ISUZU TF SERIES 2004 Workshop Manual

ENGINE MECHANICAL (6VE1 3.5L) 6A-97
Connecting rod and Water pump
N
 m (kg
 m/ lb ft)




E06RW042

6A-98 ENGINE MECHANICAL (6VE1 3.5L)
Engine mount
N
 m (kg
 m/ lb ft)








RTW36ALF000101

ENGINE MECHANICAL (6VE1 3.5L) 6A-99
Special Tool
ILLUSTRATION PART NO.
PART NAME
ILLUSTRATION PART NO.
PART NAME

5-8840-0011-0
(J-21687-02)
Remover; tie rod end 5-8840-2445-0
(J-42985)
Installer; Camshaft
oil seal

5-8840-0203-0
(J-36390)
Wrench; Oil filter (79) 5-8840-2545-0
(J-39206)
Installer; Pilot bearing

5-8840-2446-0
(J-8062)
Compressor;
Valve spring (1)
5-8840-2547-0
(J-42898)
Adapter; Compressor,
Valve spring (2) 5-8840-0133-0
(J-8614-01)
Holder; Crankshaft

5-8840-0623-0
(J-37281)
Remover; Oil controller 5-8840-2153-0
(J-37228)
Seal cutter

5-8840-0624-0
(J-38537)
Installer; Oil controller 5-8840-2286-0
(J-39201)
Installer; Real oil seal

5-8840-2005-0
(J-29107)
Universal pitman arm
remover 5-8840-2287-0
(J-39202)
Installer; Oil pump
oil seal

6A-100 ENGINE MECHANICAL (6VE1 3.5L)

ILLUSTRATION PART NO.
PART NAME


9-8511-4209-0
(J-24239-1)
Cylinder head bolt wrench





5-8840-2442-0
(J-42899)
Replacer; Valve guide (1,2)
5-8840-2548-0
(J-42687)
Installer; Valve guide (1)
5-8840-2549-0
(J-37985-1)
Remover; Valve guide (2)




5-8840-2444-0
(J-42689)
Adjusting Tool; Valve
clearance




5-8840-2443-0
(J-42686)
Lever; Gear spring




5-8840-2447-1
(J-43041)
Holder; Universal

ENGINE COOLING (6VE1 3.5L) 6B-1
ENGINE
ENGINE COOLING (6VE1 3.5L)
CONTENTS

Service Precaution............................................. 6B–1
General Description ........................................... 6B–2
Diagnosis ........................................................... 6B–5
Draining and Refilling Cooling System .............. 6B–6
Water Pump ...................................................... 6B–7
Water Pump and Associated Parts ................ 6B–7
Removal ......................................................... 6B–7
Inspection ....................................................... 6B–7
Installation....................................................... 6B–7
Thermostat ........................................................ 6B–9
Thermostat and Associated Parts .................. 6B–9
Removal ......................................................... 6B–9
Inspection ....................................................... 6B–9

Installation ...................................................... 6B–9
Radiator ............................................................. 6B–10
Radiator and Associated Parts ....................... 6B–10
Removal ......................................................... 6B–11
Inspection ....................................................... 6B–11
Installation ...................................................... 6B–12
Drive Belt and Cooling Fan ................................ 6B–15
Drive Belt and Associated Parts ..................... 6B–15
Inspection ....................................................... 6B–15
Installation ...................................................... 6B–15
Main Data and Specifications ............................ 6B–16
Special Tool .................................................... 6B–18


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.

6B-2 ENGINE COOLING (6VE1 3.5L)
General Description



030RW001
Legend (7)Cylinder Head
(1) Water Pump (8) Right Bank
(2) Thermostat (9) Throttle Body
(3) Radiator (10) Cylinder Block
(4) Reserve Tank (11) Cylinder Head
(5) Cooling Fan (12) Left Bank
(6) Cylinder Block (13) Heater


The engine cooling system consists of the radiator, the
water pump, the cooling fan, and the thermostat.
To quickly increase cold engine coolant temperature fo
r
smooth engine operation, the coolant is circulated by
the water pump and thermostat through the bypass
hose and back to the cylinder body.
The coolant does not circulate through the radiator.
When the coolant temperature reaches specified value,
the thermostat will begin to open and a gradually
increasing amount of coolant will circulate through the
radiator.
The thermostat will be fully open when the coolan
t
temperature reaches specified value. All of the coolant
is now circulating through the radiator for effective
engine cooling.

ENGINE COOLING (6VE1 3.5L) 6B-3
Water Pump
The EC pump is a centrifugal impeller type and is driven
by a timing belt.


030RS001
Thermostat
The thermostat is a wax pellet type with a air hole(1)
and is installed in the thermostat housing.


031RW002
Radiator
The radiator is a tube type with corrugated fins. In order
to raise the boiling point of the coolant, the radiator is
fitted with a cap in which the valve is operated at 93.3


122.7 kPa (13.5
17.8 psi) pressure. (No oil cooler
provided for M/T)


110RS001
Antifreeze Solution
 Calculating mixing ratio






F06RW005

6B-4 ENGINE COOLING (6VE1 3.5L)
NOTE: Antifreeze solution + Water = Total cooling
system capacity.
Total Cooling System Capacity
M/T 12.3Lit (13.0Us qt)
A/T 12.2Lit (12.9Us qt)

See section 0B MAINTENACE AND LUBRICATION.

Mixing ratio
NOTE: To maintain the corrosion resistance of the
aluminum radiator, water and antifreeze must be
combined in a 1:1 solution (50% antifreeze and 50%
water).



RTW46BSH000201

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

6B-6 ENGINE COOLING (6VE1 3.5L)
Draining and Refilling Cooling
System
Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order.
The engine coolant (EC) level should be between the
“ MIN" and “MAX" lines of reserve tank when the engine
is cold. If low, check for leakage and add EC up to the
“ MAX" line.
There should not be any excessive deposit of rust o
r
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening the
drain plug at the bottom of the radiator.




P1010064
2. Remove the radiator cap.
WARNING: To avoid the danger of being burned, do
not remove the cap while the engine and radiato
r
are still hot. Scalding fluid and steam can be blown
out under pressure.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water, then
drain it. Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a
solution that is 50 percent antifreeze.
Procedure for filling with coolant (in case of full change)
 Make sure that the engine is cool.
 Open radiator cap pour coolant up to filler neck.
 Pour coolant into reservoir tank up to “MAX" line.

 Tighten radiator cap and start the engine. Afte
r
idling for 2 to 3 minutes, stop the engine and reopen
radiator cap. If the water level is lower, replenish.
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
not 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.

After tightening radiator cap, warm up the engine at
about 2000 rpm. Set heater adjustment to the
highest temperature position, and let the coolan
t
circulate also into heater water system.
 Check to see the thermostat has opened through
the needle position of water thermometer, conduct a
5 –minute idling again and stop the engine.
 When the engine has been cooled, check filler neck
for water level and replenish if required. Should
extreme shortage of coolant is found, check the
cooling system and reservoir tank hose for leakage.
 Pour coolant into the reservoir tank up to “MAX"
line.