torque ISUZU TF SERIES 2004 Workshop Manual

6D – 30 ENGINE ELECTRICAL


RTW46DSH005601
Important Operations
1. Magnetic Switch Assembly
1. Attach the torsion spring to the hole in the magnetic
switch as illustrated.
2. Insert the shift lever into the plunger hole of the
magnetic switch.




RTW46DSH005701











7. Gear Case
3,8. Dust Cover
1. Install the magnetic switch assembly in the gear case.
2. Install the dust cover.

Dust Cover Bolt Torque Nm (kgm/lbft)
8 (0.8/5.4)



10. Pinion Assembly
Apply a coat of grease to the reduction gear and install the
pinion assembly to the armature shaft.
065RY00041



RTW46DSH004501
21. Brush Holders
1. Install the brushes into the brush holder with raising
the spring end of the brush spring.
Take care not to damage the commutator face.
2. Install the brush holder with aligning the peripheries of
the yoke and the brush holder.

ENGINE ELECTRICAL 6D – 31






24. Through Bolt
Install the through bolts in the rear cover and tighten them
to the specified torque.
Through Bolt Torque Nm (kgm/lbft)
8.1 (0.83/6.00)

065RY00044


RTW46DSH002601






25. Lead Wire
Connect the lead wire in the magnetic switch and tighten
the terminal nut to the specified torque.
Lead Wire Terminal Nut Torque Nm (kgm/lbft)
8.6 (0.88/6.40)







RTW46DSH005801












Inspection After Assembly
Use a vernier caliper to measure the pinion shaft thrust
play.
The pinion shaft thrust play is equal to the pinion shaft end
and pinion stopper clearance.
Pinion Shaft Thrust Play mm (in)
0.1 – 2.0 (0.004 – 0.078)

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–383
HESITATION, SAG, STUMBLE SYMPTOM
DEFINITIONS: Momentary lack of response as the
accelerator is pushed down. Can occur at any vehicle
speed. Usually most pronounced when first trying to
make the vehicle move, as from a stop sign. May cause
the engine to stall if severe enough.
time rpm
Sug
Hesitation Stumble
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2Go to On Board
Diagnostic
(OBD) System
Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom?—Verify repair Go to Step 3
3 Was a visually/physical check performed?
—Go to Step 4Go to Visual /
physical Check
4 Is the customer using the incorrect fuel type? Diesel fuel
onlyReplace with
diesel fuel Go to Step 5
5 Check the torque converter clutch (TCC) for proper
operation (if A/T model). If a problem is found, repair
as necessary.
Was a problem found?—Verify repair Go to Step 6
6 Visually/physically inspect for the following conditions.
Restrict air intake system. Check for a restricted air
filter element, or foreign objects blocking the air
intake system
Check for objects blocking or ex cessive deposits in
the throttle bore and on the throttle plate
Check for a condition that causes a large vacuum
leak, such as an incorrectly installed or faulty
crankcase ventilation hose.
Restrict air intake system at the turbocharger.
Check for objects blocking the turbocharger
compressor wheel or turbine shaft sticking.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 7
7 Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
Was a problem found?—Verify repair Go to Step 8

6E–402 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
POOR FUEL ECONOMY SYMPTOM
DEFINITIONS: Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, economy
is noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test. (Larger than
standard tires will cause odometer readings to be incorrect, and that may cause fuel economy to appear poor when it
is actually normal.)
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2Go to On Board
Diagnostic
(OBD) System
Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom?—Verify repair Go to Step 3
3 Was a visually/physical check performed?
—Go to Step 4Go to Visual /
physical Check
4 Check owner's driving habits.
Is the A/C “On” full time?
Are tires at the correct pressure?
Are ex cessively heavy loads being carried?
Is acceleration too much, too often?—Go to Step 5Go to Step 6
5 Review the items in Step 4 with the customer and
advise as necessary.
Is the action complete?—System OK—
6 Check for low engine coolant level.
Was a problem found? —Verify repair Go to Step 7
7 Check for incorrect or faulty engine thermostat. Refer
to Engine Cooling.
Was a problem found?—Verify repair Go to Step 8
8 Check for proper calibration of the speedometer.
Does the speed indicated on the speed meter closely
match the vehicle speed displayed on the Tech 2?—Go to Step 10Go to Step 9
9 Diagnose and repair the inaccurate speedometer
condition as necessary. Refer to Vehicle Speed
Sensor in Electrical Diagnosis.—Veri fy repai r—
10 Check for proper calibration of the fuel gauge.
Was a problem found? —Verify repair Go to Step 11
11 Check the torque converter clutch (TCC) for proper
operation (if A/T model). If a problem is found, repair
as necessary.
Was a problem found?—Verify repair Go to Step 12
12 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Neutral Switch” in the data display.
Does the Tech 2 indicate correct “Neutral Switch”
status depending on any shift positions?
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 13

6E–418 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
ON-VEHICLE SERVICE PROCEDURE
ENGINE CONTROL MODULE
(ECM)
Location
Under the left-hand side seat.
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the seat left-hand side.
3. Roll up the floor carpet.
4. Remove four bolts from the ECM cover.
5. Disconnect the two connectors from the ECM.
Installation Procedure
1. Connect the two connectors to the ECM.
2. Put on the ECM to the floor panel.
3. Tighten the ECM cover by four bolts with specifiedtightening torque.
Tightening torque
Bolts: 8.0 - 12.0 N·m (0.8 - 1.2 kgf·m)
4. Lay the floor carpet ex actly.
5. Put on the seat to the floor panel and tighten with
specified tightening torque.
Tightening torque
Bolts: 40.0 N·m (4.1 kgf·m)
6. Connect the negative battery cable.
NOTE: The replacement ECM must be programmed.
Refer to section of the Service Programming System
(SPS) in this manual.
Following ECM programming, the immobilizer system (if
equipped) must be linked to the ECM. Refer to section
11 “Immobilizer System-ECM replacement” for the
ECM/Immobilizer linking procedure.

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–419
CRANKSHAFT POSITION (CKP)
SENSOR
Location
Installed to the clutch housing.
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect connector from the CKP sensor.
3. Loosen a bolt and remove the CKP sensor from the
clutch housing.
Installation Procedure
1. Install the CKP sensor to the clutch housing.
2. Tighten CKP sensor by a bolt with specified
tightening torque.
Tightening Torque
Bolts: 8.0 - 12.0 N·m (0.8 - 1.2 kgf·m)
3. Connect a CKP sensor connector to the CKP
sensor.
4. Connect the negative battery cable.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.
ENGINE COOLANT TEMPERATURE
(ECT) SENSOR
Location
Installed to the thermostat housing.
Removal Procedure
1. Disconnect the negative battery cable.
2. Drain enough engine coolant so that the coolant
level will be below the ECT sensor.
3. Disconnect connector from the ECT sensor.
4. Loosen and remove the ECT sensor from the
thermostat housing.
NOTE: Cool down the engine before above procedures
are carried out.
Installation Procedure
1. Apply sealer to threads of screw at the ECT sensor.
2. Tighten the ECT sensor with specified tightening
torque.
Tightening Torque
Bolt: 13N·m (1.3kgf·m)
3. Connect a ECT sensor connector to the ECT
sensor.
4. Fill the engine coolant.
5. Connect the negative battery cable.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.
Verify no engine coolant leaking from the sensor
threads after replacement.

EXHAUST SYSTEM 6F – 5




































Important Operations – Installation
Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention to
the important points during the installation procedure.

1. Front Pipe Nut
Connect the exhaust pipe to the catalytic converter.
Torque N
m (kg
m/lb
ft)
67 (6.8/49)

2. Middle pipe Nut (4




4 only)
Connect the middle pipe to the front pipe.
Torque N
m (kg
m/lb
ft)
43 (4.4/32)

3. Silencer Front Nut
Connect the silencer to the front or middle pipe.
Torque N
m (kg
m/lb
ft)
43 (4.4/32)

6F – 14 EXHAUST SYSTEM
Installation
1. EGR Cooler Adapter
2. Gasket
3. EGR Cooler Assembly
4. Bolt
Tighten the bolts to the specified torque.
EGR adapter bolt torque N
m(kg
m/lb ft)
27(2.8/20)
5. Gasket
6. EGR Pipe Assembly
7. Bolt
Tighten bolts temporarily.
8. Bolt
Tighten bolts temporarily.
9. Gasket
10. Bolt
Tighten bolts temporarily.
11.Gasket
12.Bolt
Tighten bolts temporarily.
Finally tighten all bolts to the specified torque.
Confirm that there is no misalignment on the sealing
surface.
Bolt torque (Cooler-pipe) N
m(kg
m/lb ft)
27(2.8/20)
Bolt torque (Cooler-bracket) N
m (kg
m/lb ft)
24(2.4/17)
Bolt torque (Adapter-EGR valve) N
m (kg
m/lb ft)
27(2.8/20)
Bolt torque (Pipe-manifold) N
m (kg
m/lb ft)
27(2.8/20)

6A-2 ENGINE MECHANICAL (6VE1 3.5L)
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
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 o
r
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.

ENGINE MECHANICAL (6VE1 3.5L) 6A-5
3. Trouble In Fuel System
Symptom Possible Cause Action
Starting motor turns over and spark
occurs but engine does not start. Fuel tank empty Fill
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
circuit clogged Correct or replace
Multiport Fuel Injection System faultyRefer to “Electronic Fuel Injection"
section

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.
9. Repeat the test with each cylinder.
If the compression pressure obtained falls belo
w
the limit, engine overhaul is necessary.
Limit; 1000 kPa (145 psi)