2004 ISUZU TF SERIES torque

6F-4 ENGINE EXHAUST (6VE1 3.5L)
Three Way Catalytic Converter and Center Exhaust Pipe
Three Way Catalytic Converter and Center Exhaust Pipe and Associated Parts



RTW46FMF000201
Legend (4) Three Way Catalytic Converter LH
(1) Front Exhaust Pipe Fixing Nuts (5) Mounting Rubber
(2) O
2 Sensor (6) Exhaust Pipe Fixing Nuts
(3) Three Way Catalytic Converter RH (7) Center Exhaust Pipe


Removal
1. Disconnect battery ground cable.
2. Lift up the vehicle and support with suitable safety
stands.
3. Disconnect O
2 sensor harness connectors (2).
4. Remove the center exhaust pipe fixing nuts (6) and
the exhaust silencer fixing bolts, then remove the
center exhaust pipe and the mounting rubber.
5. Remove the front exhaust pipe fixing nuts (1) and
the mounting rubber, then remove the three way
catalytic converter (3) (4).
Installation
1. Install the three way catalytic converter (3) (4) and
the mounting rubber, and tighten the fixing nuts (1)
to the specified torque.
Torque : 67 N




m (6.8 kg




m/49 lb ft)
2. Install the center exhaust pipe and the mounting
rubbler, and tighten the fixing nuts (6) and bolts to
the specified torque.
Torque : 43 N




m (4.4 kg




m/32 lb ft)
3. Connect the O
2 sensor connectors (2).

ENGINE EXHAUST (6VE1 3.5L) 6F-5
Exhaust Silencer and Rear Exhaust Pipe
Exhaust Silencer & Tail Pipe and Associated Parts



RTW46FMF000301
Legend (4) Exhaust Silencer Mounting Rubber
(1) Center Exhaust Pipe (5) Exhaust Silencer & Tail Pipe
(2) Exhaust Pipe Fixing Bolts (6) Rear Exhaust Pipe Mounting Rubber
(3) Exhaust Pipe Fixing Nuts


Removal
1. Disconnect battery ground cable.
2. Lift up the vehicle and support with suitable safety
stands.
3. Remove the exhaust pipe fixing nuts (3) and bolts
(2).
4. Remove the silencer and rear exhaust pipe
mounting rubber (4)(6), then remove the exhaus
t
silencer (5) and rear exhaust pipe (6).

Installation
1. Install the exhaust silencer and pipe (5), then install
the exhaust silencer and rear exhaust pipe
mounting rubber (4)(6).
2. Tighten the exhaust pipe fixing nuts (3) and exhaus
t
pipe fixing bolts (2).
Torque: 43 N




m (4.4 kg




m/32 lb ft)

6F-6 ENGINE EXHAUST (6VE1 3.5L)
Main Data and Specifications
Torque Specifications
N




m (kg




m/lb ft)









RTW36FLF000301

ENGINE LUBRICATION (6VE1 3.5L) 6G-1
ENGINE
ENGINE LUBRICATION (6VE1 3.5L)
CONTENTS

Service Precaution................................................. 6G-1
General Description............................................... 6G-2
Oil Pump.................................................................. 6G-3
Oil Pump and Associated Parts........................ 6G-3
Disassembly........................................................ 6G-4
Inspection and Repair........................................ 6G-4
Reassembly......................................................... 6G-5
Oil Pan and Crankcase.......................................... 6G-7
Removal............................................................... 6G-7

Installation............................................................. 6G-7
Oil Pump.................................................................. 6G-9
Removal................................................................ 6G-9
Installation............................................................. 6G-9
Oil Pump Oil Seal.................................................... 6G-11
Removal................................................................ 6G-11
Installation............................................................. 6G-11
Main Data and Specification.................................. 6G-12


Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.


CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners o
r
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

ENGINE LUBRICATION (6VE1 3.5L) 6G-5
 Measure the side clearance with a precision straight
edge and a feeler gauge.
Clearance
Standard : 0.03 mm–0.09 mm
(0.0011 in–0.0035 in)
Limit : 0.15mm (0.0059 in)







051RS005
Oil Strainer
Check the oil strainer for cracking and scoring. If
cracking and scoring are found, the oil strainer must be
replaced.





051RS006

Reassembly
1. Install drive gear (11).
2. Install driven gear (10).
3. Install oil pump cover (9) and first, loosely tighten all
of the attaching screws. Next, tighten the attaching
screws to the specified torque.
Torque : 10 N




m (1.0 kg




m/7 lb ft)
After installation, check that the gear rotates
smoothly.
4. Install relief valve (8) and apply engine oil to the
relief valve and spring (7).
5. Install spring (7).
6. Install the plug (6).
Torque : 8 N




m (0.8 kg




m/6 lb ft)






051RS007
7. Install oil pump assembly (5).
 Carefully remove any oil from the cylinder body
and the pump. Apply sealant (TB–1207B o
r
equivalent) to the pump fitting face as shown in
illustration. Take care that sealant is not applied
to oil port surfaces. The oil pump assembly
must be installed within 5 minutes after sealan
t
application to prevent premature hardening o
f
sealant.
CAUTION: Do not apply an excessive amount o
f
sealant to the contact surface. Applying too much
sealant will overflow the contact surfaces. This
could cause serious damage to the engine.
 Attach oil pump assembly to cylinder body.
 Tighten the oil pump fixing bolts.
Torque : 25 N




m (2.6 kg




m/18 lb ft)

6G-6 ENGINE LUBRICATION (6VE1 3.5L)


051RW002





051RW001
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin


8. Install the new oil seal (12). Apply engine oil to the
oil seal lip before installation then use 5–8840–
2287–0 oil seal Installer, install oil seal.






015RS001
9. Install oil strainer (4) with O-ring (13).
Torque: 25 N




m (2.6 kg




m/18 lb ft)
10. Install oil pipe (3) with O-ring (13).
Torque: 25 N




m (2.6 kg




m/18 lb ft)
11. Install crankcase with oil pan (2).
 Remove oil on crankcase mounting surface and
dry the surface.

Apply a proper 4.5 mm (0.7 in) wide bead of
sealant (TB1207C or equivalent) to the
crankcase mounting surface. The bead must be
continuous.
 The crankcase must be installed within 5
minutes after sealant application to preven
t
premature hardening of sealant.
 Tighten fixing bolts to the specified torque.
Torque : 10 N




m (1.0 kg




m/7 lb ft)





013RW010
12. Install crankshaft timing pulley.

6G-8 ENGINE LUBRICATION (6VE1 3.5L)
3. Install crankcase, tighten crankcase fixing bolts
to the specified torque.
Torque : 10 N




m (1.0 kg




m/89 lb in)





013RW004
2. Install oil pan
1. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
2. Properly apply a 4.5 mm (0.17 in) wide bead o
f
sealant (TB-1207C or equivalent) to mounting
surface of oil pan.
Sealant beat must be continuous.
 The crankcase must be installed within 5
minutes after sealant application before the
sealant hardens.




013RW003

3. Install oil pan, tighten oil pan fixing bolts to the
specified torque.
Torque : 25 N




m (2.5 kg




m/18 lb ft)
3. Install axle housing assembly and tighten fixing
bolts to the specified torque (4WD model).
Axle case bolts
Torque : 116 N




m (11.8 kg




m/85 lb ft)
Mounting bolts
Torque : 168 N




m (17.2 kg




m/124 lb ft)




RTW34CSH000101
4. Install relay lever assembly and tighten fixing bolts.
Torque: 44 N




m (4.5 kg




m/32 lb ft)
5. Engage teeth of pitman arm and steering unit, and
tighten nut to the specified torque.
Torque : 216 N




m (22.0 kg




m/159 lb ft)
6. Install suspension cross member and tighten fixing
bolts to the specified torque.
Torque : 78 N




m (8.0 kg




m/58 lb ft)
7. Install radiator under fan shroud.
8. Install stone guard.
9. Install engine oil level dipstick.
10. Fill engine oil until full level on engine oil gauge
dipstick.

6G-10 ENGINE LUBRICATION (6VE1 3.5L)
 Tighten fixing bolts to the specified torque.
Torque : 25 N




m (2.5 kg




m/18 lb ft)



051RW001
2. Install oil pipe with O-ring, tighten fixing bolt to the
specified torque.
Torque : 10 N




m (1.0 kg




m/7 lb ft)
3. Install oil strainer with O-ring, tighten fixing bolt to
the specified torque.
Torque : 25 N




m (2.5 kg




m/18 lb ft)
4. Install oil filter assembly and tighten bolts to the
specified torque.
Torque : 25 N




m (2.5 kg




m/18 lb ft)





050RW001
Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter


5. Install timing pulley on crankshaft.
Install timing belt.
 Refer to installation procedure for Timing Belt in
this manual.
6. Install crankshaft pulley.
 Refer to install procedure for Crankshaft Pulley
in this manual.
7. Install crankcase assembly.
 Refer to installation procedure for Oil Pan and
Crankcase in this manual.
8. Refill engine oil until full level on engine oil dipstick.