Isuzu Engine TF 6VE1 3.5L Workshop Manual

WORKSHOP MANUAL

TF SERIES

ENGINE

6VE1

SECTION 6

ENGINE

CONTENTS

ENGINE MECHANICAL (6VE1 3.5L) 6A-1

Engine Mechanical................................................. 6A

Engine Cooling........................................................ 6B

Engine Fuel ............................................................. 6C

Engine Electrical..................................................... 6D1

Ignition System ....................................................... 6D2

Starting and Changing System............................. 6D3

ENGINE MECHANICAL (6VE1 3.5L)

Service Precaution ................................................. 6A-2

General Description ............................................... 6A-3

Engine Diagnosis.................................................... 6A-4

Cylinder Head Cover LH........................................ 6A-21

Removal ............................................................... 6A-21

Installation ............................................................ 6A-21

Cylinder Head Cover RH....................................... 6A-23

Removal ............................................................... 6A-23

Installation ............................................................ 6A-23

Common Chamber................................................. 6A-24

Removal ............................................................... 6A-24

Installation ............................................................ 6A-25

Exhaust Manifold LH.............................................. 6A-26

Removal ............................................................... 6A-26

Installation ............................................................ 6A-26

Exhaust Manifold RH ............................................. 6A-27

Removal ............................................................... 6A-27

Installation ............................................................ 6A-27

Crankshaft Pulley ................................................... 6A-28

Removal ............................................................... 6A-28

Installation ............................................................ 6A-28

Timing Belt .............................................................. 6A-29

Removal ............................................................... 6A-29

Installation ............................................................ 6A-30

Camshaft ................................................................. 6A-34

Removal ............................................................... 6A-34

Installation ............................................................ 6A-34

Cylinder Head ......................................................... 6A-37

Removal ............................................................... 6A-37

Installation ............................................................ 6A-37

Valve Stem Oil Controller , Valve Spring

and Valve Guide .................................................... 6A-39

Driveability and Emissions.....................................6E

Engine Exhaust .......................................................6F

Engine Lubrication ..................................................6G

Engine Speed Control System ..............................6H

Induction...................................................................6J

CONTENTS

Removal................................................................ 6A-39

Installation............................................................. 6A-39

Piston, Piston Ring and Connecting Rod ............ 6A-40

Removal................................................................ 6A-40

Installation............................................................. 6A-41

Crankshaft and Main Bearings.............................. 6A-43

Removal................................................................ 6A-43

Installation............................................................. 6A-44

Rear Oil Seal ........................................................... 6A-48

Removal................................................................ 6A-48

Installation............................................................. 6A-48

Engine Assembly .................................................... 6A-49

Removal................................................................ 6A-49

Installation............................................................. 6A-49

Cylinder Head.......................................................... 6A-52

Cylinder Head and Associated Parts ................ 6A-52

Disassembly ......................................................... 6A-53

Clean ..................................................................... 6A-53

Inspection and Repair ......................................... 6A-53

Reassembly.......................................................... 6A-54

Valve Spring, Oil Controller, Valve, Valve

Guide ....................................................................... 6A-56

Valve Spring, Oil Controller, Valve, Valve

Guide and Associated Parts ............................. 6A-56

Disassembly ......................................................... 6A-57

Inspection and Repair ......................................... 6A-57

Reassembly.......................................................... 6A-61

Camshaft.................................................................. 6A-64

Camshaft and Associated Parts........................ 6A-64

Disassembly ......................................................... 6A-64

Inspection and Repair ......................................... 6A-65

Reassembly.......................................................... 6A-67

6A-2 ENGINE MECHANICAL (6VE1 3.5L)

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Crankshaft............................................................... 6A-71

Crankshaft and Associated Parts ..................... 6A-71

Disassembly ........................................................ 6A-71

Inspection and Repair ........................................ 6A-73

Reassembly ......................................................... 6A-75

Piston and Connecting Rod .................................. 6A-79

Piston, Connecting Rod and Associate

Parts .................................................................... 6A-79

Disassembly ........................................................ 6A-79

Inspection and Repair ........................................ 6A-80

Reassembly ......................................................... 6A-84

Cylinder Block ......................................................... 6A-87

Cylinder Block and Associated Parts ............... 6A-87

Disassembly ........................................................ 6A-88

Inspection and Repair ........................................ 6A-88

Reassembly ......................................................... 6A-89

Main Data and Specification ................................. 6A-93

Special Tool ......................................................... 6A-99

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

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
other corrosion inhibitors) on threaded fasteners o
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.

General Description

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Engine Cleanliness And Care

n automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, i
should be understood that proper cleaning and
protection of machined surfaces and friction areas is
part of the repair procedure. This is considered
standard shop practice even if not specifically stated.

·

liberal coating of engine oil should be applied to
all friction areas during assembly to protect and
lubricate the surfaces on initial operation.

· Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and
crankshaft journal bearings are removed fo
service, they should be retained in order.

·

t the time of installation, they should be installed
in the same locations and with the same mating
surfaces as when removed.

· Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.

· The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaf

pulley side to flywheel side.

ENGINE MECHANICAL (6VE1 3.5L) 6A-3

Cylinder Block

The cylinder block is made of aluminum die-cast casting
for 75°V-type six cylinders. It has a rear plate integrated
structure and employs a deep skirt. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width is differen
between No.2, No.3 and No.1, No.4; the width of No.3
bearing on the body side is different in order to suppor
the thrust bearing. The bearing cap is made of nodula
cast iron and each bearing cap uses four bolts and two
side bolts.

Cylinder Head

The cylinder head, made of aluminum alloy casting
employs a pent-roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V-type design. The ports are cross-flo
type.

Valve Train

Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing
belt. The valves are operated by the camshaft and the
valve clearance is adjusted to select suitable thickness
shim.

Intake Manifold

The intake manifold system is composed of the
aluminum cast common chamber and intake manifold
attached with six fuel injectors.

General Information on Engine Service

The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance.

· When raising or supporting the engine for any
reason, do not use a jack under the oil pan. Due to
the small clearance between the oil pan and the oil
pump strainer, jacking against the oil pan may
cause damage to the oil pick-up unit.

· The 12-volt electrical system is capable o
damaging circuits. When performing any work
where electrical terminals could possibly be
grounded, the ground cable of the battery should
be disconnected at the battery.

·

ny time the intake air duct or air cleaner is
removed, the intake opening should be covered.
This will protect against accidental entrance o
foreign material into the cylinder which could
cause extensive damage when the engine is
started.

Exhaust Manifold

The exhaust manifold is made of nodular cast iron.

Pistons and Connecting Rods

luminum pistons are used after selecting the grade
that meets the cylinder bore diameter. Each piston has
two compression rings and one oil ring. The piston pin
made of chromium steel is offset 1mm toward the thrus
side, and the thrust pressure of piston to the cylinde
wall varies gradually as the piston travels. The
connecting rods are made of forged steel. The
connecting rod bearings are graded for correct size
selection.

Crankshaft and Bearings

The crankshaft is made of Ductile cast-iron. Pins and
journals are graded for correct size selection for thei
bearing.

Engine Control Module (ECM)

The ECM location is on the common charmber.

6A-4 ENGINE MECHANICAL (6VE1 3.5L)

Engine Diagnosis

Hard Starting

1. Starting Motor Does Not Turn Over

Troubleshooting Procedure
Turn on headlights and starter switch.

Symptom Possible Cause Action

Headlights go out or dim considerably Battery run down or under charged Recharge or replace battery

Terminals poorly connected Clean battery posts and terminals

and connect properly

Starting motor coil circuit shorted Overhaul or replace

Starting motor defective Overhaul or replace

2. Ignition Trouble ---- Starting Motor Turns Over But
Engine Does Not Start Spark Test

Disconnect an ignition coil from any spark plug.
Connect the spark plug tester 5-8840-0383-0, start the
engine, and check if a spark is generated in the spark
plug tester. Before starting the engine, make sure that
the spark plug tester is properly grounded. To avoid
electrical shock, do not touch the part where insulation
of the ignition coil is broken while the engine is running.

Symptom Possible Cause Action

Spark jumps across gap Spark plug defective Clean or replace

Ignition timing incorrect Refer to Ignition System

Fuel not reaching fuel injector(s) or

engine

Valve timing incorrect Adjust

Engine lacks compression Refer to item 4 (Engine lacks

No sparking takes place Ignition coil disconnected or broken Connect properly or replace

Electronic Ignition System with

module

Poor connections in engine harness Correct

Engine Control Module cable

disconnected or defective

Refer to item 3 (Trouble in fuel
system)

compression)

Replace

Correct or replace

ENGINE MECHANICAL (6VE1 3.5L) 6A-5

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3. Trouble In Fuel System

Symptom Possible Cause Action

Starting motor turns over and spark
occurs but engine does not start.

Water in fuel system Clean

Fuel filter clogged Replace filter

Fuel pipe clogged Clean or replace

Fuel pump defective Replace

Fuel pump circuit open Correct or replace

Evaporative Emission Control System

Multiport Fuel Injection System faulty Refer to “Electronic Fuel Injection"

4. Engine Lacks Compression

Symptom Possible Cause Action

Engine lacks compression Spark plug loosely fitted Tighten to specified torque

Valve timing incorrect Adjust

Cylinder head gasket defective Replace gasket

Valve incorrectly seated Lap valve

Valve stem seized Replace valve and valve guide

Valve spring weakened or broken Replace

Cylinder or piston rings worn Overhaul engine

Piston ring seized Overhaul engine.

Engine Compression Test Procedure

1. Start and run the engine until the engine reaches
normal operating temperature.

2. Turn the engine off.

3. Remove all the spark plugs.

4. Remove ignition coil fuse (15A) and disable the
ignition system.

5. Remove the fuel pump relay from the relay and
fuse box.

6. Engage the starter and check that the cranking
speed is approximately 300 rpm.

7. Install cylinder compression gauge into spark plug
hole.

8. With the throttle valve opened fully, keep the
starter engaged until the compression gage needle
reaches the maximum level. Note the reading.

Fuel tank empty Fill

Correct or replace

circuit clogged

section

9. Repeat the test with each cylinder.
If the compression pressure obtained falls belo

the limit, engine overhaul is necessary.

Limit; 1000 kPa (145 psi)

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

Rough Engine Idling or Engine Stalling

Symptom Possible Cause Action

Trouble in fuel injection system Idle air control valve defective Replace

Throttle shutting off incomplete Replace

Throttle position sensor circuit open

or shorted

Fuel injector circuits open or shorted Correct or replace

Fuel injectors damaged Replace

Fuel pump relay defective Replace

Mass Airflow Sensor circuit open or

poor connections

Mass Airflow Sensor defective Replace

Engine Coolant Temperature Sensor

circuit open or poor connections

Engine Coolant Temperature Sensor

defective

Intake Air Temperature sensor circuit

open or poor connections

Intake Air Temperature sensor

defective

Vehicle Speed Sensor circuit open or

shorted

Vehicle Speed Sensor defective Replace

Trouble in emission control system EGR valve defective Replace

EGR valve circuit open or poor

Engine Control Module defective Replace

Canister purge valve circuit open or

Canister purge valve defective Replace

Evaporative Emission Canister Purge

Trouble in ignition system Refer to “Hard Start"

Others Engine lacks compression Refer to “Hard Start"

Valve incorrectly seated Lap valve

Air Cleaner Filter clogged Replace filter element

Valve timing incorrect Readjust

Idle air control valve broken Replace

Fast idle solenoid defective Replace

Positive Crankcase Ventilation valve

connection

poor connections

control valve defective

defective or clogged

Correct or replace

Correct or replace

Correct or replace

Replace

Correct or replace

Replace

Correct or replace

Correct or replace

Correct or replace

Replace

Replace

ENGINE MECHANICAL (6VE1 3.5L) 6A-7

Rough Engine Running

Symptom Possible Cause Action

Engine misfires periodically Ignition coil layer shorted Replace

Spark plugs fouling Clean or install hotter type plug

Spark plug(s) insulator nose leaking Replace

Fuel injector(s) defective Replace

Engine control module faulty Replace

Engine knocks periodically Spark plugs running too hot Install colder type spark plugs

Engine control module faulty Replace

Engine lacks power Spark plugs fouled Clean

Fuel injectors defective Replace

Mass Airflow Sensor or Intake Airflow

Sensor circuit defective

Engine Coolant Temperature Sensor

or Engine Coolant Temperature
Sensor circuit defective

Engine Control Module faulty Replace

Intake Air Temperature Sensor or

Intake Air Temperature Sensor circuit
defective

Throttle Position Sensor or Throttle

Position Sensor circuit defective

Correct or replace

Correct or replace

Correct or replace

Correct or replace

6A-8 ENGINE MECHANICAL (6VE1 3.5L)

Hesitation

Symptom Possible Cause Action

Hesitation on acceleration Throttle Position Sensor adjustment

incorrect

Throttle Position Sensor circuit open

or shorted

Excessive play in accelerator linkage Adjust or replace

Mass Airflow Sensor circuit open or

poor connections

Mass Airflow Sensor defective Replace

Intake Air Temperature (IAT) Sensor

circuit open or poor connections

IAT Sensor defective Replace

Hesitation at high speeds

(Fuel pressure too low)

Fuel pipe clogged Clean or replace

Fuel filter clogged Replace

Defective fuel pump system Check and replace

Fuel Pressure Control Valve leaking Replace

Hesitation at high speeds

(Fuel injector not working normally)

Fuel Injector defective Replace

Cable of Multiport Fuel Injection

Fuel tank strainer clogged Clean or replace

Power supply or ground circuit for
Multiport Fuel Injection System
shorted or open

System circuit open or poor
connections

Replace throttle valve assembly

Correct or replace

Correct or replace

Correct or replace

Check and correct or replace

Correct or replace

ENGINE MECHANICAL (6VE1 3.5L) 6A-9

Symptom Possible Cause Action

Hesitation at high speeds Engine Control Module defective Replace

Throttle Position Sensor cable broken

or poor connections

Throttle Position Sensor defective Replace

Engine Coolant Temperature Sensor

circuit open or shorted

Engine Coolant Temperature Sensor

defective

Mass Airflow Sensor circuit open or

poor connections

Mass Airflow Sensor defective Replace

IAT Sensor circuit open or poor

connections

IAT Sensor defective Replace

Throttle valve not fully opened Check and correct or replace

Air Cleaner Filter clogged Replace filter element

Power supply voltage too low Check and correct or replace

Correct or replace

Correct or replace

Replace

Correct or replace

Correct or replace

6A-10 ENGINE MECHANICAL (6VE1 3.5L)

Engine Lacks Power

Symptom Possible Cause Action

Trouble in fuel system Fuel Pressure Control Valve not

working normally

Fuel injector clogged Clean or replace

Fuel pipe clogged Clean

Fuel filter clogged or fouled Replace

Fuel pump drive circuit not working

normally

Fuel tank not sufficiently breathing

due to clogged Evaporative Emission
Control System circuit

Water in fuel system Clean

Inferior quality fuel in fuel system Use fuel of specified octane rating

Engine Control Module supplied poor

voltage

Throttle Position Sensor cable broken

or poor connections

Throttle Position Sensor defective Replace

Mass Airflow Sensor not working

normally

Manifold Absolute Pressure Sensor

not working normally

Intake Air Temperature Sensor not

working normally

Engine Coolant Temperature Sensor

circuit open or shorted

Engine Coolant Temperature Sensor

defective

Engine Control Module defective Replace

Trouble in intake or exhaust system Air Cleaner Filter clogged Replace filter element

Air duct kinked or flattened Correct or replace

Exhaust system clogged Correct or replace

Ignition failure ———— Refer to Hard Start Troubleshooting

Heat range of spark plug inadequate Install spark plugs of adequate heat

Ignition coil defective Replace

Replace

Correct or replace

Clean or replace

Correct circuit

Correct or replace

Replace

Replace

Replace

Correct or replace

Replace

Guide

range

ENGINE MECHANICAL (6VE1 3.5L) 6A-11

Symptom Possible Cause Action

Engine overheating Level of Engine Coolant too low Replenish

Fan clutch defective Replace

Thermostat defective Replace

Engine Coolant pump defective Correct or replace

Radiator clogged Clean or replace

Radiator filler cap defective Replace

Level of oil in engine crankcase too

low or wrong engine oil

Resistance in exhaust system

increased

Throttle Position Sensor adjustment

incorrect

Throttle Position Sensor circuit open

or shorted

Cylinder head gasket damaged Replace

Engine overcooling Thermostat defective Replace (Use a thermostat set to

Engine lacks compression ———— Refer to Hard Start

Others Tire inflation pressure abnormal Adjust to recommended pressures

Brake drag Adjust

Clutch slipping Adjust or replace

Level of oil in engine crankcase too

high

EGR valve defective Replace

Change or replenish

Clean exhaust system or replace
defective parts

Replace with Throttle Valve ASM

Correct or replace

open at 82C (180F))

Correct level of engine oil

6A-12 ENGINE MECHANICAL (6VE1 3.5L)

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Engine Noisy

bnormal engine noise often consists of various noises
originating in rotating parts, sliding parts and othe
moving parts of the engine. It is, therefore, advisable to
locate the source of noise systematically.

Symptom Possible Cause Action

Noise from crank journals or from
crank bearings

(Faulty crank journals and crank
bearings usually make dull noise that
becomes more evident when
accelerating)

Crankshaft out of round Replace crank bearings and

Crank bearing seized Crank bearing seized Replace crank

Troubleshooting Procedure

Short out each spark plug in sequence using insulated
spark plug wire removers. Locate cylinder with defective
bearing by listening for abnormal noise that stops when
spark plug is shorted out.

Symptom Possible Cause Action

Oil clearance increased due to worn
crank journals or crank bearings

Replace crank bearings and
crankshaft or regrind crankshaft and
install the undersize bearing

crankshaft or regrind crankshaft and
install the undersize bearing

bearings and crankshaft or regrind
crankshaft and install the undersize
bearing

Noise from connecting rods or from

connecting rod bearings

(Faulty connecting rods or connecting
rod bearings usually make an
abnormal noise slightly higher than
the crank bearing noise, which
becomes more evident when engine
is accelerated)

Crankpin out of round Replace connecting rod bearings and

Connecting rod bent Correct or replace

Connecting rod bearing seized Replace connecting rod bearings and

Bearing or crankshaft pin worn Replace connecting rod bearings and

crankshaft or regrind crankshaft pin
and install the undersize bearing

crankshaft or regrind crankshaft pin
and install the undersize bearing

crankshaft or regrind crankshaft pin
and install the undersize bearing

ENGINE MECHANICAL (6VE1 3.5L) 6A-13

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Troubleshooting Procedure

bnormal noise stops when the spark plug on the
cylinder with defective part is shorted out.

Symptom Possible Cause Action

Piston and cylinder noise

(Faulty piston or cylinder usually
makes a combined mechanical
thumping noise which increases
when engine is suddenly accelerated
but diminishes gradually as the
engine warms up)

Piston seized Replace piston and cylinder body

Piston ring broken Replace piston and cylinder body

Piston defective Replace pistons and others

Troubleshooting Procedure

Short out each spark plug and listen for change in
engine noise.

Symptom Possible Cause Action

Piston clearance increased due to
cylinder wear

Replace piston and cylinder body

Piston pin noise

(Piston makes noise each time it
goes up and down)

Piston pin or piston pin hole worn Replace piston, piston pin and

connecting rod assembly

6A-14 ENGINE MECHANICAL (6VE1 3.5L)

Troubleshooting Procedure

The slapping sound stops when spark plug on bad
cylinder is shorted out.

Symptom Possible Cause Action

Timing belt noise Timing belt tension is incorrect Replace pusher or adjust the tension

Tensioner bearing defective Replace

Timing belt defective Replace

Timing pulley defective Replace

Timing belt comes in contact with

timing cover

Valve noise Valve clearance incorrect Replace adjusting shim

Valve and valve guide seized Replace valve and valve guide

Valve spring broken or weakened Replace

Valve seat off–positioned Correct

Camshaft worn out Replace

Crankshaft noise Crankshaft end play excessive (noise

occurs when clutch is engaged)

Engine knocking Preignition due to use of spark plugs

of inadequate heat range

Carbon deposits in combustion

chambers

Fuel too low in octane rating Replace fuel

Wide Open Throttle enrichment

system failure

Selection of transmission gear

incorrect

Engine overheating Refer to “Engine Lacks Power"

Others Water pump defective Replace

Drive belt slipping Replace auto tentioner or drive belt

pulley or replace timing belt

Replace timing belt and timing cover

Replace thrust bearing

Install Spark Plugs of adequate heat
range

Clean

Refer to Section 6E

Caution operator of incorrect gear
selection

ENGINE MECHANICAL (6VE1 3.5L) 6A-15

Abnormal Combustion

Symptom Possible Cause Action

Trouble in fuel system Fuel pressure control valve defective Replace

Fuel filter clogged Replace

Fuel pump clogged Clean or replace

Fuel tank or fuel pipe clogged Clean or replace

Fuel injector clogged Clean or replace

Fuel pump relay defective Replace

Power supply cable for fuel pump

broken or poor connections

Mass Airflow (MAF) Sensor circuit

open or defective

MAF Sensor defective Replace

Engine Coolant Temperature (ECT)

Sensor circuit open or shorted

ECT Sensor defective Replace

Throttle Position Sensor adjustment

incorrect

Throttle Position Sensor defective Replace

Throttle Position Sensor connector

poor connections

Vehicle Speed Sensor cable poor

connections or defective

Vehicle Speed Sensor loosely fixed Fix tightly

Vehicle Speed Sensor in wrong

Engine Control Module cable poor

contact or defective

connections or defective

Reconnect, correct or replace

Correct or replace

Correct or replace

Readjust

Reconnect

Correct or replace

Replace

Correct or replace

6A-16 ENGINE MECHANICAL (6VE1 3.5L)

Symptom Possible Cause Action

Trouble in emission control system Heated Oxygen Sensor circuit open Correct or replace

Heated Oxygen Sensor defective Replace

Signal vacuum hose loosely fitted or

defective

EGR Valve circuit open or shorted Correct or replace

EGR Valve defective Replace

ECT Sensor circuit open or shorted Correct or replace

Canister Purge Valve circuit open or

shorted

Canister Purge Valve defective Replace

ECT Sensor defective Replace

Positive Crankcase Ventilation (PCV)

valve and hose clogged

Evaporator system Refer to Section 6E

Trouble in ignition system ———— Refer to “Engine Lacks Power"

Trouble in cylinder head parts Carbon deposits in combustion

chamber

Carbon deposit on valve, valve seat

and valve guide

Correct or replace

Correct or replace

Correct or replace

Remove carbon

Remove carbon

ENGINE MECHANICAL (6VE1 3.5L) 6A-17

Engine Oil Consumption Excessive

Symptom Possible Cause Action

Oil leaking Oil pan drain plug loose Retighten or replace gasket

Crankcase fixing bolts loosened Retighten

Oil pan setting bolts loosened Retighten

Oil pan gasket broken Replace gasket

Front cover retaining bolts loose or

gasket broken

Head cover fixing bolts loose or

gasket broken

Oil filter adapter cracked Replace

Oil filter attachings bolt loose or

rubber gasket broken

Oil cooler broken Replace

Crankshaft front or rear oil seal

defective

Oil pressure unit loose or broken Retighten or replace

Blow–by gas hose broken Replace hose

Positive Crankcase Ventilation Valve

clogged

Engine/Transmission coupling failed Replace oil seal

Oil leaking into combustion chambers
due to poor seal in valve system

Valve stem or valve guide worn Replace valve and valve guide

Oil leaking into combustion chambers

due to poor seal in cylinder parts

Piston ring gaps incorrectly

Piston rings set with wrong side up Correct

Piston ring sticking Replace cylinder body assembly and

Piston ring and ring groove worn Replace pistons and others

Return ports in oil rings clogged Clean piston and replace rings

Positive Crankcase Ventilation
System malfunctioning

Others Improper oil viscosity Use oil of recommended S.A.E.

Continuous high speed driving and/or

Valve stem oil seal defective Replace

Cylinders and pistons worn
excessively

positioned

Positive Crankcase Ventilation Valve
clogged

severe usage such as trailer towing

Retighten or replace gasket

Retighten or replace gasket

Retighten or replace oil filter

Replace oil seal

Clean

Replace cylinder body assembly and
pistons

Correct

pistons

Clean

viscosity

Continuous high speed operation
and/or severe usage will normally
cause increased oil consumption

6A-18 ENGINE MECHANICAL (6VE1 3.5L)

Fuel Consumption Excessive

Symptom Possible Cause Action

Trouble in fuel system Mixture too rich or too lean due to

trouble in fuel injection system

Fuel cut function does not work Refer to “Abnormal Combustion"

Trouble in ignition system Misfiring or abnormal combustion due

to trouble in ignition system

Others Engine idle speed too high Reset to Section 6E

Returning of accelerator control

sluggish

Fuel system leakage Correct or replace

Clutch slipping Correct

Brake drag Correct

Selection of transmission gear

incorrect

Refer to “Abnormal Combustion"

Refer to “Hard Start" or “Abnormal
Combustion"

Correct

Caution operator of incorrect gear
selection

Lubrication Problems

Symptom Possible Cause Action

Oil pressure too low Wrong oil in use Replace with correct engine oil

Relief valve sticking Replace

Oil pump not operating properly Correct or replace

Oil pump strainer clogged Clean or replace strainer

Oil pump worn Replace

Oil pressure gauge defective Correct or replace

Crankshaft bearing or connecting rod

bearing worn

Oil contamination Wrong oil in use Replace with correct engine oil

Oil filter clogged Replace oil filter

Cylinder head gasket damage Replace gasket

Burned gases leaking Replace piston and piston rings or

Oil not reaching valve system Oil passage in cylinder head or

cylinder body clogged

Replace

cylinder body assembly

Clean or correct

ENGINE MECHANICAL (6VE1 3.5L) 6A-19

Engine Oil Pressure Check

1. Check for dirt, Fuel or water in the engine oil.
a. Check the viscosity of the oil.
b. Check the viscosity of the oil.
c. Change the oil if the viscosity is outside the

specified standard.

d. Refer to the “Maintenance and Lubrication"

section of this manual.

2. Check the engine oil level.

The level should fall somewhere between the

“ADD" and the “FULL" marks on the oil level
dipstick.

If the oil level does not reach the “ADD" mark on

the oil level dipstick, engine oil must be added.

3. Remove the oil pressure unit.

4. Install an oil pressure gauge.

5. Start the engine and allow the engine to reach
normal operating temperature (About 80°C).

6. Measure the oil pressure.

Oil pressure should be:
392----550 kPa (56.9----80.4 psi) at 3000 rpm.

7. Stop the engine.

8. Remove the oil pressure gauge.

9. Install the oil pressure unit.

10. Start the engine and check for leaks.

6A-20 ENGINE MECHANICAL (6VE1 3.5L)

Malfunction Indicator Lamp

The instrument panel “CHECK ENGINE" Malfunction
Indicator Lamp (MIL) illuminates by self diagnostic
system when the system checks the starting of engine,
or senses malfunctions. ”CHECK ENGINE" MIL does
not illuminate at the starting of engine

Symptom Possible Cause Action

“CHECK ENGINE" MIL does not
illuminate at the starting of engine

MIL circuit open Correct or replace

Command signal circuit to operate

Engine Control Module (ECM) cable

ECM defective Replace

“CHECK ENGINE" MIL illuminates,
and stays on

Heated oxygen sensor connector

Heated oxygen sensor lead wire

Heated oxygen sensor circuit open Correct or replace

Deterioration of engine coolant

Engine coolant temperature sensor

Engine coolant temperature sensor

Engine coolant temperature sensor

Throttle position sensor open or

Deterioration of crankshaft position

Crankshaft position sensor circuit

Vehicle speed sensor circuit open Correct or replace

Intake air temperature sensor circuit

Fuel injector circuit open or shorted Correct or replace

ECM driver transistor defective Replace ECM

Malfunctioning of ECM RAM

Bulb defective Replace

Correct or replace

self diagnostic system shorted

Correct or replace

loosely connected, disconnected or
defective

Deterioration of heated oxygen

Replace

sensor internal element

Reconnect properly

terminal improper contact

Correct

shorted

Replace

temperature sensor internal element

Reconnect properly

connector terminal improper contact

Correct

lead wire shorted

Correct or replace

circuit open

Correct or replace

shorted circuits

Replace

sensor

Correct or replace

open or shorted

Correct or replace

open or shorted

Replace ECM

(Random Access Memory) or ROM
(Read Only Memory)

Cylinder Head Cover LH

t

Removal

1. Disconnect battery ground cable.

2. Disconnect positive crankcase ventilation hose.

3. Remove camshaft angle sensor connector.

4. Remove ground cable fixing bolt on cylinder head
cover.

5. Ignition coil connector and ignition coil.

· Disconnect the three connectors from the

ignition coils.

· Remove harness bracket bolt on cylinder head

cover.

· Remove fixing bolts on ignition coils.

ENGINE MECHANICAL (6VE1 3.5L) 6A-21

7. Remove eight fixing bolts, then the cylinder head
cover.

010RW001

Installation

Legend

(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assemblies

6. Remove fixing bolt for fuel injector harness
bracket.

060RW078

1. Install cylinder head cover.

· Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.

· Apply sealant (TB-1207B or equivalent) of bead
diameter 2-3 mm at eight place of arched area
of camshaft bracket on front and rear sides.

· The cylinder head cover must be installed with
in 5 minutes after sealant application to preven
hardening of sealant.

· Tighten bolts to the specified torque.

Torque : 9 N××××m (0.9 kg××××m/7 lb ft)

010RW006

6A-22 ENGINE MECHANICAL (6VE1 3.5L)

2. Install fuel injection harness bracket and tighten
bolt to the specified torque.

Torque : 8 N××××m (0.8 kg××××m/8 lb ft)

3. Connect ignition coil connector and ignition coil,
then tighten bolt to the specified torque.

Torque : 4 N××××m (0.4 kg××××m/3 lb ft)

060RW078

Legend

(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assembly

4. Connect ground cable and tighten bolts to the

specified torque.

Torque : 8 N××××m (0.8 kg××××m/6 lb ft)

5. Connect camshaft angle sensor connector.

6. Install positive crankcase ventilation hose.

Cylinder Head Cover RH

r

r

Removal

1. Disconnect battery ground cable.

2. Remove air cleaner duct assembly.

3. Disconnect ventilation hose from cylinder head
cover.

4. Disconnect three ignition coil connectors from
ignition coils and remove harness bracket bolts on
cylinder head cover then remove ignition coil fixing
bolts on ignition coils and remove ignition coils.

5. Remove heater pipe fixing bolts from the bracket.

6. Disconnect fuel injector harness connector then
remove fuel injector harness bracket bolt.

7. Remove eight fixing bolts then the cylinder head
cover.

Installation

1. Install cylinder head cover.

· Clean the sealing surface of cylinder head and

cylinder head cover to remove oil and sealing
materials completely.

· Apply sealant (TB-1207B or equivalent) of bead

diameter 2‐3 mm at eight place of arched
area of camshaft bracket on front and rea
sides.

· The cylinder head cover must be installed

within 5 minutes after sealant application to
prevent premature hardening of sealant.

· Tighten bolts to the specified torque.

Torque : 9 N××××m (0.9 kg××××m/7 lb ft)

010RW002

ENGINE MECHANICAL (6VE1 3.5L) 6A-23

2. Install exhaust gas recirculation pipe and tighten to
specified torque.

Torque :
Exhaust manifold side: 29 N××××m (3.0 kg××××m/21 lb ft)
Flare nut: 44 N××××m (4.5 kg××××m/33 lb ft)
Cylinder head side: 20 N××××m (2.0 kg××××m/14 lb ft)

3. Tighten fuel injector harness bracket bolts to
specified torque then reconnect fuel injecto
harness connector.

Torque : 8 N××××m (0.8 kg××××m/5.7 lb ft)

4. Install heater pipe bolt to the specified torque.

Torque : 20 N××××m (2.0 kg××××m/14 lb ft)

5. Connect ignition coil connector and tighten ignition
coil fixing bolts to specified torque.

Torque : 4 N××××m (0.4 kg××××m/3 lb ft)

6. Connect ventilation hose to cylinder head.

7. Install air cleaner duct assembly.

014RW019

6A-24 ENGINE MECHANICAL (6VE1 3.5L)

w

r

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Removal

1. Disconnect battery ground cable.

2. Remove air cleaner duct assembly.

3. Remove the ECM.

· Disconnect the two connectors from the ECM.

· Remove fixing bolts on the common chamber.

· Remove fixing bolts for ground cable.

4. Remove the accelerator control cable from

accelerator control cable bracket.

· Slide the lock in direction A

· Rotate the ratchet ring in indirection an arro
90°

Common Chamber

Legend

(1) Cable Bracket
(2) Ratchet ring
(3) Outer Cap
(4) Lock
(5) Paint Mark
(6) Arrow Mark

5. Remove the accelerator control cable from the
throttle.

6. Disconnect vacuum booster hose from common
chamber.

7. Disconnect connector from manifold absolute
pressure sensor, idle air control valve, throttle
position sensor, solenoid valve, electric vacuum
sensing valve.

8. Disconnect vacuum hose on canister VSV and
positive crankcase ventilation hose, fuel rail
assembly with pressure control valve bracket.

9. Remove ventilation hose from throttle valve and
intake duct and remove water hose.

10. Remove exhaust gas recirculation valve assembly
fixing bolt and nut on common chamber.

11. Remove two bolts from common chamber rea
side for remove fuel hose bracket.

060RW025

12. Remove common chamber four bolts and fou
nuts then remove the common chamber.

025RW001

RTW46ASH000201

Legend

(1) Common Chamber
(2) Throttle Valve Assembly
(3) Bolt

13. Remove the four throttle body fixing bolts.

Installation

r

r

1. Install throttle body and tighten bolts to the
specified torque.

Torque : 25 N××××m (2.5 kg××××m/18 lb ft)

2. Install common chamber and tighten bolts and
nuts to the specified torque.

Torque :
Bolt : 18 N××××m (1.8 kg××××m/13 lb ft)
Nut : 18 N××××m (1.8 kg××××m/13 lb ft)

3. Install fuel hose bracket and tighten bolts to
specified torque.

Torque : 10 N××××m (1.0 kg××××m/89 lb in)

4. Install ventilating hose to throttle valve and intake
duct.

5. Connect vacuum hoses on canister VSV and
positive crankcase ventilation hose. Tighten bolts
for fuel rail assembly with pressure control valve
bracket.

Torque : 25 N××××m (2.5 kg××××m/18 lb ft)

6. Connect each connector without fail.

7. Connect vacuum booster hose.

8. 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.

9. Install accelerator control cable to accelerato
cable bracket.

· Rotate the ratchet ring in direction an arrow 90°

· Confirm marking of outer cap must be uppe

side.

· Slider the lock of outer cap must be upper side.

· Confirm ratchet ring is locked.

ENGINE MECHANICAL (6VE1 3.5L) 6A-25

Legend

(1) Cable Bracket
(2) Ratchet ring
(3) Outer Cap
(4) Lock
(5) Paint Mark
(6) Arrow Mark

10. Install the cable clips to accelerator control cable.

11. Install air cleaner duct assembly.

060RW093

6A-26 ENGINE MECHANICAL (6VE1 3.5L)

f

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Exhaust Manifold LH

Removal

Installation

1. Disconnect battery ground cable.

2. Disconnect O

3. Remove torsion bar. Refer to removal procedure in
Front Suspension section.

4. Remove exhaust front pipe three stud nuts from
exhaust side and two nuts from rear end o
exhaust front pipe.

sensor connector.

2

1. Install exhaust manifold and tighten exhaust
manifold fixing nuts to the specified torque with
new nuts.

Torque: 52 N××××m (5.3 kg××××m/38 lb ft)

2. Install heat protector.

3. Install exhaust front pipe and tighten three stud
nuts and two nuts to the specified torque.

Torque:
Stud nuts: 67 N××××m (6.8 kg××××m/49 lb ft)
Nuts: 43 N××××m (4.4 kg××××m/32 lb ft)

5. Remove heat protector two fixing bolts then the

heat protector.

6. Remove a bolt on engine LH side for ai
conditioner (A/C) compressor bracket and loosen
two bolts for A/C compressor then move A/C
compressor to front side.

7. Remove exhaust manifold eight fixing nuts and
remove exhaust manifold from the engine.

RTW36FSH000201

RTW36FSH000201

4. Install the torsion bar and readjust the vehicle
height. Refer to installation and vehicle heigh
adjustment procedure for front suspension.

5. Set A/C compressor to normal position and tighten
two bolts and a bolt to the specified torque.

Torque : 40 N××××m (4.1 kg××××m/30 lb ft)

6. Reconnect O

7. Install air cleaner duct assembly.

sensor connector.

2

Removal

ENGINE MECHANICAL (6VE1 3.5L) 6A-27

Exhaust Manifold RH

Installation

1. Disconnect battery ground cable.

2. Remove exhaust front pipe three stud nuts and
two nuts then disconnect exhaust front pipe.

3. Remove steering shaft. Refer to removal
procedure in Steering section.

4. Remove heat protector two fixing bolts then the
heat protector.

5. Remove EGR pipe.

6. Remove exhaust manifold eight fixing nuts then
the exhaust manifold.

1. Install exhaust manifold and tighten bolts to the
specified torque.

Torque: 52 N××××m (5.3 kg××××m/38 lb ft)

2. Install EGR pipe.

Torque: 29 N××××m (3.0 kg××××m/22 lb ft)

3. Install heat protector

4. Install exhaust front pipe and tighten three stud
nuts and two nuts to the specified torque.

Torque:
Stud nuts: 67 N××××m (6.8 kg××××m/49 lb ft)
Nuts: 43 N××××m (4.4 kg××××m/32 lb ft)

5. Install steering shaft. Refer to installation
procedure in Steering section.

RTW36FSH000101

6A-28 ENGINE MECHANICAL (6VE1 3.5L)

t

Removal

Crankshaft Pulley

Installation

1. Disconnect battery ground cable.

2. Remove air cleaner assembly.

3. Remove radiator upper fan shroud from radiator.

4. Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.

Legend

(1) Crankshaft Pulley
(2) Cooling Fan Pulley

(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Serpentine Belt

1. Install crankshaft pulley using 5-8840-0133-0
crankshaft holder, hold the crankshaft pulley and
tighten center bolt to the specified torque.

Torque: 167 N××××m (17.0 kg××××m/123 lb ft)

2. 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/88.5 lb in) for fan and
clutch assembly.

3. Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.

4. Install radiator upper fan shroud.

5. Install air cleaner assembly.

850RW001

5. Remove cooling fan assembly four fixing nuts,
then the cooling fan assembly.

6. Remove crankshaft pulley assembly using
5-8840-0133-0 crankshaft holder, hold crankshaf
pulley then remove center bolt and pulley.

Timing Belt

t

Removal

1. Disconnect battery ground cable.

2. Remove air cleaner assembly.

3. Remove radiator upper fan shroud from radiator.

4. Move drive belt tensioner to loose side using
wrench then remove drive belt.

ENGINE MECHANICAL (6VE1 3.5L) 6A-29

13. Remove pusher.

CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.

Legend

(1) Crankshaft Pulley
(2) Cooling Fan Pulley

(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt

5. Remove cooling fan assembly four nuts, then the
cooling fan assembly.

6. Remove cooling fan drive pulley assembly.

7. Remove idle pulley assembly.

8. Remove serpentine belt tensioner assembly.

9. Remove power steering pump assembly.

10. Remove crankshaft pulley assembly using
5-8840-0133-0 crankshaft holder, hold crankshaf
pulley remove center bolt, then the pulley.

11. Remove right side timing belt cover then left side
timing belt cover.

12. Remove lower timing belt cover

850RW001

014RW011

Legend

(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin

14. Remove timing belt.

CAUTION:

1. Do not bend or twist the belt, otherwise its
core could be damaged. The belt should not be
bent at a radius less than 30 mm.

2. Do not allow oil or other chemical substances
to come in contact with the belt. They will
shorten the life.

3. Do not attempt to pry or stretch the belt with a
screw driver or any other tool during
installation.

4. Store timing belt in a cool and dark place.
Never expose the belt direct sunlight or heat.

6A-30 ENGINE MECHANICAL (6VE1 3.5L)

t

A

A

A

A

Installation

For correct belt installation, the letter on the belt mus
be able to be read as viewed from the front of the
vehicle.

Legend

(7) Alignment Mark on Oil Pump.
(8) Alignment Mark on Timing Belt
(9)

lignment Mark (notch) on Crankshaft Timing

Pulley

(10)

lignment Mark (groove) on Crankshaft Timing

Pulley.

Legend

(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley
(4) Idle Pulley
(5) LH Bank Camshaft Drive Gear Pulley
(6) Tension Pulley

014RY00042

Legend

(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side

1. Install timing belt.

1.

lign the mark (notch) of crankshaft timing

pulley (2) with mark on oil pump (1).

lign the mark (groove) on the crankshaft
timing pulley (3) with alignment mark (white
dots line) on the timing belt (4).

014RW006

014RY00043

ENGINE MECHANICAL (6VE1 3.5L) 6A-31

t

A

t

t

A

t

t

r

r

NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.

014RW003

Legend

(1) Alignment Mark on Oil Pump
(2) Groove on Crankshaft Timing Pulley
(3) Alignment Mark on Crankshaft Timing Pulley
(4) Alignment Mark on Timing Belt

Legend

(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear Pulley.
(3) Alignemnt Mark on Cylinder Head Cover RH.

4. Align the alignment mark on the LH bank
camshaft drive gear pulley (2) to the alignmen
mark of the cylinder head cover LH (3).

5.

lign the alignment mark (white line) on the
timing belt (1) with the alignment mark on the
LH bank camshaft drive gear pulley (2).

When aligning the timing marks, use a wrench

to turn the camshaft drive gear pulley, then se
the timing mark between timing belt and
camshaft drive gear pulley and put the timing
belt on the camshaft drive gear pulley.

Secure the belt with a double clip or equivalen

clip.

NOTE: It is recommended for easy installation that the
belt be secured with a double clip or equivalent clip afte
it is installed the timing belt to each pulley.

2. Align the alignment mark on the RH bank
camshaft drive gear pulley (2) to the alignmen
mark of the cylinder head cover RH (3).

3.

lign the alignment mark (white line) on the

timing belt (1) with alignment mark on the RH
bank camshaft drive gear pulley (2) (on the left
side as viewed from the front of the vehicle)
and put the timing belt on the camshaft drive
gear pulley.

Secure the belt with a double clip or equivalen

clip.

014RW00005

Legend

(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear Pulley.
(3) Alignemnt Mark on Cylinder Head Cover LH.

6. Install crankshaft pulley temporarily and tighten
center bolt by hand (do not use a wrench).

Turn the crankshaft pulley clockwise to give

some belt slack between the crankshaft timing
pulley and the RH bank camshaft drive gea
pulley.

014RW00004

6A-32 ENGINE MECHANICAL (6VE1 3.5L)

2. Install pusher and tighten bolt to the specified
torque.

Torque: 25 N××××m (2.5 Kg××××m/18 lb ft)

1. Install the pusher while pushing the tension

pulley to the belt.

2. Pull out pin from the pusher.

NOTE: When reusing the pusher, press the pusher with
approximately 100Kg to retract the rod, and insert a pin
(1.4 mm piano wire).

Legend

(1) Up Side
(2) Down Side

(3) Direction for Installation
(4) Locking Pin

014RW011

3. Install timing belt cover.
Remove crankshaft pulley that was installed in

step 1 item 5.

Tighten bolts to the specified torque.

Torque: 18 N××××m (1.8 kg××××m/13 lb ft)

020RW004

Legend

(1) Timing Belt Cover RH
(2) Timing Belt Cover LH
(3) Timing Belt Cover Lower

3. Remove double clips or equivalent clips, from

timing belt pulleys.

Turn the crankshaft pulley clockwise by two

turns.

Legend

(1) Timing Belt Cover
(2) Rubber Bushing
(3) Sealing Rubber
(4) Cylinder Body

020RW003

ENGINE MECHANICAL (6VE1 3.5L) 6A-33

4. Install crankshaft pulley using 5-8840-0133-0, hold
the crankshaft pulley and tighten center bolt to the
specified torque.

Torque: 167 N××××m (17.0 kg××××m/123 lb ft)

5. Install fan pulley bracket and tighten fixing bolts to
the specified torque.

Torque: 25 N××××m (2.5 kg××××m/18 lb ft)

6. Install power steering pump assembly and tighten
to the specified torque.

Torque:
M8 bolt: 25 N××××m (2.5 kg××××m/18 lb ft)
M10 bolt: 43 N××××m (4.4 kg××××m/32 lb ft)

7. 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.

8. Move drive belt tensioner to loose side using
wrench, then install drive belt to normal position.

9. Install radiator upper fan shroud.

10. Install air cleaner assembly.

Legend

(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt

850RW001

6A-34 ENGINE MECHANICAL (6VE1 3.5L)

t

t

t

t

Removal

1. Disconnect battery ground cable.

2. Remove crankshaft pulley.

· Refer to removal procedure for Crankshaf

Pulley in this manual.

3. Remove timing belt.

· Refer to removal procedure for Timing Belt in

this manual.

4. Remove cylinder head cover LH.

· Refer to removal procedure for Cylinder Head

Cover LH in this manual.

5. Remove cylinder head cover RH.

· Refer to removal procedure for Cylinder Head

Cover RH in this manual.

6. Remove twenty fixing bolts from inlet and exhaus
camshaft bracket on one side bank, then camshaf
brackets.

Camshaft

Legend

(1) Right Bank
(2) Left Bank
(3) Timing Mark on Retainer

014RW026

7. Remove camshaft assembly.

8. Remove fixing bolt for camshaft drive gear pulley.

9. Remove three fixing bolts from camshaft drive
gear retainer, then camshaft drive gear assembly.

014RW027

Installation

1. Install camshaft drive gear assembly and tighten
three bolts to the specified torque.

Torque: 10 N××××m (1.0 kg××××m/7 lb ft)

2. Tighten bolt for camshaft drive gear assembly
pulley to the specified torque.

Torque: 98 N××××m (10.0 kg××××m/72 lb ft)

3. Tighten sub gear setting bolt.

1. Use 5-8840-2443-0 to turn sub gear to righ

direction until it aligns with the M5 bolt hole
between camshaft driven gear and sub gear.

2. Tighten the M5 bolt to a suitable torque to

prevent the sub gear from moving.

ENGINE MECHANICAL (6VE1 3.5L) 6A-35

A

A

t

t

4. Install camshaft assembly and camshaft brackets,
tighten twenty bolts on one side bank to the
specified torque.

1.

pply engine oil to camshaft journal and

bearing surface of camshaft bracket.

2.

lign timing mark on intake camshaft (one do
for right bank, two dot for left bank) and
exhaust camshaft (one dot for right bank, two
dots for left bank) to timing mark on camshaf
drive gear (one dot).

014RW041

Legend

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

014RW023

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)

6A-36 ENGINE MECHANICAL (6VE1 3.5L)

r

Legend

(1) Right Bank
(2) Left Bank

3. Tighten twenty bolts on numerical order an one
side bank as shown in the illustration.

Torque : 10 N××××m (1.0 kg××××m/7 lb ft)

(3) Alignment Mark on Camshaft Drive Gear

014RW024

(4) Alignment Mark on Camshaft
(5) Alignment Mark on Retainer

8. Install crankshaft pulley.

· Refer to installation procedure fo
CRANKSHAFT PULLEY in this manual.

5. Install cylinder head cover RH.

· Refer to installation procedure for CYLINDER
HEAD COVER RH in this manual.

6. Install cylinder head cover LH.

· Refer to installation procedure for CYLINDER
HEAD COVER LH in this manual.

7. Install timing belt.

· Refer to installation procedure for TIMING
BELT in this manual.

014RW031

Removal

t

t

t

ENGINE MECHANICAL (6VE1 3.5L) 6A-37

Cylinder Head

Installation

1. Remove engine hood.

2. Disconnect battery ground cable.

3. Drain radiator coolant.

4. Drain engine oil.

5. Remove crankshaft pulley.

· Refer to removal procedure for Crankshaf
Pulley in this manual.

6. Remove timing belt.

· Refer to removal procedure for Timing Belt in
this manual.

7. Remove cylinder head cover LH.

· Refer to removal procedure for Cylinder Head
Cover LH in this manual.

8. Remove cylinder head cover RH.

· Refer to removal procedure for Cylinder Head
Cover RH in this manual.

9. Remove common chamber.

· Refer to removal procedure for Common
Chamber in this manual.

10. Remove cylinder head assembly.

1. Loosen eights bolts for tight cylinder head.

2. Remove cylinder head assembly.

1. Install cylinder head assembly to cylinder block.

1. Put cylinder head gasket on the cylinder block.

NOTE: There is discrimination mark “R" for righ
bank and “L" for left bank on the cylinder head
gasket as shown in the illustration.

Do not reuse cylinder head gasket.

2. Align dowel pin hole to dowel pin on the
cylinder block.

3. Tighten two bolts temporarily by hand to
prevent the cylinder head assembly from
moving.

4. Using 9-8511-4209-0 cylinder head bol
wrench, tighten bolts in numerical order as
shown in the illustration to the specified torque.

011RW005

Legend

(1) Cylinder Head
(2) Cylinder Head Bolt
(3) Camshaft

014RW028

6A-38 ENGINE MECHANICAL (6VE1 3.5L)

r

r

t

NOTE: Do not reuse cylinder head bolts.
Do not apply any lubricant to the cylinder head bolts.

Torque:
Temporary: 29 N××××m (3.0 kg××××m/21 lb ft)
Final: 64 N××××m (6.5 kg××××m/47 lb ft)

2. Install common chamber.

· Refer to installation procedure for Common
Chamber in this manual.

3. Install cylinder head cover RH.

· Refer to installation procedure for Cylinde
Head Cover RH in this manual.

4. Install cylinder head cover LH.

· Refer to installation procedure for Cylinde
Head Cover LH in this manual.

5. Install timing belt.

· Refer to installation procedure for Timing Belt in
this manual.

6. Install crankshaft pulley.

· Refer to installation procedure for Crankshaf
Pulley in this manual.

014RW029

Valve Stem Oil Controller, Valve Spring and Valve Guide

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Removal

ENGINE MECHANICAL (6VE1 3.5L) 6A-39

Installation

1. Disconnect battery ground cable.

· Drain engine oil.

2. Drain engine coolant.

3. Remove cylinder head assembly.

· Refer to removal procedure for Cylinder Head
in this manual.

4. Remove camshaft.

· Refer to removal procedure for Camshaft in this
manual.

5. Remove tappets with shim.

NOTE: Do not damage shim surface.

6. Remove valve springs using 5-8840-2446-0
valve spring compressor and 5-8840-2547-0
valve spring compressor adapter then remove
upper valve spring seat and lower seat.

1. Install valve guide using 5-8840-2442-0 valve
guide installer.

2. Install oil controller using 5-8840-0624-0 oil
controller installer.

3. Install lower valve spring seat, valve spring and
upper valve spring seat then put split collars on the
upper spring seat, using 5-8840-2442-0 valve
spring compressor and 5-8840-0624-0 valve
spring compressor adapter to install the spli
collars.

7. Remove oil controller using 5-8840-0623-0 oil
controller remover, remove each valve stem oil
controller.

8. Remove valve guide using 5-8840-2549-0 valve
guide replacer.

014RW042

4. Install tappet with shim.

5. Install camshaft assembly.

· Refer to installation procedure for Camshaft in
this manual.

6. Install cylinder head assembly.

· Refer to installation procedure for Cylinde
Head in this manual.

7. Fill engine oil until full level.

8. Fill engine coolant.

014RW042

6A-40 ENGINE MECHANICAL (6VE1 3.5L)

Piston, Piston Ring and Connecting Rod

Removal

Legend

(1) Cylinder Head
(2) Crankcase with Oil Pan
(3) Oil Pipe

1. Remove cylinder head assembly.

· Refer to removal procedure for Cylinder Head
in this manual.

2. Remove crankcase with oil pan.

· Refer to removal procedure for Oil Pan and
Crankcase in this manual.

(4) Oil Strainer
(5) Oil Gallery
(6) Piston with Connecting Rod Assembly

F06RW011

ENGINE MECHANICAL (6VE1 3.5L) 6A-41

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3. Remove oil strainer fixing bolts, remove oil straine
assembly with O-ring.

Legend

(1) Oil Pump
(2) Oil Strainer
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter

4. Remove three fixing bolts, oil pipe with O-ring.

5. Remove eight fixing bolts, oil gallery.

6. Remove piston with connecting rod assembly,

before removing the bearing cap, remove carbon
on the top of cylinder bore and push piston with
connecting rod out from the top of cylinder bore.

050RW002

Legend

(1) Piston Front Mark
(2) Piston Grade
(3) Connecting Rod Front Mark

2. Install oil gallery and tighten the bolts in two steps,
in the order shown in illustration.

Torque:
1st step: 29 N××××m (3.0 kg××××m/21 lb ft)
2nd step: 55°°°°----65°°°°

015RW003

Installation

1. Install piston with connecting rod assembly.

·

pply engine oil to cylinder bore, connecting

rod bearing and crank pin.

· When installing the piston, its front mark mus
face the engine front side.

· The bearing cap number must be the same as
connecting rod number.

·

pply engine oil to the thread and seating

surface of each nut.

· Tighten nuts to the specified torque.

Torque: 54 N××××m (5.5 kg××××m/40 lb ft)

·

fter tightening the nuts, make sure that the

crankshaft rotates smoothly.

NOTE: Do not apply engine oil to the bearing back
faces and connecting rod bearing fitting surfaces.

3. Install oil pipe with O-ring.

Torque: 10 N××××m (1.0 kg××××m/7 lb ft)

4. Install oil strainer assembly with O-ring.

Torque: 25 N××××m (2.5 kg××××m/18 lb ft)

5. Install crankcase with oil pan.

· Refer to installation procedure for Oil Pan and
Crankcase in this manual.

051RS009

6A-42 ENGINE MECHANICAL (6VE1 3.5L)

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6. Install cylinder head assembly.

· Refer to installation procedure for Cylinde
Head in this manual.

Removal

ENGINE MECHANICAL (6VE1 3.5L) 6A-43

Crankshaft and Main Bearings

Legend

(1) Engine Assembly
(2) Crankshaft Pulley
(3) Timing Belt Cover
(4) Timing Belt
(5) Crankcase with Oil Pan
(6) Oil Pipe
(7) Oil Strainer

(8) Oil Pump Assembly
(9) Cylinder Body Side Bolt

(10) Oil Gallery
(11) Flywheel
(12) Rear Oil Seal Retainer
(13) Connecting Rod Cap
(14) Crankshaft Main Bearing Cap
(15) Crankshaft and Main Bearing

F06RW010

6A-44 ENGINE MECHANICAL (6VE1 3.5L)

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1. Remove engine assembly.

· Refer to removal procedure for Engine
Assembly in this manual.

2. Remove timing belt.

· Refer to removal procedure for Timing Belt in
this manual.

3. Remove oil pan and crankcase.

· Refer to removal procedure for Oil Pan and
Crankcase in this manual.

4. Remove oil pipe with O-ring.

5. Remove oil strainer assembly with O-ring.

6. Remove oil pump assembly.

· Refer to removal procedure for Oil Pump in this
manual.

7. Remove cylinder body side bolts.

8. Remove oil gallery.

9. Remove flywheel.

10. Remove rear oil seal retainer.

· Refer to removal procedure for Rear Oil Seal in
this manual.

11. Remove connecting rod caps.

12. Remove crankshaft main bearing caps.

13. Remove crankshaft and main bearings.

015RS012

Installation

1. Install crankshaft and main bearings.

· Install main bearing in the cylinder block and
main bearing cap respectively.

pply new engine oil to upper and lower main

NOTE:

bearings.

· Do not apply engine oil to the bearing back faces.

· Make sure that main bearings are in correc

position.

· Install crankshaft with care.

· Apply engine oil to the thrust washer.

· Install thrust washer on No.3 journal.

· Oil grooves in thrust washer must face the

crankshaft.

015RS013

2. Install crankshaft main bearing caps.

·

pply engine oil to the thread and seating

surface of each bearing cap fixing bolt.

NOTE:

· Do not apply engine oil to the bearing back faces.

· Install bearing caps in the order of numbers,

starting with cylinder block front side.

· Tighten main bearing fixing bolts to the specified
torque.

Torque: 39 N××××m (4.0 kg××××m/29 lb ft)

·

fter tightening the bolts, make sure that the

crankshaft rotates smoothly.

3. Install connecting rod caps.

· The cap number must be same as connecting

rod number.

·

pply engine oil to the thread and seating

surface of each nut.

ENGINE MECHANICAL (6VE1 3.5L) 6A-45

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· Tighten nuts to the specified torque.

Torque: 54 N××××m (5.5 kg××××m/40 lb ft)

·

fter tightening the nuts, make sure that the

crankshaft rotates smoothly.

4. Install rear oil seal retainer.

· Remove oil on cylinder block and retainer fitting
surface.

·

pply sealant (TB1207B or equivalent) to

retainer fitting surface as shown in illustration.

· The oil seal retainer must be installed within 5
minutes after sealant application to preven
premature hardening of sealant.

Legend

(1) Around Bolt Holes
(2) Around Dowel Pin

· Tighten retainer fixing bolts to the specified

torque.

Torque: 18 N××××m (1.8 kg××××m/13 lb ft)

015RW001

5. Install flywheel.

· Clean tapped holes in the crankshaft.

· Remove oil on crankshaft and flywheel fitting

surface.

NOTE:

· Do not reuse the bolts.

· Do not apply oil or thread lock to the bolts.

· Tighten fixing bolts to the specified torque.

015RW002

Torque: 54 N××××m (5.5 kg××××m/40 lb ft)

· Apply engine oil to oil seal lip and align a dowel

pin hole in the cylinder block with that in the
retainer.

015RS018

6A-46 ENGINE MECHANICAL (6VE1 3.5L)

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6. Install oil gallery.

· Clean contact surface of oil gallery and main
bearing cap.

pply engine oil to oil gallery fixing bolts and
tighten the bolts in two steps, in the orde
shown.

Torque:
1st step: 29 N××××m (3.0 kg××××m/21 lb ft)
2nd step: 55°°°°----65°°°°

7. Install cylinder body side bolts and tighten bolts in
order to the specified torque.

Torque: 39 N××××m (4.0 kg××××m/29 lb ft)

NOTE: Do not apply the oil to the bolts.

· Install oil pump in the cylinder block and tighten
fixing bolts to the specified torque.

Torque: 25 N××××m (2.5 kg××××m/18 lb ft)

051RW002

Legend

(1) Around Bolt Holes
(2) Around Dowel Pin

8. Install oil pump assembly.

· Remove oil on cylinder block and oil pump
mounting surface.

· Apply sealant (TB1207B or equivalent) to the oil
pump mounting surface.

· The oil pump assembly must be installed within
5 minutes after sealant application to preven
premature hardening of sealant.

· Apply engine oil to oil seal lip.

012RS007

051RW001

9. Install oil strainer with O-ring, tighten to the
specified torque.

Torque: 25 N××××m (2.5 kg××××m/18 lb ft)

10. Install oil pipe with O-ring, tighten fixing bolts to the
specified torque.

Torque: 25 N××××m (2.5 kg××××m/18 lb ft)

ENGINE MECHANICAL (6VE1 3.5L) 6A-47

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11. Install crankcase.

· Remove oil on crankcase mounting surface
and dry the surface.

· Properly apply a 4.5 mm (0.7 in) wide bead o
sealant (TB1207C or equivalent) to the
crankcase mounting surface. The bead mus
be continuous.

· The crankcase must be installed within 5
minutes after sealant application to preven
premature hardening of sealant.

· Tighten fixing bolts to the specified torque.

Torque: 10 N××××m (1.0 kg××××m/1 lb ft)

· Properly apply a 4.5 mm (0.7 in) wide bead o
sealant (TB1207C or equivalent) to the oil pan
mounting surface. The bead must be
continuous.

· The oil pan must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.

· Tighten fixing bolts to the specified torque.

Torque: 25 N××××m (2.5 kg××××m/18 lb ft)

12. Install oil pan

· Remove oil on oil pan mounting surface and
dry the surface.

013RW003

013RW010

013RW002

13. Install timing belt.

· Refer to installation procedure for Timing Belt in

013RW004

this manual.

14. Install engine assembly.

· Refer to installation procedure for Engine
Assembly in this manual.

6A-48 ENGINE MECHANICAL (6VE1 3.5L)

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Rear Oil Seal

Removal

1. Remove transmission assembly.

· See Transmission section in this manual.

2. Remove flywheel.

3. Remove rear oil seal using a seal remover.

NOTE: Take care not to damage the crankshaft or oil
seal retainer when removing oil seal.

Installation

1. Apply engine oil to oil seal lip and install oil seal
using 5-8840-2286-0.

015RS018

3. Install transmission.

· See Transmission section in this manual.

2. Install flywheel.

· Clean tapped holes in the crankshaft.

· Remove oil on the crankshaft and flywheel

mounting surface.

· Tighten fixing bolts to the specified torque.

NOTE: Do not reuse the bolts and do not apply oil o
thread lock to the bolts.

Torque: 54 N××××m (5.5 kg××××m/40 lb ft)

015RS017

CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Take care that dowel positions are different
between the manual transmission and the
automatic transmission. Otherwise, the
transmission may be damaged.

012RS009

Engine Assembly

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Removal

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
front side of engine compartment), disconnect shift
on the fly harness connector from front side o
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
bank.

ENGINE MECHANICAL (6VE1 3.5L) 6A-49

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.

P1010068

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
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.

6A-50 ENGINE MECHANICAL (6VE1 3.5L)

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1. Install engine assembly. Tighten engine moun
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
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)

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.

012RS009

Legend

(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt

850RW001

7. Reconnect O2 sensor connector.

LTW36FSH000101

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
right dash panel.

ENGINE MECHANICAL (6VE1 3.5L) 6A-51

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19. Reconnect ground cable between engine and
chassis.

20. Reconnect harness connector to transmission and
install transmission harness bracket on engine lef
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

cable bracket.

· Rotate the ratchet ring in direction an arrow 90°

· Confirm marking of outer cap must be uppe

side.

· Slider the lock in direction B.

· Confirm ratchet ring is locked.

29. Install the cable clips to accelerator control cable.

Legend

(1) Cable Bracket
(2) Ratchet ring
(3) Outer Cap
(4) Lock
(5) Paint Mark
(6) Arrow Mark

RTW46ASH000201

6A-52 ENGINE MECHANICAL (6VE1 3.5L)

Cylinder Head

Cylinder Head and Associated Parts

Legend

(1) Spark Plug
(2) Cylinder Head Bolt
(3) Camshaft Drive Gear Pulley Fixing Bolt
(4) Camshaft Drive Gear Pulley
(5) Camshaft Drive Gear Pulley
(6) Camshaft Bracket
(7) Camshaft Exhaust

(8) Camshaft Intake
(9) Retainer Fixing Bolt

(10) Retainer Assembly
(11) Tappet with Shim
(12) Split Collar
(13) Valve Spring and Spring Upper Seat
(14) Valve

011RW008

Disassembly

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ENGINE MECHANICAL (6VE1 3.5L) 6A-53

Inspection and Repair

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
bracket (6), then camshaft exhaust (7), and intake
side (8).

3. Remove tappet with shim (11).

4. Use the 5-8840-2446-0 valve spring compresso
and 5-8840-2547-0 valve spring compresso
adapter to remove the split collar (12), valve spring
with upper seat (13) and valve (14).

5. Remove spark plug (1).

014RW042

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
the surfaces are “out of flat" by more than
specification, the surface should be ground to
within specifications. Replace the head if i
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)

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.

011RW019

6A-54 ENGINE MECHANICAL (6VE1 3.5L)

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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 5-8840-2443-0 gear spring lever to turn

sub gear to right direction until the M5 bol
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.

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

014RW020

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.

lign timing mark on intake camshaft (one do
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
drive gear (one dot).

014RW041

Legend

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

014RW023

ENGINE MECHANICAL (6VE1 3.5L) 6A-55

Legend

(1) Right Bank
(2) Left Bank

(3) Alignment Mark on Camshaft Drive Gear
(4) Alignment Mark on Camshaft
(5) Alignment Mark on Retainer

014RW024

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)

5. Tighten bolt for camshaft drive gear assembly
pulley to the specified torque.

Torque: 98 N××××m (10.0 kg××××m/72 lb ft)

014RW031

6A-56 ENGINE MECHANICAL (6VE1 3.5L)

Valve Spring, Oil Controller, Valve, Valve Guide

Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts

Legend

(1) Camshaft Bracket Fixing Bolts
(2) Camshaft Assembly Inlet
(3) Camshaft Assembly Exhaust
(4) Shim
(5) Tappet
(6) Split Collar

(7) Spring Upper Seat
(8) Valve Spring
(9) Oil Controller

(10) Spring Lower Seat
(11) Valve Guide
(12) Valve

014RW039

Disassembly

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1. Remove camshaft bracket fixing bolts (1).

2. Remove camshaft assembly (intake).

3. Remove camshaft assembly (Exhaust side).

4. Remove shim (4) and tappet (5).

5. Use the 5-8840-2446-0 valve spring compresso
and 5-8840-2547-0 valve spring compresso
adapter to remove split collar.

ENGINE MECHANICAL (6VE1 3.5L) 6A-57

2. Measure the valve spring squareness with a steel
square and replace the valve springs if the
measured value exceeds the specified limit.

Limit: 2 mm (0.079 in)

014RS004

6. Remove valve spring.

7. Remove valve.

8. Remove oil controller and spring lower seat.

9. Remove the valve guide using the 5-8840-2442-0

valve guide replacer.

Inspection and Repair

Valve Spring

CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is
evident.

1. Measure the free height of the springs. The
springs must be replaced if the free height is belo
the specified limit.

Standard: 44.6 mm (1.756 in)
Limit: 43.6 mm (1.717 in)

014RW042

014RS005

3. Using a spring tester to compress the springs to
the installed height, measure the compressed
spring tension, and replace the springs if the
measured tension is below the specified limit.

At installed height: 35.0 mm (1.38 in)
Standard: 196 N (44 lb)
Limit: Less than 181 N (41 lb)

6A-58 ENGINE MECHANICAL (6VE1 3.5L)

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LNW21BSH056701

Valve Guide

CAUTION: Take care not to damage the valve seat
contact surface, when removing carbon adhering to
the valve head. Carefully inspect the valve stem fo
scratchs or abnormal wear. If these conditions are
present, the valve and the valve guide must be
replaced as a set.

1. Measure the valve stem diameter with a
micrometer. If the valve stem diameter is less than
the specified limit, the valve and the valve guide
must be replaced as a set.

Diameter of Valve Stem
Intake

Standard: 5.977 mm----5.959 mm
(0.2353 in----0.2346 in)
Limit: 5.90 mm (0.2323 in)

Exhaust

Standard: 5.952 mm----5.970 mm
(0.2343 in----0.2350 in)
Limit: 5.90 mm (0.2323 in)

014RS007

2. Measure the inside diameter of the valve guide
with a micrometer. Subtract the measured oute
diameter of the valve stem from the measured
inner diameter of the valve guide. If the value
exceeds the specified limit, the valve and the valve
guide must be replaced as a set.

Inside Diameter of the Vale Guide
Inlet clearance

Standard : 0.023 mm----0.056 mm(0.0009
in----0.0002 in)

Limit : 0.20 mm (0.00787 in)

Exhaust clearance

Standard : 0.030 mm----0.063 mm(0.0012
in----0.0025 in)

Limit : 0.20 mm (0.00787 in)

ENGINE MECHANICAL (6VE1 3.5L) 6A-59

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Valve Guide Replacement

1. Using Valve guide replacer: 5 ?8840 ?2442 ?0,

drive out the valve guide from the combustion
chamber side.

2. Apply engine oil to the outside of the valve guide.

Using valve guide replacer 5 ?8840 ?2442 ?0,
drive in a new valve guide from the camshaft side,
and check the valve guide height.

Valve guide upper end height: 13.0 mm (0.5118

in)

(Measured from the cylinder head upper face)

014RS008

Valve Seat

1. Measure the protrusion of the valve stem when a
new valve is installed in the cylinder head. If the
protrusion of the valve stem exceeds the limit,
replace the valve seat insert or the cylinder head
assembly.

Protrusion of valve stem
Intake

Standard: 39.32 mm (1.5480 in)
Limit: 39.47 mm (1.5539 in)

Exhaust

Standard: 39.30 mm (1.5472 in)
Limit: 39.45 mm (1.5531 in)

014RW047

014RW046

3. Check the clearance. If the clearance is less than
the specified value, ream the inside diameter o
valve guide. Using a sharp 6 mm reamer, ream the
valve guide to obtain the specified clearance.

6A-60 ENGINE MECHANICAL (6VE1 3.5L)

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2. Measure the valve seat contact width. Make the
necessary corrections if the seat contact surface is
damaged or rough or if the contact width wea
exceeds the limit.

Valve seat contact width
Standard: 1.1 mm (0.0433 in)
Limit: 1.7 mm (0.0669 in)

Valve Seat Insert Correction

1. Remove the carbon from the valve seat insert
surface.

2. Use a valve cutter to minimize scratches and othe
rough areas. This will bring the contact width back
to the standard value. Remove only the scratches
and rough areas. Do not cut away too much. Take
care not to cut away unblemished areas of the
valve seat surface.

Valve seat angle degree: 90°°°°

Contact Surface Angle on Valve Seat on
Valve

1. Measure contact surface angle on valve seat.

2. If the measured value exceeds the limit, replace

valve, valve guide and valve seat as a set.

Valve contact surface angle: 45°°°°

014RS011

014RW059

3. Apply abrasive compound to the valve seat insert
surface.

4. Insert the valve into the valve guide.

5. Turn the valve while lapping it to fit the valve sea
insert.

6. Check that the valve contact width is correct.

7. Check that the valve seat insert surface is in
contact with the entire circumference of the valve.

014RS012

014RS014

ENGINE MECHANICAL (6VE1 3.5L) 6A-61

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Valve Seat Insert Replacement

1. Arc weld the rod at several points. Be careful no
to damage the aluminum section.

2.

llow the rod to cool for a few minutes. This will

cause the valve seat to shrink.

3. Strike the rod and pull it out.

Reassembly

1. Install valve guide (1) to cylinder head. Apply
engine oil to the outside of the valve guide. Using
valve guide replacer 5-8840-2442-0, drive in a
new valve guide from the camshaft side.

2. Install oil controller (3) and spring lower seat (2).
Using oil controller replacer 5-8840-0623-0, drive
in a new oil controller.

4. Carefully clean the valve seat press-fit section on
the cylinder head side.

5. Heat the press-fit section with steam or some
other means to cause expansion. Cool the valve
seat with dry ice or some other means.

6. Insert the press-fit section into the valve sea

horizontally.

Standard fitting interference: 0.14 mm----0.09 mm

(0.0055 in----0.0035 in)

7.

fter insertion, use a seat grinder to grind finish
the seating face. Carefully note the seating angle,
the contact width, and the depression.

8. Lap the valve and the seat.

014RS015

014RW058

3. Install valve to valve guide. Before install valve
guide apply engine oil to the outside of the valve
stem.

4. Install valve spring to cylinder head. Attach the
valve spring to the lower spring seat. The painted
area of the valve spring should be facing
downward.

014RS020

6A-62 ENGINE MECHANICAL (6VE1 3.5L)

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5. Install lower valve spring seat, valve spring and
upper valve spring seat then put split collars on the
upper spring seat, using the 5-8840-2446-0 valve
spring compresor and 5-8840-2547-0 valve
spring compressor adapter to install the spli
collars.

6. Install tappet with shim.

7. Install camshaft assembly.

· Refer to installation procedure for Camshaft in

this manual.

Valve Clearance Adjustments

NOTE: To adjust valve clearance, apply engine oil to

the cam as well as to the adjusting shim (2) with the
cylinder head built on the cylinder block, give a fe
turns to the camshaft by means of timing pulley
tightening bolt, and measure valve clearance when the
nose of cam is just opposite to maximum cam lift (1) as
shown in illustration below.

014RW042

014RW081

Legend

(1) Cam
(2) Shim
(3) Tappet

Valve Clearance Standard Value (cold)

Intake: 0.23 mm----0.33 mm
(0.0091 in----0.0130 in)
Exhaust: 0.25 mm----0.35 mm
(0.0098 in----0.0138 in)

Selection of Adjusting Shim

Shim to be selected = (Thickness of removed
shim) + (Valve clearance measurement - Standard
value) Based on the above formula, the best suited
shim should be selected from 41 sorts of shim
(differently thick at 0.02mm (0.0008 in) intervals from

2.40mm (0.0945 in) through 3.2mm (0.1260 in) thick).
Install the shim and check valve clearance.

Replacement of Shim

Let the cam push down the edge of tappet by using
5-8840-2444-0 valve clearance adjusting tool and
push out the shim with a flat blade screw driver as
shown in illustrations below.

ENGINE MECHANICAL (6VE1 3.5L) 6A-63

014RW084

014RW082

014RW083

6A-64 ENGINE MECHANICAL (6VE1 3.5L)

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Camshaft and Associated Parts

Camshaft

Legend

(1) Camshaft Bracket Fixing Bolt
(2) Camshaft Bracket
(3) Camshaft Assembly Intake
(4) Camshaft Assembly Exhaust
(5) Pulley Fixing Bolt

Disassembly

1. Remove fixing bolt (5) for camshaft drive gea
pulley using 5-8840-2447&-ndash;0 universal
holder.

(6) Camshaft Drive Gear Pulley
(7) Retainer Fixing Bolt
(8) Retainer
(9) Camshaft Drive Gear
(10) Oil Seal

014RW040

ENGINE MECHANICAL (6VE1 3.5L) 6A-65

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2. Remove twenty fixing bolts from inlet and exhaus
camshaft bracket on one side bank, then camshaf
brackets (2).

3. Remove camshaft assembly (3), (4).

4. Remove three fixing bolts (7) from camshaft drive
gear retainer (8), then camshaft drive gea
assembly.

014RW060

014RW027

Inspection and Repair

1. Use a micrometer to measure the cam lobe height
and uneven wear. Replace the camshaft if eithe
the lobe height or the uneven wear exceeds the
specified limit.

Lobe height: 44.709 mm (1.7602 in)
Uneven wear: 0.05 mm (0.0020 in)

2. Use a micrometer to measure the diameter and
the uneven wear of the camshaft journals.

Replace the camshaft if the diameter or the

uneven wear exceeds the specified limit.

Journal Diameter
Standard: 25.972 mm----25.993 mm (1.0225

in----1.0233 in)
Limit: 25.8 mm (1.0157 in)
Uneven wear: 0.05 mm (0.0020 in)

014RW043

014RS023

6A-66 ENGINE MECHANICAL (6VE1 3.5L)

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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)

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)

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)

014RW044

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

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

014RW031

ENGINE MECHANICAL (6VE1 3.5L) 6A-67

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3. Measure the camshaft thrust clearance with a dial
indicator. Replace the camshaft and/or the cylinde
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)

3. Install camshaft assembly and camshaft brackets,
tighten twenty bolts on one side bank to the
specified torque.

1.

pply engine oil to camshaft journal and

bearing surface of camshaft bracket.

2.

lign 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
drive gear (one dot).

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

direction until the M5 bolt hole aligns between
camshaft driven gear and sub gear.

2. Tighten M5 bolt suitable torque for preven

moving the sub gear.

014RW035

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

014RW020

014RW041

6A-68 ENGINE MECHANICAL (6VE1 3.5L)

Legend

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

014RW023

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

Legend

(1) Right Bank
(2) Left Bank

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)

014RW024

(3) Alignment Mark on Camshaft Drive Gear
(4) Alignment Mark on Camshaft
(5) Alignment Mark on Retainer

4. If the oil seal requires replacement, use the

5-8840-2445-0 to install the oil seal.

014RW034

014RW031

6A-70 ENGINE MECHANICAL (6VE1 3.5L)

5. Tighten bolt for camshaft drive gear assembly
pulley to the specified torque using the
5-8840-2447-0 universal holder.

Torque: 98 N××××m (10.0 kg××××m/72 lb ft)

014RW060

Crankshaft and Associated Parts

ENGINE MECHANICAL (6VE1 3.5L) 6A-71

Crankshaft

Legend

(1) Cylinder Head Assembly
(2) Crankcase with Oil Pan
(3) Oil Pipe and O-Ring
(4) Oil Strainer and O-Ring
(5) Oil Pump Assembly
(6) Cylinder Block Side Bolts
(7) Oil Gallery

Disassembly

1. Remove cylinder head assembly (1). Refer to
“Head" in this manual.

013RW009

(8) Piston and Connecting Rod Assembly
(9) Flywheel

(10) Rear Oil Seal Retainer and Oil Seal
(11) Main Bearing Cap
(12) Crankshaft
(13) Main Bearing Cap Fixing Bolts
(14) Oil Gallery Fixing Bolts

2. Remove crankcase with oil pan (2). Refer to “Oil
Pan and Crankcase" in this manual.

CAUTION: Take care not to damage or deform the
sealing flange surface of crankcase.

6A-72 ENGINE MECHANICAL (6VE1 3.5L)

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3. Remove oil pipe and O-ring (3).

4. Remove oil strainer and O-ring (4).

5. Remove oil pump assembly (5).

6. Remove crankcase side bolts (6).

7. Remove oil gallery (7).

8. Remove piston and connecting rod assembly (8).
Refer to “Piston, Piston Ring and Connecting Rod"
in this manual.

9. Remove flywheel (9).

10. Remove rear oil seal retainer (10).

11. Remove main bearing cap (11).

12. Remove crankshaft (12).

Inspection and Repair

1. Crankshaft

Set the dial indicator as shown in the illustration

and measure the crankshaft thrust clearance. I
the thrust clearance exceeds the specified limit,
replace the thrust bearings as a set.

Thrust Clearance
Standard : 0.06 mm----0.24 mm
(0.0024 in----0.0094 in)
Limit : 0.30 mm (0.0118 in)

3. Remove the crankshaft. Remove the main
bearings.

4. Clean the upper and lower bearings as well as the
crankshaft main journal.

5. Check the bearings for damage or excessive wear.

The bearings must be replaced as a set if damage

or excessive wear is discovered during inspection.

6. Set the upper bearings and the thrust washers to
their original positions.

Carefully install the crankshaft.

7. Set the lower bearings to the bearing cap original
position.

8.

pply plastigage to the crankshaft journal unit as

shown in the illustration.

NOTE: Do not set the plastigage on the oil hole.

015RS004

015RS003

Main Bearing Clearance

1. Remove the bearing caps and measure the oil
clearance.

2. Remove the main bearing cap fixing bolts in the
sequence shown in the illustration.

rrange the removed main bearing caps in the

cylinder number order.

Remove the main bearings.

9. Install main bearing caps, oil gallery and crank
case bolts in the order shown, and tighten each
bolt to the specified torque.

NOTE: Do not apply engine oil to the crank case side

015RS005

ENGINE MECHANICAL (6VE1 3.5L) 6A-73

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bolts.

Main bearing cap bolts.

Torque: 39 N××××m (4.0 Kg××××m/29 lb ft)

Oil gallery fixing bolts.

Torque:
1st step: 29 N××××m (3.0 Kg××××m/21 lb ft)
2nd step 55°°°° ~~~~ 65°°°°

Crank case side bolts

Torque : 39 N××××m (4.0 Kg××××m/29 lb ft)

NOTE: Do not allow the crankshaft to rotate.

(0.0007 in----0.0017 in)

Limit : 0.08 mm (0.0031 in)

12. Clean the plastigage from the bearings and the
crankshaft.

Remove the crankshaft and the bearings.

015RS008

10. Remove the main bearing caps in the sequence
shown in the illustration.

015RS006

Crankshaft (12) Inspection

Inspect the surface of the crankshaft journal and crank
pins for excessive wear and damage. Inspect the oil
seal fitting surfaces for excessive wear and damage.
Inspect the oil ports for obstructions.

Inspection and Repair

1. Carefully set the crankshaft on the V-blocks.
Slowly rotate the crankshaft and measure the
runout. If the crankshaft runout exceeds the
specified limit, the crankshaft must be replaced.

Runout : 0.04 mm (0.0016 in)

015RS004

11. Measure the plastigage width and determine the
oil clearance. If the oil clearance exceeds the
specified limit, replace the main bearings as a se
and/or replace the crankshaft.

Standard : 0.019 mm----0.043 mm

015RS007

6A-74 ENGINE MECHANICAL (6VE1 3.5L)

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2. Measure the diameter and the uneven wear o
main journal and crank pin. If the crankshaft wea
exceeds the specified limit, crankshaft must be
replaced.

Main journal diameter : 63.918 mm----63.933 mm
(2.5165 in.----2.5170 in.)

Crank pin diameter : 53.922 mm----53.937 mm
(2.1229 in.----2.1235 in.)

Uneven wear limit : 0.005 mm (0.0002 in)

Crankshaft Bearing Selection

2. The crankshaft journal diameter grade mark (1)
are stamped on the No.1 crankshaft balancer (2)
as shown in the illustration.

3. Match the cylinder block journal grade marks and
the crankshaft journal grade marks in the table
below to determine the correct crankshaft bearing
size.

The size color code is painted to side of the

015RS009

crankshaft bearings.

015R200005

Crankshaft bearing selection is based on the measured
diameters of the crankshaft journals and the bearing

inserts.

1. The grade mark (1) for cylinder block journal are
stamped on the lower face of cylinder block as
shown in the illustration.

RTW31BSH000701

RTW31BSH000601

ENGINE MECHANICAL (6VE1 3.5L) 6A-75

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Grade

Mark

1

2

3

Cylinder Block

Journal

68.994-69.000

(2.7163-2.7165)

63.926-63.933

68.987-68.993

(2.7160-2.7163)

63.926-63.933

68.980-68.986

(2.7157-2.7160)

63.926-63.933

Crank Shaft Journal

63.918-63.925

(2.5165-2.5167)

(2.5168-2.5170)

63.918-63.925

(2.5165-2.5167)

(2.5168-2.5170)

63.918-63.925

(2.5165-2.5167)

(2.5168-2.5170)

Diameter

Reassembly

1. Crankshaft (12)

· Install the main bearings to the cylinder block

and the main bearing caps.

· Be sure that they are positioned correctly.

·

pply new engine oil to the upper and lowe

main bearing faces.

NOTE: Do not apply engine oil to the main bearing back
faces.

Grade

Color Code

Oil Clearance

Mark

2 Blue

1 Brown

2

1 Green

2

1 Yellow

(0.0009-0.0017)

(0.0009-0.0016)

(0.0009-0.0016)

(0.0008-0.0016)

(0.0009-0.0016)

(0.0008-0.0015)

(Reference)

0.024-0.043

0.022-0.041

0.023-0.042

0.021-0.040

0.022-0.041

0.020-0.039

Legend

(1) Numver 1 and 4 main bearing upper and lower
(2) Numver 2 and 3 main bearing upper
(3) Numver 2 and 3 main bearing lower

· Carefully mount the crankshaft.

· Apply engine oil to the thrust washer.

·

ssemble the thrust washer to the No.3 bearing
journal. The oil grooves must face the
crankshaft.

015RS012

2. Rear oil seal (10)

· Remove the oil from the cylinder block and the
retainer mounting surface.

· Apply sealant (TB-1207B or equivalent) to the
retainer mounting surface, following the pattern
shown in the illustration.

The retainer must be installed within 5 minutes

after sealant application before the sealan
hardens.

015RS013

6A-76 ENGINE MECHANICAL (6VE1 3.5L)

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Legend

(1) Around Bolt Holes
(2) Around Dowel Pin

· Apply engine oil to the oil seal lip.

·

lign the cylinder block dowel pin holes with the

rear retainer dowel pins.

· Tighten the rear retainer fixing bolts. New bolts
should be used when installing rear retainer.

Torque: 18 N××××m (1.8 Kg××××m/13 lb ft)

NOTE: Be very careful not to disengage the oil seal
garter spring during installation of the rear retainer.

If the seal was removed from retainer fo

replacement, apply engine oil to the oil seal lip
and install the oil seal using 5-8840-2286-0 oil
seal installer.

015RW002

3. Flywheel (9)

1. Thoroughly clean and remove the oil from the
threads of crankshaft.

2. Remove the oil from the crankshaft and
flywheel mounting faces.

3. Mount the flywheel on the crankshaft and then
install the washer.

4. Hold the crankshaft to prevent from rotating
then install the bolts in the order shown to the
specified torque.

Torque: 54 N××××m (5.5 Kg××××m/40 lb ft)

NOTE: Do not reuse the bolt and do not apply oil o
thread lock to the bolt.

015RS017

015RS018

015RW001

4. Piston and connecting rod assembly (8)

·

pply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaf
pins. Check to see that the piston ring end gaps
are correctly positioned.

ENGINE MECHANICAL (6VE1 3.5L) 6A-77

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Legend

(1) No.1 Compression Ring
(2) No.2 Compression Ring
(3) Oil Ring Side Rail Upper
(4) Oil Ring Side Rail Lower
(5) Piston Front Mark

015RS019

015RS020

5. Install oil gallery (7) and tighten the bolts in 2
steps, in the order shown.

1st step: 29 N××××m (3.0 Kg××××m/22 lb ft)
2nd step: 55°°°° ~~~~ 65°°°°

· Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor.
The front marks must be facing the front of the
engine.

· Match the numbered caps with the numbers on

the connecting rods. Align the punched marks
on the connecting rods and caps.

· Apply engine oil to the threads and seating
faces of the nuts.

· Tighten the nuts.

Torque: 54 N××××m (5.5 Kg××××m/40 lb ft)

fter tightening the cap nuts, check to see tha

the crankshaft rotates smoothly.

NOTE: Do not apply engine oil to the bearing back
faces.

051RS009

6. Cylinder block side bolts (6)

· Tighten all the bolts to the specified torque in
the order shown.

NOTE: Do not apply engine oil to the crank case side
bolts.

Torque: 39 N××××m (4.0 Kg××××m/29 lb ft)

6A-78 ENGINE MECHANICAL (6VE1 3.5L)

¾

7. Install oil pump assembly (5), refer to “Oil pump" in
this manual.

8. Install oil strainer and O-ring (4).

9. Install oil pipe and O-ring (3) and tighten the bolts.

Torque: 25 N××××m (2.5 Kg××××m/18 lb ft)

10. Install crankcase with oil pan (2).

1. Completely remove all residual sealant,

lubricant and moisture from the sealing
surfaces. The surfaces must be perfectly dry.

2. Apply a correct width bead of sealant (TB

1207C or its equivalent) to the contact surfaces
of the oil pan. There must be no gaps in the
bead.

3. The crankcase assembly must be installed

within 5 minutes after sealant application to
prevent premature hardening of the sealant.

4. Tighten the bolts and nuts to the specified

torque.

Torque : 10 N××××m (1.0 Kg××××m/7 lb ft)

012RS001

Legend

(1) Portion Between Bolt Holes
(2) Bolt Hole Portion

11. Install cylinder head assembly, refer to “Cylinder
head" in this manual.

013RW010

Piston and Connecting Rod

Piston, Connecting Rod and Associate Parts

ENGINE MECHANICAL (6VE1 3.5L) 6A-79

Legend

(1) Cylinder Head Assembly
(2) Cylinder Head Gasket
(3) Crankcase with Oil Pan
(4) Oil Pipe and O-Ring
(5) Oil Strainer and O-Ring
(6) Oil Gallery

Disassembly

1. Remove cylinder head assembly (1). Refer to
“Cylinder Head Removal" in this manual.

(7) Piston and Connecting Rod Assembly
(8) Piston Ring
(9) Piston Pin

(10) Piston
(11) Connecting Rod
(12) Connecting Rod Cap

2. Remove cylinder head gasket (2).

3. Remove crankcase with oil pan (3). Refer to ”Oil
Pan and Crankcase" in this manual.

4. Remove oil pipe and O-ring (4).

015RW019

6A-80 ENGINE MECHANICAL (6VE1 3.5L)

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5. Remove oil strainer and O-ring (5).

6. Remove oil gallery (6).

7. Remove connecting rod cap with connecting rod
lower bearing (12).

8. Remove piston and connecting rod assembly (7).

NOTE: Before removing piston and connecting rod
assembly, measure thrust clearance.

· Remove any ridge or carbon build up from the

top end of the cylinder.

9. Remove the piston rings (8) with a piston ring
expander. Arrange the removed piston rings in the
cylinder number order.

NOTE: Keep the parts removed from each cylinde

separate. All parts must be reinstalled in their original
positions. Heating the connecting rod will permit easy
removal of the piston pin.

Legend

(1) Press Ram

015RS031

(2) Piston
(3) Connecting Rod
(4) Piston Pin

11. Piston (10)

12. Connecting rod (11)

Inspection and Repair

015RX001

015RS022

10. Remove the piston pin (9) using 5-8840-0551-0
piston pin service set and piston support with a
press.

Pistons (10)

Carefully clean away all the carbon adhering to the
piston head and the piston ring grooves.

NOTE: Never use a wire brush to clean the pistons.
Damage will result. Visually check each piston fo
cracking, scoring, and other signs of excessive wear. I
any of the above conditions are found, the piston mus
be replaced.

Piston Diameter

1. Measure the piston outside diameter with
micrometer at the piston grading position and a
right angle to the piston pin.

Piston grading position (from piston head)

Piston grading position : 43.0 mm (1.6929 in)

ENGINE MECHANICAL (6VE1 3.5L) 6A-81

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The size mark (1) for piston outside diameter is
represented as shown in illustration below.

Outside Diameter
Size Mark A : 93.360 mm----93.370 mm

(3.6756 in----3.6760 in)
Size Mark B : 93.371 mm----93.380 mm

(3.6760 in----3.6764 in)
Size Mark C : 93.381 mm----93.390 mm

(3.6764 in----3.6768 in)

015RV014

012RS002

Piston Rings (8)

Any worn or damaged part discovered during engine
overhaul must be replaced with a new one.

1. Ring end gap measurement

· Insert the piston ring into the bore.

· Push the ring by the piston, at a right angle to

the wall, into the point at which the cylinde
bore diameter is the smallest.

· Measure the ring end gap.

Compression Ring
1st ring

Standard: 0.300 mm-0.400 mm
(0.0118 in-0.0157 in)
Limit: 1.0 mm (0.0394 in)

2nd ring

Standard: 0.450 mm-0.600 mm
(0.0177 in-0.0236 in)
Limit: 1.2 mm (0.0472 in)

Oil ring

Standard: 0.150 mm-0.450 mm
(0.0059 in-0.0177 in)
Limit: 1.05 mm (0.0413 in)

015RS025

Measure the cylinder bore inside diameter (refe
to ”Cylinder Block" in this manual).

6A-82 ENGINE MECHANICAL (6VE1 3.5L)

f

· 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 illustration.

015RS026

015RS028

Piston Pin (9)

NOTE: Do not reuse the old piston pin.

1. Use a micrometer to measure the new piston pin
outside diameter in both directions at three
different positions.

2. Measure the inside diameter of the connecting rod
small end. If the fitting interference between the
small end and pin does not conform to the
specified value, the connecting rod must be
replaced.

Standard : 0.023 mm----0.038 mm
(0.0009 in----0.0015 in)

015RS027

2. Measure the clearance between the piston ring
groove and the piston ring with a feeler gauge. I
the piston ring groove / piston ring clearance
exceeds the specified limit, the piston must be
replaced.

Compression Ring Clearance
Standard : 0.016 mm----0.038 mm
(0.0006 in. ----0.0015 in)
Limit : 0.15mm (0.0059 in)

015RS029

3. Insert the new pin into the piston and rotate it. I

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the pin rotates smoothly with no backlash, the
clearance is normal. If there is backlash o
roughness, measure the clearance. If the
clearance exceeds the specified limit, the piston
must be replaced.

Clearance
Standard : 0.010 mm----0.017 mm

(0.0004 in. ----0.0007 in)
Limit : 0.040 mm (0.0016 in)

Connecting Rods (11)

ENGINE MECHANICAL (6VE1 3.5L) 6A-83

1. Check the connecting rod alignment If either the
bend or the twist exceeds the specified limit, the
connecting rod must be replaced.

Bend per 100 mm (3.937 in)
Limit: 0.15 (0.0059)
Twist per 100 mm (3.937 in)
Limit: 0.20 (0.0078)

015RS031

3. Measure the oil clearance between the connecting
rod and the crankshaft.

1. Remove the connecting rod cap nuts and the

rod caps (12).

rrange the removed rod caps in the cylinder

number order.

2. Clean the rod bearings and the crankshaft pins.

3. Carefully check the rod bearings. If even one

bearing is found to be damaged or badly worn,
the entire bearing assembly must be replaced
as a set. Reinstall the bearings in their original
positions. Apply plastigage to the crank pin.

015RS030

2. Measure the connecting rod thrust clearance. Use
a feeler gauge to measure the thrust clearance a
the large end of the connecting rod If the clearance
exceeds the specified limit, the connecting rod
must be replaced.

Standard : 0.16 mm----0.35 mm
(0.0063 in. ----0.0138 in)

Limit : 0.40 mm (0.0157 in)

015RS032

4. Reinstall the rod caps (12) to their original
positions.

Tighten the rod cap nuts.

Torque: 54 N××××m (5.5 kg××××m/40 lb ft)

6A-84 ENGINE MECHANICAL (6VE1 3.5L)

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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 clearance exceeds the
limit, replace the rod bearing as a set.

Standard : 0.019 mm----0.043 mm
(0.0007 in----0.0017 in)
Limit : 0.08 mm (0.003 in)

1 Size Mark

A

B

C

Big end Bore

56.994-57.000

(2.2439-2.2441)

56.988-56.994

(2.2436-2.2439)

56.982-56.988

(2.2434-2.2436)

Crankshaft Pin

Diameter

53.922-53.937

(2.1229-2.1235)

Reassembly

7. Clean the plastigage from the bearings and the
crankshaft pins.

Con----rod Bearing Selection

Select and install the new connecting rod bearings,
paying close attention to the connecting rod big end
diameter size mark (1).

NOTE: Take care not to confuse the alignment mark (2)
and the size mark (1) during the installation procedure.

015RS008

Connecting Rod

Diameter

1.512-1.516

1.504-1.508

Bearing Thickness

(Reference)

(0.0595-0.0597)

1.508-1.512

(0.0594-0.0595)

(0.0592-0.0594)

Color of

Size Mark

Yellow

Green

Pink

015RS034

Oil Clearance

(Reference)

0.025-0.054

(0.0010-0.0021)

0.027-0.056

(0.0011-0.0022)

0.029-0.058

(0.0011-0.0023)

1. Install connecting rod

2. Install piston

3. Install piston pin

·

pply a thin coat of engine oil to the piston pin.
Try to insert the piston pin into the piston pin
hole with normal finger pressure.

NOTE: When changing piston / connecting rod
combinations, do not change the piston / piston pin
combination and do not reuse the old piston pin.

·

ttach the piston to the connecting rod with the
piston front mark and the connecting rod fron
mark on the same side.

ENGINE MECHANICAL (6VE1 3.5L) 6A-85

t

RUW36ASH000501

· With 5-8840-0551-0 Piston pin service se
and a press, press fit the piston pin.

NOTE: Heat the connecting rod small end to a suitable
temperature to ensure smooth installation.

015RS027

· Install piston rings in the following sequence.

1. Oil ring

1. Expander ring

2. Upper side rail

3. Lower side rail

2. 2nd compression ring

· The 2nd compression ring must be set with the
T2 mark facing up.

3. 1st compression ring

· The compression ring must be set with
direction of origin.

· After installation, apply engine oil to the entire
circumference of the piston rings. Check to see
that all the rings rotate smoothly.

015RX001

Legend

(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin

4. Install piston ring with the piston ring expander.
The No.2 compression ring must be set with the

T2 mark (1) facing up.

015RS038

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.

· Tighten the connecting rod cap nuts

Torque : 54 N××××m (5.5 kg××××m/40 lb ft)

NOTE: Do not apply engine oil to the bearing back
faces.

6. Oil gallery, refer to “Crankshaft and main bearing"
in this manual.

7. Oil strainer and O-ring.

8. Oil pipe and O-ring.

9. Install crankcase with oil pan, refer to “Oil pan and
Crankcase" in this manual.

10. Install cylinder head gasket.

11. Install Cylinder head assembly.

· Refer to “Cylinder head" in this manual.

Cylinder Block

Cylinder Block and Associated Parts

ENGINE MECHANICAL (6VE1 3.5L) 6A-87

Legend

(1) Cylinder Head Assembly
(2) Cylinder Head Gasket
(3) Crankcase with Oil Pan
(4) Oil Pipe and O-Ring
(5) Oil Strainer and O-Ring
(6) Oil Pump Assembly
(7) Cylinder Block Side Bolts

(8) Oil Gallery
(9) Piston and Connecting Rod Assembly

(10) Flywheel
(11) Rear Oil Seal Retainer Assembly
(12) Main Bearing Cap
(13) Crankshaft
(14) Cylinder Block

012RW010

6A-88 ENGINE MECHANICAL (6VE1 3.5L)

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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.

012RS004

Inspection and Repair

1. Remove the cylinder head gasket and any othe
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
damage is discovered, the cylinder block mus
either be repaired or replaced.

Flatness

1. Using a straight-edge and feeler gauge, check
that the upper surface of the cylinder block is no
warped.

NOTE: Be very careful not to allow any material to
accidentally drop into the upper surface of the cylinde
block. Be very careful not to scratch the upper surface
of the cylinder block.

2. The cylinder block must be reground or replaced i
the warpage exceeds the limit.

Warpage
Limit : 0.15 mm (0.0059 in)
Maximum repairable limit: 0.15 mm (0.0059 in)

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)

ENGINE MECHANICAL (6VE1 3.5L) 6A-89

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NOTE: For information on piston diameter, please refer
to the section "Inspection of the Piston and Connecting
Rod Assembly" in this manual.

· The "Grade" mark (1) is stamped at the

position illustrated.

012RS005

Legend

(1) Number 1 and 4 main bearing upper and lower.
(2) Number 2 and 3 main bearing upper.
(3) Number 2 and 3 main bearing lower.

· Carefully mount the crankshaft.

· Apply engine oil to the thrust washer.

· Assemble the thrust washer to the No. 3

bearing journal. The oil grooves must face the
crankshaft.

015RS012

012RS006

Reassembly

1. Install cylinder block.

2. Install crankshaft.

· Install the main bearings to the cylinder block

and the main bearing caps.

· Be sure that they are positioned correctly.

·

pply new engine oil to the upper and lowe

main bearing faces.

NOTE: Do not apply engine oil to the bearing back
faces.

3. Install rear oil seal retainer.

· Remove oil on cylinder block and retainer fitting
surface.

·

pply sealant (TB1207B or equivalent) to

retainer fitting surface as shown in illustration.

· The oil seal retainer must be installed within 5
minutes after sealant application before the
sealant hardens.

015RS013

6A-90 ENGINE MECHANICAL (6VE1 3.5L)

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Legend

(1) Around Bolt Holes
(2) Around Dowel Pin

· Apply engine oil to oil seal lip and align a dowel
pin hole in the cylinder block with that in the
retainer.

· Tighten retainer fixing bolts to the specified
torque.

Torque: 25 N××××m (2.5 kg××××m/18.4 lb ft)

Torque: 54 N××××m (5.5 kg××××m/40 lb ft)

NOTE: Do not reuse the bolts and do not apply oil o
thread lock to the bolts.

015RW002

5. Install piston and connecting rod assembly.

· Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaf
pins.

NOTE: Do not apply engine oil to the bearing back
faces.

· Check to see that the piston ring end gaps are
correctly positioned.

015RS018

4. Install flywheel

1. Thoroughly clean and remove the oil from the
threads of crankshaft.

2. Remove the oil from the crankshaft and
flywheel mounting faces.

3. Mount the flywheel on the crankshaft and then
install the washer.

4. Holding the crankshaft stationary, tighten the
flywheel bolts in the order shown.

015RW001

015RS019

Legend

(1) No.1 Compression Ring
(2) No.2 Compression Ring
(3) Oil Ring Side Rail Upper
(4) Oil Ring Side Rail Lower
(5) Piston Front Mark

· Insert the piston/connecting rod assemblies into

f

each cylinder with the piston ring compressor.

· The front marks (1) must be facing the front o
the engine.

ENGINE MECHANICAL (6VE1 3.5L) 6A-91

6. Install oil gallery and tighten the bolts in 2 steps in
the order shown.

1st step : 29 N××××m (3.0 kg××××m/22 lb ft)
2nd step : 55°°°° ~~~~ 65°

015RS020

012RW005

8. Install oil pump assembly. Refer to “Oil Pump" in
this manual.

9. Install oil strainer and O-ring.

10. Install oil pipe and O-ring.

11. Install crankcase with oil pan.

1. Completely remove all residual sealant,

lubricant and moisture from the sealing
surfaces. The surfaces must be perfectly dry.

2. Apply a correct width bead of sealant (TB-

1207C or its equivalent) to the contact surfaces
of the crankcase. There must be no gaps in the
bead.

3. The oil pan must be installed within 5 minutes

after sealant application to prevent premature
hardening of sealant.

7. Install cylinder block side bolts (1) and tighten
crankcase bolts in sequence shown in the
illustration.

Torque : 39 N××××m (4.0 kg××××m/29 lb ft)

012RS007

6A-92 ENGINE MECHANICAL (6VE1 3.5L)

r

4. Tighten the bolts and nuts to the specified

torque.

Torque : 10 N××××m (1.0 kg××××m/7 lb ft)

Legend

(1) Portion Between Both Holes
(2) Bolt Hole Portions

013RW010

12. Install cylinder head gasket.

13. Install cylinder head assembly. Refer to “Cylinde
Head" in this manual.

ENGINE MECHANICAL (6VE1 3.5L) 6A-93

Main Data and Specification

General Specification

Item Specifications

Engine type, number of cylinders and arrangement Water cooled, four cycle V6

Form of combustion chamber Pent-roof type

Valve mechanism 4-Cams, 4-Valves, DOHC Gear & Belt Drive

Cylinder liner type Casted in cylinder block

Total piston displacement 3494 cc

Cylinder bore x stroke 93.4mm x 85.0mm

Compression ratio 8.6

Compression pressure at 300rpm 1.37 MPa (14.0 Kg/cm2)

Engine idling speed rpm Non adjustable (750)

Valve clearance Intake: 0.28 mm (0.11 in)

Oil capacity 5.3 liters

Ignition timing

Spark plug PK16PR11, RC10PYP4, K16PR-P11

Plug gap 1.0 mm – 1.1 mm (0.0394 in – 0.0433 in)

Non adjustable (12° BTDC at idle rpm)

(3.6772 in ´ 3.3465 in)

Exhaust: 0.30mm (0.12 in)

6A-94 ENGINE MECHANICAL (6VE1 3.5L)

Torque Specifications

Ignition coil, Spark plug, Crankshaft angle sensor and Under cover

N××××m (kg××××m/ lb ft)

RTW460LF000101

ENGINE MECHANICAL (6VE1 3.5L) 6A-95

Cylinder head cover, Cylinder head, Camshaft bracket, Common chamber, ECM

N××××m (kg××××m/ lb ft)

RTW46ALF000601

6A-96 ENGINE MECHANICAL (6VE1 3.5L)

Crankshaft main bearing, Flywheel, Crankcase, Oil pan, Timing belt tensioner, Timing pulley, timing belt
cover, Oil pump, Oil gallery, Oil strainer and water pump

N××××m (kg××××m/ lb ft)

RTW46ALF000701

Connecting rod and Water pump

ENGINE MECHANICAL (6VE1 3.5L) 6A-97

N××××m (kg××××m/ lb ft)

E06RW042

6A-98 ENGINE MECHANICAL (6VE1 3.5L)

Engine mount

N××××m (kg××××m/ lb ft)

RTW36ALF000101