air condition 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 1853 of 4264
ENGINE MECHANICAL (6VE1 3.5L) 6A-29
Timing Belt
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.
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
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
5884001330 crankshaft holder, hold crankshaf
t
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 13. Remove pusher.
CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.
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.
Page 1857 of 4264
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.
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
9. Install radiator upper fan shroud.
10. Install air cleaner assembly.
Page 1873 of 4264
ENGINE MECHANICAL (6VE1 3.5L) 6A-49
Engine Assembly
Removal
P1010068
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
t
front side of engine compartment), disconnect shift
on the fly harness connector from front side o
f
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
t
bank.
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.
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
f
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.
Page 1874 of 4264
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.
Page 1877 of 4264
ENGINE MECHANICAL (6VE1 3.5L) 6A-53
Disassembly
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
t
bracket (6), then camshaft exhaust (7), and intake
side (8).
3. Remove tappet with shim (11).
4. Use the 5884024460 valve spring compresso
r
and 5884025470 valve spring compressor
adapter to remove the split collar (12), valve spring
with upper seat (13) and valve (14).
014RW042
5. Remove spark plug (1).
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.
Inspection and Repair
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
f
the surfaces are “out of flat" by more than
specification, the surface should be ground to
within specifications. Replace the head if i
t
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)
011RW019
Page 1904 of 4264
6A-80 ENGINE MECHANICAL (6VE1 3.5L)
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.
015RS031
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.
015RS022
10. Remove the piston pin (9) using 5884005510
piston pin service set and piston support with a
press.
NOTE: Keep the parts removed from each cylinde
r
separate. All parts must be reinstalled in their original
positions. Heating the connecting rod will permit easy
removal of the piston pin.
015RX001
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
11. Piston (10)
12. Connecting rod (11)
Inspection and Repair
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
r
cracking, scoring, and other signs of excessive wear. If
any of the above conditions are found, the piston must
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)
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 1939 of 4264
ENGINE COOLING (6VE1 3.5L) 6B-15
Drive Belt and Cooling Fan
Drive Belt and Associated Parts
015RW005
Legend (4) Water Pump and Cooling Fan Pulley
(1) Crankshaft Pulley (5) Idle Pulley
(2) Generator (6) Tension Pulley
(3) Power Steering Pump (7) Drive Belt
The drive belt adjustment is not required as automatic
drive belt tensioner is equipped.
Inspection
Check drive belt for wear or damage, and replace with a
new one as necessary.
Installation
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.
NOTE: Fan belts for 6VE1 Gasoline Engine mounted on
98MY (UX) have been brought into one. As a result, the
rotating direction of a fan belt is opposite to the direction
of cooling fan for 92 to 97MY 6VD1 with no
interchangeability.
Therefore, incorrect installation of a fan may cause the
air for cooling to flow in the opposite direction, this
resulting in the poor performance of the air-conditione
r
and a rise temperature in engine cooling water.
Page 1945 of 4264
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.
Page 1962 of 4264
6D1-4 ENGINE ELECTRICAL (6VE1 3.5L)
Jump Starting Procedure
1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission, place the selector level in the “PARK"
position.
If the vehicle is equipped with a manual
transmission, place the shift lever in the
“ NEUTRAL" position.
Turn “OFF" the ignition.
Turn “OFF" all lights and any other accessory
requiring electrical power.
2. Look at the built –in hydrometer.
If the indication area of the built –in hydrometer is
completely clear, do not try to jump start.
3.
Attach the end of one jumper cable to the positive
terminal of the booster battery.
Attach the other end of the same cable to the
positive terminal of the discharged battery.
Do not allow the vehicles to touch each other. This
will cause a ground connection, effectively
neutralizing the charging procedure.
Be sure that the booster battery has a 12 volt rating.
4. Attach one end of the remaining cable to the
negative terminal of the booster battery.
Attach the other end of the same cable to a solid
engine ground (such as the air conditioning
compressor bracket or the generator mounting
bracket) of the vehicle with the discharged battery.
The ground connection must be at least 450 mm
(18 in.) from the battery of the vehicle whose battery
is being charged.
WARNING: NEVER ATTACH THE END OF THE
JUMPER CABLE DIRECTLY TO THE NEGATIVE
TERMINAL OF THE DEAD BATTERY.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical
accessories have been turned “OFF".
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above directions in reverse order.
Be sure to first disconnect the negative cable from
the vehicle with the discharged battery.
Battery Removal
P1010001
1. Remove negative cable.
2. Remove positive cable (2).
3. Remove retainer screw and rods.
4. Remove retainer.
5. Remove battery.
Battery Installation
1. Install battery.
2. Install retainer.
3. Install retainer screw and rods.
NOTE: Make sure that the rod is hooked on the body
side.
4. Install positive cable.
5. Install negative cable.