2004 ISUZU TF SERIES engine remove

6G-4 ENGINE LUBRICATION (6VE1 3.5L)
Disassembly
1. Remove crankshaft timing pulley.
2. Remove crankcase with oil pan.
3. Remove oil pipe.
4. Remove oil strainer.
5. Remove oil pump assembly.
6. Remove plug.
7. Remove spring.
8. Remove relief valve.
9. Remove oil pump cover.
10. Remove driven gear.
11. Remove drive gear.
12. Remove oil seal.
13. Remove O-ring.
Inspection and Repair
CAUTION: Make necessary correction or parts
replacement if wear, damage or any other abnormal
conditions are found during inspection.
Relief Valve (8)
 Check to see that the relief valve slides freely.
 The oil pump must be replaced if the relief valve
does not slide freely.
 Replace the spring and/or the oil pump assembly
(5) if the spring is damaged or badly worn.





051RS002
Body (14) and Gears (10, 11)
The pump assembly must be replaced if one or more of
the conditions below is discovered during inspection.
 Badly worn or damaged driven gear (10).
 Badly worn drive gear (11) driving face.
 Badly scratched or scored body sliding face (14) o
r
driven gear (10).
 Badly worn or damaged gear teeth.
Measure the clearance between the body and the
driven gear with a feeler gauge.
Standard : 0.10 mm–0.18 mm
(0.0039 in.–0.0070 in)
Limit : 0.20mm (0.0079 in)





051RS004
 Measure the clearance between the drive gear and
driven gear with a feeler gauge.
Standard : 0.11 mm–0.24 mm
(0.0043 in–0.0094 in)
Limit : 0.35mm (0.0138 in)




051RS003

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.

ENGINE LUBRICATION (6VE1 3.5L) 6G-7
Oil Pan and Crankcase
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Lift vehicle by supporting the frame.
4. Remove front wheels.
5. Remove oil level dipstick from level gauge tube.
6. Remove stone guard.
7. Remove radiator under fan shroud.
NOTE: For 4WD model, remove front axle housing
assembly from chassis (steps 8 to 10).
8. Remove suspension cross member fixing bolts, 2
pcs each per side and remove suspension cross
member.
9. Remove pitman arm and relay lever assembly,
using the 5–8840–2005–0 remover, remove pitman
arm from the steering unit and remove four fixing
bolts for relay lever assembly.
10. Remove axle housing assembly four fixing bolts
from housing isolator side and mounting bolts from
wheel side. At this time support the axle with a
garage jack and remove axle housing assembly.
11. Remove oil pan fixing bolts.
12. Remove oil pan, using 5–8840–2153–0 seale
r
cutter, remove oil pan.



013RS003
13. Remove crankcase fixing bolts.
14. Remove crankcase, using 5–8840–2153–0 seale
r
cutter, remove crankcase.

NOTE: Do not deform or damage the flange of oil pan
and crankcase.
Replace the oil pan and/or crankcase if deformed o
r
damaged.



013RS003
Installation
1. Install crankcase.
1. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
2. Properly apply a 4.5 mm (0.7 in) wide bead o
f
sealant (TB-1207C or equivalent) to mounting
surface of crankcase.
Sealant beat must be continuous.
 The crankcase must be installed within 5
minutes after sealant application before the
sealant hardens.





013RW010

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.

ENGINE LUBRICATION (6VE1 3.5L) 6G-9
Oil Pump
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove crankcase assembly.
 Refer to removal procedure for Oil Pan and
Crankcase in this manual.
4. Remove crankshaft pulley.
 Refer to removal procedure for Crankshaf
t
Pulley in this manual.
5. Remove timing belt.
 Refer to removal procedure for Timing Belt in
this manual.
6. Remove timing pulley from crankshaft.
7. Remove four fixing bolts from oil filter assembly.
8. Remove oil strainer fixing bolts, remove oil straine
r
assembly with O-ring.
9. Remove three bolts from oil pipe and O-ring.
10. Remove eight oil pump fixing bolts, then oil pump
assembly.
11. Remove sealant from mounting surface of oil pump
assembly, cylinder block and take care not to
damage mounting surfaces of oil pump and cylinde
r
block.
Installation
1. Install oil pump assembly
 Apply sealant (TB-1207B or equivalent) to the oil
pump mounting surfaces as shown in the
illustration.
 The oil pump assembly must be installed within
5 minutes after sealant application before the
sealant hardens.
NOTE: Do not apply sealant to the oil ports.




051RW002
 Use 5–8840–2287–0 installer when installing
new oil seal.
 Apply engine oil to oil seal lip.
 Install oil pump assembly to the cylinder block.
NOTE: Do not damage oil seal during installation of oil
pump assembly.





015RS001

ENGINE LUBRICATION (6VE1 3.5L) 6G-11
Oil Pump Oil Seal
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove crankshaft pulley.
 Refer to removal procedure for Crankshaf
t
Pulley in this manual.
4. Remove timing belt.
 Refer to removal procedure for Timing Belt in
this manual.
5. Remove timing pulley from crankshaft.
6. Remove oil pump oil seal using a sealer puller.
NOTE: Take care not to damage sealing surfaces of oil
pump and crankshaft when removing oil seal.

Installation
1. Install oil pump oil seal, apply engine oil to oil seal
lip, then install oil seal using 5–8840–2287–0
installer.





015RS001
2. Install timing pulley to crankshaft.
3. Install timing belt.
 Refer to installation procedure for Timing Belt in
this manual.
4. Install crankshaft pulley.
 Refer to installation procedure for Crankshaf
t
Pulley in this manual.
5. Refill engine oil until full level.

6H-2 ENGINE SPEED CONTROL SYSTEM (6VE1 3.5L)
Accelerator Pedal Control Cable



RTW46HLF000101

Removal
1. Disconnect the accelerator control cable from the
accelerator pedal and dash panel.
2. Remove the cable clips.
3. Remove the accelerator control cable from
accelerator control cable bracket.
1) Slide the lock in direction A
2) Rotate the ratchet ring in indirection an arro
w
90
.