylinder block is no
t
warped.
NOTE: Be very careful not to allow any material to
accidentally drop into the upper surface of the cylinde
r
block. Be very careful not to scratch the upper surface
of the cylinder block.
2. The cylinder block must be reground or replaced i
f
the warpage exceeds the limit.
Warpage
Limit : 0.15 mm (0.0059 in)
Maximum repairable limit: 0.15 mm (0.0059 in)

012RS004
Cylinder Bore
Use a cylinder gauge to measure the cylinder bore
diameter in both the axial and thrust directions. Each
measurement should be made at six points.
CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
upper surface of the cylinder block.
Cylinder Bore Inside Diameter
Limit : 93.530 mm (3.6823 in)
If the measurement exceed the specified limit, the
cylinder block must be replaced.
Diameter
Grade A : 93.400 mm
93.410 mm
(3.6772 in
3.6776 in)
Grade B : 93.411 mm
93.420 mm
(3.6776 in
3.6779 in)
Grade C : 93.421 mm
93.430 mm
(3.6780 in
3.6783 in)

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