length ISUZU TF SERIES 2004 Owner's Manual

ENGINE FUEL (6VE1 3.5L) 6C-13
Filler Neck
Removal
1. Remove the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.
2. Put a marking the following point as the filler neck
assembly is restored.

Each joint area of the hose (to restore axial
direction and insertion length of the hose)

Each fasten area of the clamp (to restore axial
direction and position of the clamp)

Each bolt in the clamp (to restore fasten length
of bolt in the clamp)

The band clip (to restore position and fasten
length of the band clip)
NOTE: Cover end of each hose and pipe to prevent any
dust entering.
Installation
1. Align each marking and restore the following point.

Each joint area of the hose (Restore axial
direction and insertion length of the hose)

Each fasten area of the clamp (Restore axial
direction and position of the clamp)

Each bolt in the clamp (Restore fasten length o
f
bolt in the clamp)
Torque: 2.5 N




m (0.25 kg




m / 2 lb ft) … filler neck
side except flat deck model.

The band clip (Restore position and fasten
length of the band clip)
2. Install the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.


Fuel Gauge Unit
Removal and Installation
As for removal and installation of the Fuel Gauge Unit,
refer to “Fuel Tank" of this section 6C as the fuel gauge
unit is combined with the fuel pump and sende
r
assembly.

6D3-10 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Polish the commutator surface with sandpaper #500 to
#600 if it is rough.


065RW012
Measure the depth of insulator in commutator. Replace,
if it is below the limit.
Standard: 0.45 mm to 0.75 mm (0.0177 in to
0.0295 in)
Limit: 0.2 mm (0.008 in)




065RY00070
Legend
(1) Insulator
(2) Depth of Insulator
(3) Commutator Segments



Brush
Measure the length of brush.
Replace with a new one, if it is below the limit.
Standard: 15 mm (0.5906 in)
Limit: 11 mm (0.43 in)




065RW014
Brush Holder
Check for continuity between brush holder (+) (4) and
base (–). Replace, if there is continuity (i.e., insulation is
broken).




065RW015

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-21
Stator Coil
1. Measure resistance between respective phases.
2. Measure insulation resistance between stator coil
and core with a mega–ohmmeter.
If less than standard, replace the coil.





066RS018
Brush
Measure the brush length.
If more than limit, replace the brush.
Standard: 10.mm (0.4134 in)
Limit: 8.4.mm (0.3307 in)






066RS019

Rectifier Assembly
Check for continuity across “P" and “E" in the
100W
range of multimeter.





066RW002
Change polarity, and make sure that there is continuity
in one direction, and not in the reverse direction. In case
of continuity in both directions, replace the rectifie
r
assembly.
IC Regulator Assembly
Check for continuity across “B" and “F" in the
100W
range of multimeter.




066RS021
Change polarity, and make sure that there is continuity
in one direction, and not in the reverse direction. In case
of continuity in both directions, replace the IC regulato
r
assembly.

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-71
Basic Knowledge of Tools Required
Lack of basic knowledge of this powertrain when
performing diagnostic procedures could result in an
incorrect diagnosis or damage to powertrain
components. Do not attempt to diagnose a powertrain
problem without this basic knowledge.
A basic understanding of hand tools is necessary to
effectively use this section of the Service Manual.
Serial Data Communications
Class II Serial Data Communications
This vehicle utilizes the “Class II" communication
system. Each bit of information can have one of two
lengths: long or short. This allows vehicle wiring to be
reduced by transmitting and receiving multiple signals
over a single wire. The messages carried on Class II
data streams are also prioritized. If two messages
attempt to establish communications on the data line at
the same time, only the message with higher priority will
continue. The device with the lower priority message
must wait. The most significant result of this regulation
is that it provides Tech 2 manufacturers with the
capability to access data from any make or model
vehicle that is sold.
The data displayed on the other Tech 2 will appear the
same, with some exceptions. Some scan tools will only
be able to display certain vehicle parameters as values
that are a coded representation of the true or actual
value. For more information on this system of coding,
refer to Decimal/Binary/Hexadecimal Conversions.On
this vehicle the Tech 2 displays the actual values fo
r
vehicle parameters. It will not be necessary to perform
any conversions from coded values to actual values.
On-Board Diagnostic (OBD)
On-Board Diagnostic Tests
A diagnostic test is a series of steps, the result of which
is a pass or fail reported to the diagnostic executive.
When a diagnostic test reports a pass result, the
diagnostic executive records the following data:

The diagnostic test has been completed since the
last ignition cycle.

The diagnostic test has passed during the curren
t
ignition cycle.

The fault identified by the diagnostic test is no
t
currently active.
When a diagnostic test reports a fail result, the
diagnostic executive records the following data:

The diagnostic test has been completed since the
last ignition cycle.

The fault identified by the diagnostic test is currently
active.

The fault has been active during this ignition cycle.

The operating conditions at the time of the failure.
Remember, a fuel trim DTC may be triggered by a list o
f
vehicle faults. Make use of all information available
(other DTCs stored, rich or lean condition, etc.) when
diagnosing a fuel trim fault.
Comprehensive Component Monitor
Diagnostic Operation
Input Components:
Input components are monitored for circuit continuity
and out-of-range values. This includes rationality
checking. Rationality checking refers to indicating a
fault when the signal from a sensor does not seem
reasonable, i.e.throttle position sensor that indicates
high throttle position at low engine loads. Inpu
t
components may include, but are not limited to the
following sensors:

Vehicle Speed Sensor (VSS)

Inlet Air Temperature (IAT) Sensor

Crankshaft Position (CKP) Sensor

Throttle Position Sensor (TPS)

Engine Coolant Temperature (ECT) Sensor

Camshaft Position (CMP) Sensor

Mass Air Flow (MAF) Sensor
In addition to the circuit continuity and rationality check
the ECT sensor is monitored for its ability to achieve a
steady state temperature to enable closed loop fuel
control.
Output Components:
Output components are diagnosed for proper response
to control module commands. Components where
functional monitoring is not feasible will be monitored fo
r
circuit continuity and out-of-range values if applicable.
Output components to be monitored include, but are no
t
limited to, the following circuit:

Idle Air Control (IAC) Valve

Control module controlled EVAP Canister Purge
Valve

Electronic Transmission controls

A/C relays

VSS output

MIL control
Refer to ECM and Sensors in General Descriptions.

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-121
Step Action Value(s) YES NO
18
1. Relieve the fuel pressure. Refer to the Fuel
Pressure Relief.
2. Disconnect the fuel return line from the fuel rail.
3. Attach a length of flexible hose to the fuel rail
return outlet passage.
4. Place the open end of the flexible hose into an
approved gasoline container.
5. Run the fuel pump with the Tech 2.
6. Observe the fuel pressure indicated by the fuel
pressure gauge with the fuel pump running.
Is the fuel pressure within the specified limits? 290-376 kPa
(42-55 psi) Go to Step 19 Go to Step 20
19 Locate and correct the restriction in the fuel return
line.
Is the action complete? — Verify repair —
20 Visually and physically inspect the fuel rail outlet
passages for a restriction.
Was a restriction found? — Verify repair Go to Step 11
21
Is the fuel pressure indicated by the fuel pressure
gauge above the specified value? 0 kPa (0 psi) Go to Step 22 Go to Step 23
22
1. Command the fuel pump “ON" with the Tech 2.
2. Using suitable pliers which will not damage the fuel
hose, gradually apply pressure with the pliers to
pinch the flexible fuel return hose closed.
CAUTION: Do not let the fuel pressure exceed the
second specified value.
Does the fuel pressure indicated by the fuel pressure
gauge rise above the first specified value? 376 kPa (55
psi). 414 kPa
(60 psi). Go to Step 11 Go to Step 7
23
1. Command the fuel pump “ON" with the Tech 2.
2. Remove the fuel filler cap and listen for the sound
of the fuel pump running.
3. Turn the pump off.
Was the fuel pump running? — Go to Step 7 Go to Fuel
System
Electrical Test
Chart

ENGINE MECHANICAL (C24SE) 6A-39







Camshaft Housing, Check for Plane Surface
Clean
Sealing surfaces.

Inspection
Check length and width of sealing surface for deformation and
diagnosis for warpage and use straight edge feeler gauge.

Measure
Height of camshaft housing (sealing surface to sealing
surface).
Dimension I: (74.0 mm)



Cylinder Head, Removal and Installation
Important
Only remove cylinder head with engine cold (room
temperature).




Removal
1. Remove the alternator, power steering and V-belts.



Removal
2. Loosen the fastening bolts from alternator.
3. Loosen the lower alternator fastening bolt by swinging
the alternator to the rear.



Removal
4. Remove the front toothed belt cover.
5. Remove the toothed belt from camshaft pulley.
See operation "Timing Check and Adjust".

6A-56 ENGINE MECHANICAL (C24SE)




5. Apply a bead of sealant (TB-1207C or equivalent) in the
grooves of both bearing shells.

Important!
After installation of bearing cover, press in sealing compound
again from above, until compound emerges at the joints.


Torque - Angle Method
Bearing cover to cylinder block - 50 N
m (5.1 kgf
m) +40 to
50
Con-rod bearing cover to con-rod - 35 N

m (3.5 kgf

m) +45
to
60
.
Use new bolts.

6. Install oil pump, oil pan, bearing bridge rear crankshaft
sealing, flywheel/drive plate, and aggregates according to
the corresponding operations.









Inspection
Bearing play - bearing cover removed

Measure
With "Plastigage" (ductile plastic threads)
Cut threads to length of bearing width and lay axiaity between
crankshaft journal and bearing shell (arrowed).
Install bearing cover with correct torque.

Important!
Grease crankshaft journal and lubricate bearing shell slightly
so that the thread does not tear when the bearing cover is
moved.


Crankshaft
Inspection
End play when bearing shells are installed.
Front end contact surfaces of flywheel/flexible plate.
Permissible end play - see "Technical Data "

ENGINE MECHANICAL (C24SE) 6A-57


Inspection
Out-of-round (run-out)-middle bearing shell removed when
mounting on front and rear bearing.
Permissible out-of-round - see "Technical Data"



Bearing Free Play Measurement
Two methods for measuring bearing free play are described -
1. Plastigage method and 2. micrometer and gauge method.
The two procedures are suitable for measuring both con-rod
and main bearing free play.
For both methods ensure con-rod and main bearing caps are
identified (1) prior to removal as they are machine matched.











1.Plastigage Method
Removal
1. Remove bearing cap and shell.
2. Lightly coat journals and bearings with engine oil to
prevent Plastigage from tearing when cap is removed.

Installation
1. Lay a length of Plastigage across width of crank pin and
fit bearing cap and shell using old bolts at this stage.

Important!
Do not allow crankshaft to rotate.

Torque - Angle Method
Main bearing cap bolt - 60 N

m (6.1 kgf

m) +40
+ to 50
.
Con-rod bearing cap bolts - 35 N

m (3.6 kgf

m) +45
.




Removal
1. Remove bearing cap and shell.

Measure
Width of Plastigage -use scale supplied with Plastigage.

If con-rod bearing clearance exceeds 0.031mm/0.001in or
main journal bearing clearance exceeds 0.04mm/0.02in. -
check crankshaft journal diameters - see corresponding
operation.
Replace bearing if crankshaft is within specification - see
"Technical Data"

ENGINE MECHANICAL (C24SE) 6A-79
Cylinder Head (continued)
Valve System

Valve lifter valve play compensator
(hydraulic)

Valve rotators
(inlet or outlet) outlet

Valve play
(warm or cold) inlet mm 0
outlet mm 0

Cylinder head height mm 280.30.075
Cylinder head bottom, face parallelism mm 0.05
Valve Dimensions
C24SE
A in mm B in
mm C(diameter in mm) and identification mark D
1) 2) Normal K Oversize K1
0.075 Oversize K2
0.150 Oversize A
0.250
Inlet valve 104.2 103.8 41.8 7.012
6.998 7.087
7.073 7.162
7.148 7.262
7.248 44

Outlet valve 104.0 103.6 36.5 6.992
6.978 7.087
7.053 7.142
7.128 7.242
7.228 44

Valve stem
bore - 7.050
7.030 7.125
7.105 7.200
7.180 7.300
7.280 -
1) Production
2) Customer service
The P and A department only supplies valves with a length of 103.8mm (inlet valve) and 103.6mm (outlet valve)
only



Camshaft
2.4L
Identification letter K

Colour code Normal size -
0.1mm undersize violet

Radial runout mm 0.03

End play mm 0.09 to 0.21

Cam lift Inlet and outlet valve mm 6.67

6A-82 ENGINE MECHANICAL (C24SE)
Crankshaft, Cylinder Block (continued)
Piston Rings
2.4L
Square ring Height mm 1.2

Tapered ring Height mm 1.5

Oil scraper Height mm 2.5

Ring gap offset 180


Note that the upper steel band ring gap is offset 25 to 50mm to
the left and the lower 25 to 50mm to the right opposite the
intermediate ring gap.

Piston Pin

Length mm 61.5
Diameter mm 21
Type Shrunk into con-rod
Play mm 2.4L
in piston 0.010-0.015
in con-rod none
Installation When installing piston pins,
heat con-rods to approx.
280
C in oil bath. This
temperature should under no
circumstances be exceeded.


Crankshaft, Cylinder Block (continued)
The permissible weight variation of con-rods without piston and
bearing shell inside an engine is 8 g.
As the con-rods do not have balancing studs, reworking is not
possible.
Con-rods can only be replaced in sets.