2004 ISUZU TF SERIES torque

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.

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

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 lb ft)
2. Tighten sub gear setting bolt.
1. Use 5884024430 gear spring lever to turn
sub gear to right direction until the M5 bol
t
aligns with the hole between camshaft driven
gear and sub gear.
2. Tighten the M5 bolt to a suitable torque to
prevent the sub gear from moving.



014RW041
3. Install camshaft drive gear assembly and tighten
three bolts to the specified torque.
Torque: 10 N




m (1.0 kg




m/7 lb ft)
4. Install camshaft assembly and camshaft brackets,
tighten twenty bolts on one side bank to the
specified torque.
1. Apply engine oil to camshaft journal and
bearing surface of camshaft bracket.
2.
Align timing mark on intake camshaft (one dot
for right bank, two dots for left bank) and
exhaust camshaft (one dot for right bank, two
dots for left bank) to timing mark on camshaf
t
drive gear (one dot).







014RW020
Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discrimination Mark
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust



014RW023
Legend
(1) Right Bank Camshaft Drive Gear
(2) Left Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin

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 Retainer

3. Tighten twenty bolts in numerical order on each
bank as shown in the illustration.
Torque: 10 N




m (1.0 kg




m/7 lb ft)





014RW031
5. Tighten bolt for camshaft drive gear assembly
pulley to the specified torque.
Torque: 98 N




m (10.0 kg




m/72 lb ft)

6A-66 ENGINE MECHANICAL (6VE1 3.5L)
3. Place the camshaft on V
blocks.
Slowly rotate the camshaft and measure the
runout with a dial indicator.
Replace the camshaft if the runout exceeds the
specified limit.
Run out
Limit: 0.1 mm (0.0039 in)






014RW044
4. Measure the camshaft journal oil clearance.
1. Measure the camshaft bracket housing inside
diameter.
NOTE: Tighten camshaft bracket (2) to specified torque
before measuring the camshaft bracket inside diameter.
Torque : 10 N
 m (1.0 kg
 m/7 lb ft)






014RW031
2. Subtract the camshaft outside diameter from the
camshaft bracket housing inside diameter.
Oil Clearance
Standard : 0.027 mm




0.078 mm(0.0011 in




0.0031
in)
Limit : 0.11 mm (0.0043 in)







014RW037
5. Replace the cylinder head and/or camshaft if the
measured oil clearance exceeds the specified
limit.
1. Carefully clean the camshaft journal, the
camshaft bracket, and the cylinder head.
2. Install camshaft assembly and camshaf
t
brackets (2), tighten twenty bolts (1) on one
side bank to the specified torque.
Torque: 10 N
 m (1.0 kg
 m/7 lb ft)






014RW031

ENGINE MECHANICAL (6VE1 3.5L) 6A-67
3. Measure the camshaft thrust clearance with a dial
indicator. Replace the camshaft and/or the cylinde
r
head if the camshaft thrust clearance exceeds the
specified limit.
Camshaft thrust Clearance
Standard : 0.03 mm




0.08 mm(0.0012 in




0.0031
in)
Limit : 0.12 mm (0.0047 mm)







014RW035
Reassembly
1. Install camshaft drive gear assembly and tighten
three bolts to specified torque.
Torque: 10 N
 m (1.0 kg
 m/7 lb ft)
2. Tighten sub gear setting bolt.
1. Use 5
8840
2443
0 to turn sub gear to righ
t
direction until the M5 bolt hole aligns between
camshaft driven gear and sub gear.
2. Tighten M5 bolt suitable torque for preven
t
moving the sub gear.



014RW041
3. Install camshaft assembly and camshaft brackets,
tighten twenty bolts on one side bank to the
specified torque.
1.
Apply engine oil to camshaft journal and
bearing surface of camshaft bracket.
2.
Align timing mark on intake camshaft (one dot
for right bank, two dots for left bank) and
exhaust camshaft (one dot for right bank, two
dots for left bank) to timing mark on camshaf
t
drive gear (one dot).








014RW020
Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discerning Mark
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust

ENGINE MECHANICAL (6VE1 3.5L) 6A-69



014RW024
Legend
(1) Right Bank
(2) Left Bank
(3) Alignment Mark on Camshaft Drive Gear
(4) Alignment Mark on Camshaft
(5) Alignment Mark on Retainer

3. Tighten twenty bolts in numerical order on one
side bank as shown in the illustration.
Torque: 10 N
 m (1.0 kg
 m/7 lb ft)






014RW031
4. If the oil seal requires replacement, use the
5
8840
2445
0 to install the oil seal.






014RW034