battery ISUZU TF SERIES 2004 Workshop Manual

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-369
CRANKSHAFT POSITION (CKP)
SENSOR

Location
Right-hand side of the cylinder block.

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 cylinder block.
NOTE:
Use caution to avoid any hot oil that might drip out.




Installation Procedure
1. Install the CKP sensor to the cylinder block.
Before installation, apply small amount of engine
oil to the O-ring.
2. Tighten CKP sensor by a bolt with specified
tightening torque.
Tightening Torque





Bolt: 10N




m (1.0kgf




m).
3. Connect a sensor connector to the CKP sensor.
4. Connect the negative battery cable.

NOTE:
Verify any DTCs (diagnosis Trouble Code) are not
stored after replacement.

CAMSHAFT POSITION (CMP)
SENSOR

Location
The rear of right bank of the cylinder head.

Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect connector from the CMP sensor.
3. Loosen a bolt and remove the CMP sensor from
the cylinder head.





Installation Procedure
1. Install the CMP sensor to the cylinder head.
Before installation, apply small amount of engine
oil to the O-ring.
2. Tighten CMP sensor by a bolt with specified
tightening torque.
Tightening Torque





Bolt: 10N




m (1.0kgf




m)
3. Connect a sensor connector to the CMP sensor.
4. Connect the negative battery cable.

NOTE:
Verify any DTCs (diagnosis Trouble Code) are not
stored after replacement.

6E-370 3.5L ENGINE DRIVEABILITY AND EMISSIONS
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 coolan
t
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





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 senso
r
threads after replacement.


MASS AIR FLOW (MAF) SENSOR &
INTAKE AIR TEMPERATURE (IAT)
SENSOR
Location
Installed to the intake duct housing.

Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect a MAF & IAT sensor connector from
the MAF & IAT sensor.
3. Loosen two screws and remove the MAF & IAT
sensor from the intake duct.





Installation Procedure
1. Install the MAF & IAT sensor into intake air duct.
2. Tighten MAF & IAT sensor by two screws.
Tightening Torque : 1.5 N




m (0.15 kgf




m)
3. Connect a sensor connector to the MAF & IAT
sensor.
4. Connect the negative battery cable.

NOTE:
Verify any DTCs (diagnosis Trouble Code) are not
stored after replacement.

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-371
THROTTLE POSITION SENSOR
(TPS)

Location
Installed on the throttle body.

Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the TPS connector.
3. Loosen two screws and remove TPS from the
throttle body.




Installation Procedure
1. Temporary tighten the TPS by two screws.
2. Connect a TPS connectors to the TPS.
3. Connect the Tech2 to the vehicle.
4. Connect the negative battery cable.
5. Select "Data Display" with the Tech2.
6. Check the throttle position data and adjust the TPS
position.
7. Tighten two screws.

NOTE:
Verify any DTCs (diagnosis Trouble Code) are not
stored after replacement.



IDLE AIR CONTROL (IAC) VALVE

Location
Installed on the throttle body.

Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the IAC valve connector.
3. Loosen two screws and remove IAC valve from
the throttle body.




Cleaning and Inspection
1. Clean the IAC valve O-ring sealing surface, pintle
valve seat and air passage.
2. Use carburetor cleaner and a parts cleaning brush
to remove carbon deposit.
Do not use a cleaner that contain methyl ethyl
ketone. This is an extremely strong solvent and no
t
necessary for this type of deposit.
3. Shiny spots on the pintle are normal and do no
t
indicate misalignment or a bent pintle shaft.
4. Inspect the IAC valve O-ring for cuts, cracks o
r
distortion.

6E-372 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Measurement
In order to install a new IAC valve, messier the distance
between the tip of the pintle and the mounting flange. I
f
that measurement is 28mm (1.1in.) or less, the valve
need no adjustment. If the measurement is greater than
28mm (1.1in.), apply finger pressure and retract the
valve. The force required to retract the pintle on a ne
w
valve will not damage the valve, shaft, or pintle.




28mm(1.1in.)
or less


Installation Procedure
1. Tighten the IAC valve by two screws.
2. Connect a IAC valve connector to the IAC valve.
3. Connect the negative battery cable.

NOTE:
Verify any DTCs (diagnosis Trouble Code) are not
stored after replacement.


HEATED OXYGEN SENSOR (HO2S)

Location
Installed on the exhaust pipe for each bank.

Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the O2 sensor connector.
3. Loosen and remove the O2 sensor from the
exhaust pipe.



Bank 1 Heated Oxygen Sensor (Right bank)



Bank 2 Heated Oxygen Sensor (Left bank)

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-373
Inspection
 Inspect the louvered end of the sensor for grease,
dirt, excessive carbon build up or othe
r
contamination.
 A special anti-seize compound is used on the O2
sensor threads. This compound consists of glass
breads suspended in a liquid graphite solution.
The graphite burns away with engine heat, but the
glass breads will remain, marking the senso
r
easier to remove.
 New or service sensors will already have the
compound applied to the threads. If a sensor is
removed and is to be reinstalled for any reason,
the threads must have anti-seize compound
applied.


Installation Procedure
1. Install the O2 sensor to the exhaust pipe.
Apply anti-seize compound or the equivalent to the
threads of the oxygen sensor, if necessary.
2. Tighten the O2 sensor with specified tightening
torque.
Tightening Torque





Bolt: 42N




m (4.3kgf




m)
3. Connect a sensor connector to the O2 sensor.
4. Connect the negative battery cable.

NOTE:
Verify any DTCs (diagnosis Trouble Code) are not
stored after replacement.
Verify no exhaust gas leaking from the senso
r
threads after replacement.



EVAP CANISTER PURGE VALVE
SOLENOID

Location
On the intake manifold.

Removal Procedure
1. Disconenct the negative battery cable.
2. Disconnect a purge solenoid connector from the
purge solenoid.
3. Disconnect two hoses from the purge solenoid
valve.
4. Loosen a bolt and remove the purge solenoid from
the intake manifold.






Installation Procedure
1. Put on the purge solenoid on the intake manifold.
2. Tighten the purge solenoid by a bolt.
3. Connect a connector to the purge solenoid.
4. Connect two hoses to the purge solenoid valve.
5. Connect the negative battery cable.

NOTE:
Verify any DTCs (diagnosis Trouble Code) are not
stored after replacement.
Verify proper connection of two hoses.

6E-374 3.5L ENGINE DRIVEABILITY AND EMISSIONS
FUEL PRESSURE RELIEF
Caution:
To reduce the risk of the fire and personal injury, it
is necessary to relive the fuel system pressure
before servicing the fuel system components.
Caution:
After relieving the fuel system pressure, a small
amount of fuel may be released when servicing fuel
lines or connections. Reduce the chance o
f
personal injury by covering the fuel line fitting with
a short towel before disconnecting the fittings. The
towel will absorb any fuel that may leak out. When
the disconnect is completed, place the towel in an
approved container.

1. Remove the fuel filler cap.
2. Remove the fuel pump relay.
3. Start the engine and allow it to stall.
4. Crank the engine for about 30 seconds.
5. Disconnect the negative battery cable.



FUEL RAIL ASSEMBLY

Removal Procedure
NOTE:
 Do not attempt to remove the fuel inlet fitting on
the fuel rail. It is staked in place. Removing the
fuel inlet fitting will result in damage to the fuel
rail or the internal O-ring seal.
 Use care when removing the fuel rail assembly in
order to prevent damage to the injector electrical
connector terminals and the injector spray tips.
 Fittings should be capped and holes plugged
during servicing to prevent dirt and othe
r
contaminants from entering open lines and
passages.
Important: Before removal, the fuel rail assembly may
be cleaned with a spray type engine cleaner. Follow the
spray package instructions. Do not immerse the fuel
rails in liquid cleaning solvent.
1. Depressurize the fuel system. Refer to Fuel
Pressure Relief Procedure in this Section.
2. Disconnect the negative battery cable.
3. Remove the engine cover.
4. Disconnect the accelerator pedal cable from throttle
body and cable bracket.

5. Disconnect the connectors from, solenoid valve,
sensing valve.
6. Disconnect the vacuum hose on canister solenoid
and positive crankcase ventilation hose.
7. Remove the common chamber Refer to the
common chamber in Engine Mechanical.
1. Lift up carefully on the fuel injectors. Do no
t
separate the fuel injectors from the fuel rail.
2. If an injector becomes separated from the fuel
rail, the infector O-ring seals and the retaine
r
clip must be replaced.
3. Drain residual fuel into an approved container.




060RW044
8. If removal of the fuel pressure regulator is
necessary, refer to Fuel Pressure Regulator.
9. If removal of the fuel injectors is necessary, refer to
Fuel Injectors.

Installation Procedure
1. If the fuel injectors were removed, install them.
Refer to Fuel Injectors.
2. If the fuel pressure regulator was removed, install
it. Refer to Fuel Pressure Regulator.

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-375
3. Install the common chamber. Refer to common
chamber in engine Mechanical.




060RW044
4. Connect the vacuum hose on Canister Solenoid
and positive crankcase ventilation hose.
5. Connect the connectors to, solenoid valve.
6. Connect the accelerator pedal cable to throttle
body and cable bracket.
7. Install the engine cover.
8. Connect the negative battery cable.
9. Crank the engine until it starts. Cranking the
engine may take longer than usual due to trapped
air in the fuel rail and in the injectors.

FUEL INJECTORS

Removal Procedure
NOTE: If the fuel injectors are leaking, the engine oil
may be contaminated with fuel. Check the oil fo
r
signs of contamination and change the oil and the
filter if necessary.
NOTE: Use care in removing the fuel injectors in
order to prevent damage to the fuel injecto
r
electrical connector pins or the fuel injector
nozzles. The fuel injector is an electrical component
and should not be immersed in any type of cleane
r
as this may damage the fuel injector.
Important: Fuel injectors are serviced as a complete
assembly only.
1. Disconnect the negative battery cable.
2. Remove the upper intake manifold. Refer to
Common Chamber in Engine Mechanical..
3. Remove the fuel rail. Refer to Fuel Rail.




060RW044

6E-376 3.5L ENGINE DRIVEABILITY AND EMISSIONS
4. Remove the injector retainer clip.






F06RW017
5. Remove the fuel injector assembly.
6. Remove the O-ring from the fuel injector.
7. Remove the O-ring backup from the fuel injector .

Inspection Procedure
1. Inspect the O-rings for cracks or leaks.
2. Replace worn or damaged O-rings.
3. Lubricate the new O-rings with engine oil before
installation.

Installation Procedure
1. Install the O-ring backup on the fuel injector.
2. Install the new O-ring on the fuel injector.
3. Install the fuel injector on the fuel rail.






F06RW017

4. Use new fuel injector retainer clips to retain the fuel
injector to the fuel rail.
5. Coat the end of the fuel injector with engine oil.
6. Install the fuel rail. Refer to Fuel Rail.




060RW044
7. Install the upper intake manifold. Refer to Common
Chamber in Engine Mechanical.
8. Install the engine cover.
9. Connect the negative battery cable.

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-377
FUEL PRESSURE REGULATOR

Removal Procedure
CAUTION: To reduce the risk of fire and personal
injury, it is necessary to relieve the fuel system
pressure before servicing the fuel system
components.
CAUTION: After relieving the system pressure, a
small amount of fuel may be released when
servicing fuel lines or connections. Reduce the
chance of personal injury by covering the fuel line
fittings with a shop towel before disconnecting the
fittings. The towels will absorb any fuel that may
leak out. When the disconnect is completed, place
the towel in an approved container.
NOTE: Compressed air must never be used to test
or clean a fuel pressure regulator, as damage to the
fuel pressure regulator may result.
NOTE: To prevent damage to the fuel pressure
regulator, do not immerse the pressure regulator in
solvent.
1. Depressurize the fuel system. Refer to Fue
l
Pressure Relief Procedure.
2. Disconnect the negative battery cable.
3. Remove the fuel pump relay. Refer to Fuel Pump
Relay.
4. Remove the pressure regulator hose from the fuel
pressure regulator.
5. Remove the two bolts from the protector tha
t
secures the common chamber.



060RW066

6. Remove the fuel pressure regulator attaching
screw.




060RW116
7. Remove the fuel pressure regulator from the fuel
rail.

Disassembly Procedure
1. Remove the O-ring from the fuel pressure regulator.
2. Remove the fuel return line from the fuel pressure
regulator.
3. Remove the O-ring from the fuel return line.
 The O-ring may be left inside the fuel pressure
regulator instead of on the fuel return line.




060RW116

6E-378 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Assembly Procedure
1. Install a new O-ring on the fuel return line.
2. Install the fuel return line on the fuel pressure
regulator.
Do not over-tighten the swivel nut on the fuel pressure
regulator. The fuel pressure regulator can be damaged
and fuel may leak if the swivel nut is over-tightened.
3. Tighten the swivel nut.
4. Install a new O-ring on the fuel pressure regulator.

Installation Procedure
1. Install the fuel pressure regulator attaching screw.
Tighten
 Tighten the fuel pressure regulator attaching scre
w
to 3 Nm (0.3 kgm/26 lb in.).




060RW116
2. Install the fuel pressure regulator on the fuel rail.

3. Install the two bolts to the protector that secures
the common chamber.



060RW066
4. Install the pressure regulator hose to the fuel
pressure regulator.
5. Install the fuel pump relay. Refer to Fuel Pump
Relay.
6. Connect the negative battery cable.
7. Crank the engine until it starts. Cranking the engine
may take longer than usual due to trapped air in the
fuel lines.