sensor ISUZU TF SERIES 2004 Workshop Manual

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





012RS009
1. Install engine assembly. Tighten engine mount
fixing bolts to frame to the specified torque.
Torque: 41 N




m (4.2 kg




m/30 lb ft)
2. Reconnect fuel hose to fuel pipe on engine.
3. Install transmission assembly. Refer to
Transmission section in this manual.
4. Reconnect two heater hoses to engine.
5. Install flywheel dust covers.
6. Install exhaust pipe and temporally tighten two
(each bank) rear exhaust flange nuts then tighten
three stud nuts (each bank) between exhaus
t
manifold and exhaust pipe, finally tighten rear side
stud nuts to the specified torque.
Torque: 67 N




m (6.8 kg




m/49 lb ft)






LTW36FSH000101
7. Reconnect O2 sensor connector.
8. Install cooling fan assembly and tighten bolts/nuts
to the specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft) for fan pulley
and fan bracket.
Torque : 10 N




m (1.0 kg




m/7 lb ft) for fan and
clutch assembly.
9. Install air conditioner compressor to engine and
tighten to the specified torque.
Torque : 43 N




m (4.4 kg




m/32 lb ft)
10. Install power steering pump, tighten fixing bolt to
the specified torque.
Torque :
M8 bolts : 25 N




m (2.5 kg




m/18 lb ft)
M10 bolts : 43 N




m (4.4 kg




m/32 lb ft)
11. Move drive belt tensioner to loose side using
wrench, then install drive belt to normal position.



850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt

12. Install upper fan shroud.
13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back o
f
right dash panel.

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 COOLING (6VE1 3.5L) 6B-5
Diagnosis
Engine Cooling Trouble
Symptom Possible Cause Action
Engine overheating Low Engine Coolant level Replenish
Thermo meter unit faulty Replace
Faulty thermostat Replace
Faulty Engine Coolant temperature
sensor Repair or replace
Clogged radiator Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of
improper engine oil Replenish or change oil
Clogged exhaust system Clean exhaust system or replace
faulty parts
Faulty Throttle Position sensor Replace throttle valve assembly
Open or shorted Throttle Position
sensor circuit Repair or replace
Damaged cylinder head gasket Replace
Engine overcooling Faulty thermostat Replace
Engine slow to warm–up Faulty thermostat Replace
Thermo unit faulty Replace

ENGINE FUEL (6VE1 3.5L) 6C-3
Fuel Metering
The Engine Control Module (ECM) is in complete
control of this fuel delivery system during normal driving
conditions.
The intake manifold function, like that of a diesel, is
used only to let air into the engine. The fuel is injected
by separate injectors that are mounted over the intake
manifold.
The Barometric Pressure (BARO) sensor measures the
changes in the barometric pressure which result from
engine load and speed changes, which the BARO
sensor converts to a voltage output.
This sensor generates the voltage to change
corresponding to the flow of the air drawn into the
engine.
The changing voltage is transformed into an electric
signal and provided to the ECM.
With receipt of the signals sent from the BARO sensor,
Intake Air Temperature sensor and others, the ECM
determines an appropriate fuel injection pulse width
feeding such information to the fuel injector valves to
effect an appropriate air/fuel ratio.
The Multiport Fuel Injection system utilizes an injection
system where the injectors turn on at every crankshaf
t
revolution. The ECM controls the injector on time so
that the correct amount of fuel is metered depending on
driving conditions.
Two interchangeable “O" rings are used on the injecto
r
that must be replaced when the injectors are removed.
The fuel rail is attached to the top of the intake manifold
and supplies fuel to all the injectors.
Fuel is recirculated through the rail continually while the
engine is running. This removes air and vapors from the
fuel as well as keeping the fuel cool during hot weathe
r
operation.
The fuel pressure control valve that is mounted on the
fuel rail maintains a pressure differential across the
injectors under all operating conditions. It is
accomplished by controlling the amount of fuel that is
recirculated back to the fuel tank based on engine
demand.
See Section “Driveability and Emission" for more
information and diagnosis.

IGNITION SYSTEM (6VE1 3.5L) 6D2-1
ENGINE
IGNITION SYSTEM (6VE1 3.5L)
CONTENTS

Service Precaution................................................. 6D2-1
General Description............................................... 6D2-2
Diagnosis................................................................. 6D2-2
Ignition Coil.............................................................. 6D2-3
Removal............................................................... 6D2-3
Inspection and Repair........................................ 6D2-3
Installation............................................................ 6D2-3
Spark Plug............................................................... 6D2-4
Inspection............................................................. 6D2-4
Replacement spark plugs................................... 6D2-4
Crankshaft Position Sensor................................... 6D2-5
Removal................................................................ 6D2-5
Installation............................................................. 6D2-5
Main Data and Specifications................................ 6D2-6


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


CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU
will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners or
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.

6D2-2 IGNITION SYSTEM (6VE1 3.5L)
General Description
Ignition is done by the electronic ignition (El) that directly
fires the spark plugs from ignition coils through spark
plug wires without using a distributor. A pair of ignition
coils for the cylinders having different phases by 360

(No.1 and No.4, No.2 and No.5, No.3 and No.6) are
fired simultaneously.
Since the cylinder on exhaust stroke requires less
energy to fire its ignition plug, energy from the ignition
coils can be utilized to fire the mating cylinder on
compression stroke. After additional 360
rotation,
respective cylinder strokes are reversed.
The EI consists of six ignition coils, crankshaft position
sensor, engine control module (ECM) and othe
r
components.
The ignition coils are connected with the ECM.
The ECM turns on/off the primary circuit of ignition coils,
and also it controls the ignition timing.
A notch in the timing disc on the crankshaft activates
the crankshaft position sensor which then sends
information such as firing order and starting timing o
f
each ignition coil to the ECM.
Further, the El employs ignition control (IC) to control
similar to a distributor system.
Diagnosis
Refer to Section Drivability and Emissions for the
diagnosis to electronic ignition system (El system).

IGNITION SYSTEM (6VE1 3.5L) 6D2-5
Crankshaft Position Sensor
Removal
1. Disconnect battery ground cable
2. Wiring connector from crankshaft position sensor.
3. Remove crankshaft position sensor from cylinde
r
block.




012RS008
Installation
1. Install crankshaft position sensor into the cylinder
block.
Before installation, apply small amount of engine
oil to the O–ring.
Torque: 10 N




m (1.0 kg




m/7 lb ft)
2. Reconnect wiring connector to crankshaft position
sensor.

6D2-6 IGNITION SYSTEM (6VE1 3.5L)
Main Data and Specifications
General Specifications

Ignition System
Ignition Form Electronic Ignition System (El system) with Crankshaft position sensor
Spark Plug
Type K16PR-P11
RC10PYP4
RK16PR11
Plug gap 1.0 mm (0.04 in) – 1.1 mm (0.043 in)
Torque 18 N




m (13lb ft)

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.

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-1
ENGINE
3.5L ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS


ABBREVIATION CHARTS ................................ 6E-5
COMPONENT LOCATOR ................................. 6E-6
ENGINE COMPONENT LOCATOR TABLE .. 6E-6
ECM CIRCUIT DIAGRAM ................................. 6E-10
GROUND POINT CHART G.EXP (LHD)
WITHOUT EUROPE, ISRAEL, TURKEY (1/4). 6E-13
GROUND POINT CHART G.EXP (LHD) (2/4) .. 6E-14
GROUND POINT CHART G.EXP (LHD) (3/4) .. 6E-15
GROUND POINT CHART G.EXP (LHD) (4/4) .. 6E-16
GROUND POINT CHART G.EXP (RHD) (1/4) . 6E-17
GROUND POINT CHART G.EXP (RHD) (2/4) . 6E-18
GROUND POINT CHART G.EXP (RHD) (3/4) . 6E-19
GROUND POINT CHART G.EXP (RHD) (4/4) . 6E-20
LOCATION ........................................................ 6E-21
CABLE HARNESS & CONNECTOR
LOCATION ....................................................... 6E-22
CONNECTOR LIST ........................................... 6E-27
RELAY AND FUSE ............................................ 6E-30
RELAY AND FUSE BOX LOCATION
(LHD&RHD) ................................................... 6E-30
RELAY AND FUSE BOX LOCATION
(LHD&RHD) ................................................... 6E-31
FUSE AND RELAY LOCATION
(LHD&RHD) ................................................... 6E-32
ECM WIRING DIAGRAM (1/10) ........................ 6E-33
ECM WIRING DIAGRAM (2/10) ........................ 6E-34
ECM WIRING DIAGRAM (3/10) ........................ 6E-35
ECM WIRING DIAGRAM (4/10) ........................ 6E-36
ECM WIRING DIAGRAM (5/10) ........................ 6E-37
ECM WIRING DIAGRAM (6/10) ........................ 6E-38
ECM WIRING DIAGRAM (7/10) ........................ 6E-39
ECM WIRING DIAGRAM (8/10) ........................ 6E-40
ECM WIRING DIAGRAM (9/10) ........................ 6E-41
ECM WIRING DIAGRAM (10/10) ...................... 6E-42
ECM CONNECTOR PIN ASSIGNMENT
& OUTPUT SIGNAL ......................................... 6E-43
GENERAL DESCRIPTION FOR ECM AND
SENSORS ........................................................ 6E-51

Mass Air Flow (MAF) Sensor & Intake Air
Temperature (IAT) Sensor ............................. 6E-52
Throttle Position Sensor (TPS)....................... 6E-52
Idle Air Control (IAC) Valve ............................ 6E-53
Camshaft Position (CMP) Sensor .................. 6E-53
Crankshaft Position (CKP) Sensor ................. 6E-54
Engine Coolant Temperature (ECT) Sensor .. 6E-54
Vehicle Speed Sensor (VSS) ......................... 6E-55
Heated Oxygen (O
2) Sensor........................... 6E-55
GENERAL DESCRIPTION FOR FUEL
METERING....................................................... 6E-56
GENERAL DESCRIPTION FOR ELECTRONIC
IGNITION SYSTEM IGNITION
COILS & CONTROL ......................................... 6E-58
GENERAL DESCRIPTION FOR EVAPORATIVE
EMISSION SYSTEM ........................................ 6E-61
GENERAL DESCRIPRION FOR EXHAUST
GAS RECIRCULATION (EGR) SYSTEM......... 6E-62
ISUZU STRATEGY BASED DIAGNOSTICS .... 6E-63
Diagnostic Thought Process .......................... 6E-64
1. Verify the Complaint ................................... 6E-64
2. Perform Preliminary Checks....................... 6E-64
3. Check Bulletins and Troubleshooting
Hints ........................................................... 6E-65
4. Perform Service Manual Diagnostic
Checks ....................................................... 6E-65
5a and 5b. Perform Service Manual
Diagnostic Procedures ............................... 6E-65
5c. Technician Self Diagnoses ....................... 6E-65
5d. Intermittent Diagnosis............................ 6E-66
Symptom Simulation Tests.......................... 6E-67
5e. Vehicle Operates as Designed ................. 6E-68
6. Re-Examine the Complaint ........................ 6E-68
7. Repair and Verify Fix .................................. 6E-68
GENERAL SERVICE INFORMATION .............. 6E-69
Aftermarket Electrical and Vacuum
Equipment ..................................................... 6E-69
Electrostatic Discharge Damage .................... 6E-69