tow ISUZU TF SERIES 2004 Owner's Manual

ENGINE MECHANICAL 6A – 107


RTW36ASH002001




11. Piston and Connecting Rod with Upper Bearing
12. Connecting Rod Bearing Cap with Lower Bearing
1. Apply a coat of engine oil to the circumference of each
piston ring and piston.
2. Position the piston ring gaps as shown in the
illustration.
1. Oil ring
2. 2nd compression ring
3. 1st compression ring










3. Apply a coat of molybdenum disulfide grease to the two
piston skirts.
This will facilitate smooth break-in when the engine is
first started after reassembly.
4. Apply a coat of engine oil to the upper bearing
surfaces.
5. Apply a coat of engine oil to the cylinder wall.














6. Position the piston head front mark so that it is facing
the front of the engine.
7. Use the piston ring compressor to compress the piston
rings.
Piston Ring Compressor: 5-8840-9018-0
8. Use a hammer grip to push the piston in until the
connecting rod makes contact with the crankpin.
At the same time, rotate the crankshaft until the
crankpin is at BDC.



9. Align the bearing cap cylinder number marks and the
connecting rod cylinder number marks.
The cylinder number marks must be turned toward the
exhaust manifold.



015LX096
015R100007015R100006

6D – 8 ENGINE ELECTRICAL

033RY00009




















































Cooling Fan Drive Belt
1. Hold the generator toward the engine.
2. Install the fan belt to the three pulleys.
1 Crankshaft pulley
2 Generator pulley
3 Cooling fan drive pulley



3. Adjust the fan belt tension
Fan belt tension is adjusted by moving the generator.
Depress the drive belt mid-portion with a 98N (10
kg/22 Ib) force.
Cooling Fan Drive Belt Deflection mm (in)
New belt 4 - 7 (0.16 - 0.28)
Reuse belt 6 - 9 (0.24 - 0.35)


4. Tighten the adjusting plate bolts to the specified
torque.

Adjusting Plate Bolt N·m (kg·m/lb·ft)
19 (1.9/14)

5. Reconnect the battery cable to the battery.

6E–74 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
When current from the pump control unit (PSG) flows to
the high pressure solenoid valve coil, the magnet
anchor (a movable iron core) pushes the valve needle,
toward the valve seat.
When the valve seat is completely closed by the valve
needle, the way, of the fuel in the high pressure
passage to the low pressure circuit is closed.
The pressure of the fuel in the high pressure passage is
rapidly increased by radial plunger lift, and the high
pressure fuel is delivered through the constant pressure
valve (CPV) to the nozzle holder assembly and is
injected into the engine cylinder.
When the fuel injection quantity demanded by the
engine is reached, the current to the coil is cut and the
valve needle re-opens the valve seat.
As a result of this, a path is opened for the fuel in the
high pressure passage to the low pressure circuit and
the pressure decreases. With a decrease in injection
pressure the nozzle closes and injection ends.Timing Control Valve (TCV)
The pressure of the fuel fed from the feed pump is
adjusted in accordance with speed by the regulating
valve. This delivery pressure acts on the hydraulic
stopper's annular chamber as control pressure.
The chamber pressure of the annular chamber is
controlled by the timing control valve (TCV).
The timing plunger is connected to the cam ring by a
ball pin. Ax ial movement of the timing plunger is
transferred to the cam ring in the form of rotational
movement. Movement to the right of the timing plunger
(to the spring side) advances injection timing. (1) Valve Needle
(2) Coil
(1) Cam Ring
(2) Servo Valve
(3) Timer Piston
(4) Outlet
(5) Feed Pump
(6) Inlet
(7) Fuel Suction
(8) Ball Pin
(9) Annular Chamber
(10) Hydraulic Stopper
(11) Return Passage
(12) Timing Control Valve (TCV)

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–421
EGR EVRV (Electrical Vacuum
Regulating Valve)
Location
Back of the air cleaner case.
Removal Procedure
1. Disconenct the negative battery cable.
2. Disconnect a EVRV connector from the EVRV.
3. Disconnect two hoses from the EVRV.
4. Loosen two bolts and remove the EVRV from the
bracket.
Installation Procedure
1. Tighten the purge solenoid by tow bolts.
2. Connect a connector to the EVRV.
3. Connect two hoses to the EVRV.
4. Connect the negative battery cable.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.
Verify proper connection of two hoses.

6F – 20 EXHAUST SYSTEM

IHI SERVICE NETWORK
For inquiries relating to turbochargers, please contact your ISUZU distributor or the nearest IHI Turbocharger
Service Facility.

HEADQUARTERS
ISHIKAWAJIMA HARIMA HEAVY INDUSTRIES CO., LTD.(IHI)
General Machinery Division
Tokyo Chuo Building 1-6-2 Marunouchi Chiyoda-ku
Tokyo 100-0005 JAPAN
TEL: 81-(3)-3286-2405 to 2407 (3 lines)
FAX: 81-(3)-3286-2430

CHINA
IHI BEIJING OFFICE
Room 705, China World Trade Center, No. 1 Jian Guo Men Wai Avenue
Beijing, People’s Republic of CHINA
TEL: 86-(1)-505-4997, 0408
FAX: 86-(1)-505-4350
TLX: 210343 IHIPK CN

TAIWAN
IHI TAIPEI OFFICE
Room 1202, Chia Hsin Building, No. 96 Chung Shan
North Road, Section 2, Taipei, TAIWAN
TEL: 886-(2)-542-5520, 5521, 5523
FAX: 886-(2)-542-4362
TLX: 11320 IHICO

THAILAND
IHI BANGKOK OFFICE
8th Floor, Thaniya Building, 62 Silom Road, Bangkok, THAILAND
TEL: 66-(2)-236-3490, 7356, 9099
FAX: 66-(2)-236-7340
TLX: 82375 IHICO TH

MALAYSIA
IHI KUALA LUMPUR OFFICE
Letter Box No. 52, 22nd Floor, UBN Tower,
10 Jin. P. Ramlee 50250 Kuala Lumpur, MALAYSIA
TEL: 60-(3)-232-1255, 1271
FAX: 60-(3)-232-1418
TLX: IHI KLMA 20257

INDONESIA
IHI JAKARTA OFFICE
9th Floor, Skyline Building JI. M. H. Thamrin, No. 9, Jakarta, INDONESIA
TEL: 62-(21)-32-2147, 390-2211
FAX: 62-(21)-32-3273
TLX: 44175 IHIJKT

ENGINE MECHANICAL (6VE1 3.5L) 6A-3
General Description
Engine Cleanliness And Care
An 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
t
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.


A 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
r
service, they should be retained in order.


At 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
t
pulley side to flywheel side.
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
f
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.


Any time the intake air duct or air cleaner is
removed, the intake opening should be covered.
This will protect against accidental entrance o
f
foreign material into the cylinder which could
cause extensive damage when the engine is
started.
Cylinder Block
The cylinder block is made of aluminum die-cast casting
for 75Vtype 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
t
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
t
the thrust bearing. The bearing cap is made of nodular
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
w
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.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods
Aluminum 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
t
side, and the thrust pressure of piston to the cylinder
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
r
bearing.
Engine Control Module (ECM)
The ECM location is on the common charmber.

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 Retighten or replace gasket
Head cover fixing bolts loose or
gasket broken Retighten or replace gasket
Oil filter adapter cracked Replace
Oil filter attachings bolt loose or
rubber gasket broken Retighten or replace oil filter
Oil cooler broken Replace
Crankshaft front or rear oil seal
defective Replace oil seal
Oil pressure unit loose or broken Retighten or replace
Blow–by gas hose broken Replace hose
Positive Crankcase Ventilation Valve
clogged Clean
Engine/Transmission coupling failed Replace oil seal
Oil leaking into combustion chambers
due to poor seal in valve system Valve stem oil seal defective Replace
Valve stem or valve guide worn Replace valve and valve guide
Oil leaking into combustion chambers
due to poor seal in cylinder parts Cylinders and pistons worn
excessively Replace cylinder body assembly and
pistons
Piston ring gaps incorrectly
positioned Correct
Piston rings set with wrong side up Correct
Piston ring sticking Replace cylinder body assembly and
pistons
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 Positive Crankcase Ventilation Valve
clogged Clean
Others Improper oil viscosity Use oil of recommended S.A.E.
viscosity
Continuous high speed driving and/or
severe usage such as trailer towing Continuous high speed operation
and/or severe usage will normally
cause increased oil consumption

ENGINE ELECTRICAL (6VE1 3.5L) 6D1-3
4. Load Test
1. Connect a voltmeter and a battery load tester
across the battery terminals.
2.
Apply 300 ampere load for 15 seconds to remove
surface charge from the battery. Remove load.
3. Wait 15 seconds to let battery recover. Then apply
specified load from specifications (See Main Data
and Specifications in this section).
Read voltage after 15 seconds, then remove load.
a. VOLTAGE DOES NOT DROP BELOW THE
MINIMUM LISTED IN THE TABLE –The
battery is good and should be returned to
service.
b. VOLTAGE IS LESS THAN MINIMUM LISTED –
Replace battery.


ESTIMATED TEMPERATURE MINIMUM
VOLTAGE





F




C V
70 21 9.6
60 16 9.5
50 10 9.4
40 4 9.3
30 –1 9.1
20 –7 8.9
10 –12 8.7
0 –18 8.5
The battery temperature must be estimated by feel
and by the temperature the battery has been
exposed to for the preceding few hours.
Battery Charging
Observe the following safety precautions when charging
the battery:
1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during charging
procedure.
Battery charging should be discontinued or the rate
of charge reduced if the battery feels hot to the
touch.
Battery charging should be discontinued or the rate
of charge reduced if the battery begins to gas o
r
spew electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue do
t
or ring, it may be necessary to jiggle or tilt the
battery.
4. Battery temperature can have a great effect on
battery charging capacity.
5. The sealed battery used on this vehicle may be
either quick charged or slow charged in the same
manner as other batteries.
Whichever method you decide to use, be sure tha
t
you completely charge the battery. Never partially
charge the battery.
Jump Starting
Jump Starting with an Auxiliary (Booster)
Battery
CAUTION: Never push or tow the vehicle in an
attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.
Treat both the discharged battery and the booste
r
battery with great care when using jumper cables.
Carefully follow the jump starting procedure, being
careful at all times to avoid sparking.
WARNING: FAILURE TO CAREFULLY FOLLOW
THE JUMP STARTING PROCEDURE COULD
RESULT IN THE FOLLOWING:
1. Serous personal injury, particularly to you
r
eyes.
2. Property damage from a battery explosion,
battery acid, or an electrical fire.
3. Damage to the electronic components of one o
r
both vehicles particularly.
Never expose the battery to an open flame or electrical
spark. Gas generated by the battery may catch fire o
r
explode.
Remove any rings, watches, or other jewelry before
working around the battery. Protect your eyes by
wearing an approved set of goggles.
Never allow battery fluid to come in contact with you
r
eyes or skin.
Never allow battery fluid to come in contact with fabrics
or painted surfaces.
Battery fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes,
skin, fabric, or a painted surface, immediately and
thoroughly rinse the affected area with clean tap water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any othe
r
metal surface of the vehicle. This will protect against a
short circuit.
Always keep batteries out of reach of young children.

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-5
Starter
Removal
1. Battery ground cable.
2. Disconnect left heated O
2 sensor connector.
3. Remove exhaust front left pipe.
4. Remove dust cover.
5. Disconnect starter wiring connector from terminals
“30" and “50".
6. Remove starter assembly mounting bolts on inside
and outside.
7. Remove starter assembly toward the bottom o
f
engine.



065RY00050
Legend
(1) Terminal "30"
(2) Terminal "50"
(3) Fixing Bolts
(4) Starter Assembly


Installation
1. Install starter assembly.
2. Install mounting bolts and tighten bolts to specified
torque.
Torque: 40 N




m (4.1 kg




m/30 lb ft)
3. Reconnect the connectors to terminals “30" and
“50" and tighten Terminals “30" to specified torque.
Torque: 9 N




m (0.9 kg




m/7 lb ft)
4. Install dust cover.





065RY00050
Legend
(1) Terminal "30"
(2) Terminal "50"
(3) Fixing Bolts
(4) Starter Assembly


5. Install exhaust front left pipe and tighten bolts and
nuts to specified torque(2).
Stud Nuts
Torque: 67 N




m (6.8 kg




m/49 lb ft)
Nuts
Torque: 43 N




m (4.4 kg




m/32 lb ft)
6. Connect heated O
2 sensor connector.
7. Reconnect the battery ground cable.

6E-106 3.5L ENGINE DRIVEABILITY AND EMISSIONS

FUEL INJECTOR COIL TEST
PROCEDURE AND FUEL INJECTOR
BALANCE TEST PROCEDURE




Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart:
2.
Relieve the fuel pressure by connecting the 5–
8840–0378–0 Fuel Pressure Gauge to the fuel
pressure connection on the fuel rail.
CAUTION: In order to reduce the risk of fire and
personal injury, wrap a shop towel around the fuel
pressure connection. The towel will absorb any fuel
leakage that occurs during the connection of the
fuel pressure gauge. Place the towel in an approved
container when the connection of the fuel pressure
gauge is complete.

Place the fuel pressure gauge bleed hose in an
approved gasoline container.

With the ignition switch “OFF," open the valve on
the fuel pressure gauge.


3.
Record the lowest voltage displayed by the DVM
after the first second of the test. (During the first
second, voltage displayed by the DVM may be
inaccurate due to the initial current surge.)

Injector Specifications:

Resistance Ohms Voltage Specification at
10

C

35
C (50
F

95
F)
11.8 – 12.6 5.7 – 6.6


The voltage displayed by the DVM should be within
the specified range.
 The voltage displayed by the DVM may increase
throughout the test as the fuel injector windings
warm and the resistance of the fuel injecto
r
windings changes.
 An erratic voltage reading (large fluctuations in
voltage that do not stabilize) indicates an
intermittent connection within the fuel injector.
5.
Injector Specifications:




Highest Acceptable
Voltage Reading
Above/Below 35

C/10
C
(95

F/50
F) Acceptable Subtracted
Value
9.5 Volts 0.6 Volts
7.
The Fuel Injector Balance Test portion of this chart
(Step 7 through Step 11) checks the mechanical
(fuel delivery) portion of the fuel injector. An engine
cool-down period of 10 minutes is necessary in
order to avoid irregular fuel pressure readings due
to “Hot Soak" fuel boiling.