battery ISUZU TF SERIES 2004 Workshop Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2004, Model line: TF SERIES, Model: ISUZU TF SERIES 2004Pages: 4264, PDF Size: 72.63 MB
Page 1931 of 4264
ENGINE COOLING (6VE1 3.5L) 6B-7
Water Pump
Water Pump and Associated Parts
030RS002
Legend
(1) Timing Belt (3) Water Pump Assembly
(2) Idle Pulley (4) Gasket
Removal
1. Disconnect battery ground cable.
2. Drain coolant.
3. Radiator hose (on inlet pipe side).
4. Remove timing belt. Refer to “Timing Belt" in this
manual.
5. Remove Idle pulley.
6. Remove water pump assembly.
7. Remove gasket.
Inspection
Make necessary repair and parts replacement if
extreme wear or damage is found during inspection.
Should any of the following problems occur, the entire
water pump assembly must be replaced:
Crack in the water pump body
EC leakage from the seal unit
Play or abnormal noise in the bearing
Cracks or corrosion in the impeller.
Installation
1. Install gasket, clean the mating surface of gasket
before installation.
2. Install water pump assembly and tighten bolts to the
specified torque.
Torque: 25 N
m (2.5 kg
m/18 lb ft)
Tightening order
The tightening order are in the illustrate.
Page 1932 of 4264
6B-8 ENGINE COOLING (6VE1 3.5L)
NOTE: To prevent the oil leakage, apply the LOCTITE
262 or an equivalent, to the arrow marked fixing bol
t
thread.
030RW008
3. Idle pulley
Install idle pulley and tighten bolt to the specified
torque.
Torque: 52 N
m (5.3 kg
m/38 lb ft)
4. Timing belt
Install timing belt. Refer to timing belt installation
step in “Timing Belt" in this manual.
5. Connect radiator inlet hose and replenish EC.
6. Connect battery ground cable.
Page 1933 of 4264
ENGINE COOLING (6VE1 3.5L) 6B-9
Thermostat
Thermostat and Associated Parts
031RW001
Legend
(1) Thermostat Housing
(2) Thermostat
(3) Outlet Pipe
Removal
1. Disconnect battery ground cable.
2. Drain engine coolant from the radiator and engine.
3. Disconnect radiator hose from the inlet pipe.
4. Remove thermostat housing.
5. Remove thermostat(2).
Inspection
Suspend the thermostat in a water–filled container
using thin wire. Place a thermometer next to the
thermostat.
Do not directly heat the thermostat.
Gradually increase the water temperature. Stir the wate
r
so that the entire water is same temperature.
031RS003
Confirm the temperature when the valve first begins to
open.
Valve opening temperature 74.5
C
78.5
C
(166.1
F
173.3
F)
Confirm the temperature when the valve is fully opened.
Valve full open temperature and lift More than
8.5mm (0.33 in) at 90
C (194
F)
Make necessary repair and parts replacement i
f
extreme wear or damage is found during inspection.
Installation
1. Install thermostat into the outlet pipe(4) making sure
that the air hole is in the up position.
2. Install thermostat housing and tighten bolts to the
specified torque.
Torque: 25 N
m (2.5 kg
m/18 lb ft)
3. Installation rubber hose.
4. Replenish engine coolant (EC).
5. Start engine and check for EC leakage.
Page 1935 of 4264
ENGINE COOLING (6VE1 3.5L) 6B-11
Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug to drain EC.
3. Disconnect oil cooler hose on automatic transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose from the engine.
P1010064
5. Remove fan guide(1), clips(2) on both sides and
the bottom lock, then remove lower fan guide(3)
with fan shroud(4).
RTW46BSH000101
6. Disconnect the reserve tank hose(6) from radiator.
7. Remove bracket(5).
110RW004
8. Lift up and remove the radiator assembly with
hose, taking care not to damage the radiator core
with a fan blade.
Inspection
Radiator Cap
Measure the valve opening pressure of the pressurizing
valve with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside
the standard range.
Valve opening pressure kPa (psi) 93.3
122.7
(13.5
17.8)
Cap tester: 5 –8840 –0277 –0
Adapter: 5 –8840 –2603 –0
Check the condition of the vacuum valve in the cente
r
of the valve seat side of the cap. If considerable rust or
dirt is found, or if the valve seat cannot be moved by
hand, clean or replace the cap.
Page 1937 of 4264
ENGINE COOLING (6VE1 3.5L) 6B-13
6. Connect oil cooler hose to automatic transmission.
RTW36BSH000101
7. Connect battery ground cable.
8. Pour engine coolant up to filler neck of radiator, and
up to MAX mark of reserve tank.
RTW36BSH000101
Important operation (in case of 100% engine
coolant change) procedure for filling with engine
coolant.
Engine coolant change
1. To change engine coolant, make sure that the
engine is cool.
WARNING: When the coolant is heated to a high
temperature, be sure not to loosen or remove the
radiator cap. Otherwise you might get scalded by
hot vapor or boiling water. To open the radiato
r
cap, put a piece of thick cloth on the cap and
loosen the cap slowly to reduce the pressure when
the coolant has become cooler.
2. Open radiator cap and drain the cooling system by
loosening the drain valve on the radiator and on the
cylinder body.
NOTE: For best result it is suggested that the engine
cooling system be flushed at least once a year. It is
advisable to flash the interior of the cooling system
including the radiator before using anti-freeze
(ethylene-glycol based).
Replace damaged rubber hoses as the engine
anti-freeze coolant is liable to leak out even mino
r
cracks.
Isuzu recommends to use Isuzu genuine anti-freeze
(ethylen-glycol based) or equivalent, for the cooling
system and not add any inhibitors or additives.
CAUTION: A failure to correctly fill the engine
cooling system in changing or topping up coolant
may sometimes cause the coolant to overflow from
the filler neck even before the engine and radiato
r
are completely full.
If the engine runs under this condition, shortage o
f
coolant may possibly result in engine overheating.
To avoid such trouble, the following precautions
should be taken in filling the system.
3. To refill engine coolant, pour coolant up to filler neck
using a filling hose which is smaller in outside
diameter of the filler neck. Otherwise air between
the filler neck and the filling hose will block entry,
preventing the system from completely filling up.
4. Keep a filling rate of 9 liter/min. or less. Filling ove
r
this maximum rate may force air inside the engine
and radiator.
And also, the coolant overflow will increase, making
it difficult to determine whether or not the system is
completely full.
5.
After filling the system to the full, pull out the filling
hose and check to see if air trapped in the system is
disclodged and the coolant level goes down. Should
the coolant level go down, repeat topping-up until
there is no more drop in the coolant level.
Page 1943 of 4264
ENGINE FUEL (6VE1 3.5L) 6C-1
ENGINE
ENGINE FUEL (6VE1 3.5L)
CONTENTS
Service Precaution................................................. 6C-1
General Description............................................... 6C-2
Fuel Metering.......................................................... 6C-3
Fuel Filter................................................................. 6C-4
Removal............................................................... 6C-4
Inspection............................................................. 6C-4
Installation............................................................ 6C-4
Inspection............................................................. 6C-4
In-Tank Fuel Filter............................................... 6C-4
Fuel Pump Flow Test......................................... 6C-4
Fuel Pump............................................................... 6C-6
Fuel Pump and Associated Parts..................... 6C-6
Removal............................................................... 6C-6
Installation............................................................ 6C-7
Fuel Tube / Quick - Connector Fittings............... 6C-8
Precautions.......................................................... 6C-8
Cautions During Work........................................ 6C-8
Removal................................................................ 6C-8
Reuse of Quick-Connector................................. 6C-9
Assembling Advice.............................................. 6C-9
Fuel Pump Relay..................................................... 6C-10
General Description............................................ 6C-10
Fuel Tank................................................................. 6C-11
Fuel Tank and Associated Parts....................... 6C-11
Removal................................................................ 6C-11
Installation............................................................. 6C-12
Filler Neck................................................................ 6C-13
Removal................................................................ 6C-13
Installation............................................................. 6C-13
Fuel Gauge Unit...................................................... 6C-13
Removal and Installation.................................... 6C-13
Fuel Filler Cap......................................................... 6C-14
General Description............................................ 6C-14
Inspection............................................................. 6C-14
Main Data and Specifications................................ 6C-15
Special Tool.......................................................... 6C-16
Service Precaution
When working on the fuel system, there are several
things to keep in mind:
Any time the fuel system is being worked on,
disconnect the negative battery cable except
for those tests where battery voltage is
required.
Always keep a dry chemical (Class B) fire
extinguisher near the work area.
Replace all pipes with the same pipe and
fittings that were removed.
Clean and inspect “O" rings. Replace i
f
required.
Always relieve the line pressure before
servicing any fuel system components.
Do not attempt repairs on the fuel system until
you have read the instructions and checked
the pictures relating to that repair.
Adhere to all Notices and Cautions.
All gasoline engines are designed to use only
unleaded gasoline. Unleaded gasoline must be
used for proper emission control system operation.
Its use will also minimize spark plug fouling and
extend engine oil life. Using leaded gasoline can
damage the emission control system and could
result in loss of emission warranty coverage.
All cars are equipped with an Evaporative Emission
Control System. The purpose of the system is to
minimize the escape of fuel vapors to the
atmosphere.
Page 1946 of 4264
6C-4 ENGINE FUEL (6VE1 3.5L)
Fuel Filter
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission".
1. Disconnect the battery ground cable.
2. Loosen slowly the fuel filler cap.
NOTE: To prevent spouting out fuel to change the
pressure in the fuel tank.
NOTE: Cover opening of the filler neck to prevent any
dust entering.
3. Disconnect the quick connector into the fuel tube
from the fuel filter.
NOTE: Cover the quick connector to prevent any dus
t
entering and fuel leaking.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in
this section when performing any repairs.
4. Pull off fuel filter from holder to side member side.
Inspection
1. Replace the fuel filter if the fuel leaks from fuel filter
body or if the fuel filter body itself is damaged.
2. Replace the filter if it is clogged with dirt o
r
sediment.
Installation
1. Install the filter to holder from side member side.
NOTE: Attend direction of fuel filter. (1) to engine side
(2) to fuel tank side.
NOTE: Verify to hang holder hook to fuel filter.
NOTE: Verify to hang holder hook to fuel filter.
RTW36CSH000301
2. Connect the quick connector from the fuel tube to
the fuel filter.
NOTE: Pull of the left checker into the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in
this section when performing any repairs.
3. Tighten fuel filler cap until at least one click are
heard.
4. Connect the battery ground cable.
Inspection
After installation, start engine and check for fuel
leakage.
In–Tank Fuel Filter
The filter is located on the lower end of fuel pickup tube
in the fuel tank. It prevents dirt from entering the fuel
pipe and also stops water unless the filter is completely
submerged in the water. It is a selfcleaning type, no
t
requiring scheduled maintenance. Excess water and
sediment in the tank restricts fuel supply to the engine,
resulting in engine stoppage. In such a case, the tank
must be cleaned thoroughly.
Page 1950 of 4264
6C-8 ENGINE FUEL (6VE1 3.5L)
Fuel Tube / Quick – Connector Fittings
Precautions
Do not light a match or create a flame.
Keep flames away from your work area to preven
t
flammable materials from catching fire.
Disconnect battery ground cable to preven
t
electrical shorts.
Pre-treat piping system or associated parts from
thermal damage or from spattering when welding
or similar heat-generating work.
Cautions During Work
140R100032
Legend
(1) O-ring
(2) Port
(3) Connector
(4) Plastic Tube
Do not expose the assembly to battery electrolyte or do
not wipe the assembly with a cloth used to wipe off spil
t
battery electorolyte.
Piping that has been splattered with battery electrolyte
or battery electrolyte soaked cloth that was wiped on the
piping cannot be used.
Removal
1. Open the fuel cap to relieve the fuel pressure in the
tank.
Use compressed air to remove any dirt on the fuel
quick connect fittings prior to disconnecting the
fittings.
141R100002
When disconnecting the fuel pipe, cover the area
with a cloth to prevent fuel from splashing as the
fuel pipe may still have some pressure in it.
2. For removal of the quick connector, hold the quick
connector in one hand, and pull out the connento
r
with the other hand while pressing the square
relieve button of the connector, as illustrated.
140R100037
NOTE: Do not use tools of any kind. Only use bare
hands when disconnecting the connector. Use a
lubricant (light oil) and/or push and pull the connecto
r
until the pipe is disconnected.
Cover the connectors that was removed with a
plastic bag, to prevent dust or rain water from
entering.
Page 1951 of 4264
ENGINE FUEL (6VE1 3.5L) 6C-9
140R100028
Reuse of Quick–Connector
Replace the port and connector if scratch, dent or
crack is found.
Remove any dirt build up on the port when installing
the connector. Replace the connector, if there is any
forms of rust, dent, scratch.
After cleaning the port, insert it straight into the
connector until it clicks. After it clicks, try pulling a
t
49N (5kgf) it out to make sure that it is not drawn
and is securely locked.
140R100036
Assembling Advice
By applying engine oil or light oil to the pipe, port makes
pipe assembly easier. The pipe assembly should take
place immediately after applying oil (to prevent dus
t
from sticking to the pipe surface –which may
decrease sealing ability).
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Turn the ignition key to the “ON" position and listen
for pump start-up sound. Inspect for leaks, the
fuel pressure will increase as the fuel pump is
actuated.
3. Perform leak inspection (step 2) several times.
4. Start the engine and observe the engine idle speed.
The presence of dirt in the fuel system may affec
t
the fuel injection system.
Page 1954 of 4264
6C-12 ENGINE FUEL (6VE1 3.5L)
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission".
1. Disconnect battery ground cable.
2. Loosen slowly the fuel filler cap.
NOTE: To prevent spouting out fuel to change the
pressure in the fuel tank.
NOTE: Cover opening of the filler neck to prevent any
dust entering.
3. Jack up the vehicle.
4. Support underneath of the fuel tank with a lifter.
5. Remove the inner liner of the wheel house on rea
r
left side.
6. Remove fasten bolt to the filler neck from the
body.
7. Disconnect the quick connector (8) into the fuel
tube from the fuel pipe and the evapo tube from
evapo joint connector.
NOTE: Cover the quick connector to prevent any dus
t
entering and fuel leaking.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in
this section when performing any repairs.
8. Remove fasten bolt (1) to the tank band and the
tank band (2).
9. Disconnect the pump and sender connector on the
fuel pump and remove the harness from weld clip
on the fuel tank.
10. Lower the fuel tank (6).
NOTE: When the fuel tank is lowered from the vehicle,
don’t scratch each hose and tube by around other pars.
Installation
1. Rise the fuel tank into position.
NOTE: Ensure hoses and tubes do not foul on othe
r
component.
2. Connect the pump and sender connector to the
fuel pump and install harness to into the plastic clip
welded to the top of the fuel tank..
NOTE: The connector must be certainly connected
against stopper.
Ensure tank band anchor mates with guide hole on
frame.
3. Install the tank band to fasten bolt.
Torque: 68 N
m (6.9kg
m/50 lb ft)
NOTE: The anchor of the tank band must be certainly
installed to guide hole on frame.
4. Connect the quick connector from the fuel tube to
the fuel pipe and the evapo tube from evapo join
t
connector.
NOTE: Pull off the left checker into the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in
this section when performing any repairs.
5. Install the filler neck to the body by bolt.
6. Install the inner liner of the wheel house on rea
r
side.
7. Remove lifter to support underneath of the fuel
tank.
8. Put back the vehicle.
9. Tigten the filler cap until at least three clicks are
heard.
10. Connect the battery ground cable.