engine remove ISUZU TF SERIES 2004 Workshop Manual

6G-6 ENGINE LUBRICATION (6VE1 3.5L)


051RW002





051RW001
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin


8. Install the new oil seal (12). Apply engine oil to the
oil seal lip before installation then use 5–8840–
2287–0 oil seal Installer, install oil seal.






015RS001
9. Install oil strainer (4) with O-ring (13).
Torque: 25 N




m (2.6 kg




m/18 lb ft)
10. Install oil pipe (3) with O-ring (13).
Torque: 25 N




m (2.6 kg




m/18 lb ft)
11. Install crankcase with oil pan (2).
 Remove oil on crankcase mounting surface and
dry the surface.

Apply a proper 4.5 mm (0.7 in) wide bead of
sealant (TB1207C or equivalent) to the
crankcase mounting surface. The bead must be
continuous.
 The crankcase must be installed within 5
minutes after sealant application to preven
t
premature hardening of sealant.
 Tighten fixing bolts to the specified torque.
Torque : 10 N




m (1.0 kg




m/7 lb ft)





013RW010
12. Install crankshaft timing pulley.

ENGINE LUBRICATION (6VE1 3.5L) 6G-7
Oil Pan and Crankcase
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Lift vehicle by supporting the frame.
4. Remove front wheels.
5. Remove oil level dipstick from level gauge tube.
6. Remove stone guard.
7. Remove radiator under fan shroud.
NOTE: For 4WD model, remove front axle housing
assembly from chassis (steps 8 to 10).
8. Remove suspension cross member fixing bolts, 2
pcs each per side and remove suspension cross
member.
9. Remove pitman arm and relay lever assembly,
using the 5–8840–2005–0 remover, remove pitman
arm from the steering unit and remove four fixing
bolts for relay lever assembly.
10. Remove axle housing assembly four fixing bolts
from housing isolator side and mounting bolts from
wheel side. At this time support the axle with a
garage jack and remove axle housing assembly.
11. Remove oil pan fixing bolts.
12. Remove oil pan, using 5–8840–2153–0 seale
r
cutter, remove oil pan.



013RS003
13. Remove crankcase fixing bolts.
14. Remove crankcase, using 5–8840–2153–0 seale
r
cutter, remove crankcase.

NOTE: Do not deform or damage the flange of oil pan
and crankcase.
Replace the oil pan and/or crankcase if deformed o
r
damaged.



013RS003
Installation
1. Install crankcase.
1. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
2. Properly apply a 4.5 mm (0.7 in) wide bead o
f
sealant (TB-1207C or equivalent) to mounting
surface of crankcase.
Sealant beat must be continuous.
 The crankcase must be installed within 5
minutes after sealant application before the
sealant hardens.





013RW010

6G-8 ENGINE LUBRICATION (6VE1 3.5L)
3. Install crankcase, tighten crankcase fixing bolts
to the specified torque.
Torque : 10 N




m (1.0 kg




m/89 lb in)





013RW004
2. Install oil pan
1. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
2. Properly apply a 4.5 mm (0.17 in) wide bead o
f
sealant (TB-1207C or equivalent) to mounting
surface of oil pan.
Sealant beat must be continuous.
 The crankcase must be installed within 5
minutes after sealant application before the
sealant hardens.




013RW003

3. Install oil pan, tighten oil pan fixing bolts to the
specified torque.
Torque : 25 N




m (2.5 kg




m/18 lb ft)
3. Install axle housing assembly and tighten fixing
bolts to the specified torque (4WD model).
Axle case bolts
Torque : 116 N




m (11.8 kg




m/85 lb ft)
Mounting bolts
Torque : 168 N




m (17.2 kg




m/124 lb ft)




RTW34CSH000101
4. Install relay lever assembly and tighten fixing bolts.
Torque: 44 N




m (4.5 kg




m/32 lb ft)
5. Engage teeth of pitman arm and steering unit, and
tighten nut to the specified torque.
Torque : 216 N




m (22.0 kg




m/159 lb ft)
6. Install suspension cross member and tighten fixing
bolts to the specified torque.
Torque : 78 N




m (8.0 kg




m/58 lb ft)
7. Install radiator under fan shroud.
8. Install stone guard.
9. Install engine oil level dipstick.
10. Fill engine oil until full level on engine oil gauge
dipstick.

ENGINE LUBRICATION (6VE1 3.5L) 6G-9
Oil Pump
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove crankcase assembly.
 Refer to removal procedure for Oil Pan and
Crankcase in this manual.
4. Remove crankshaft pulley.
 Refer to removal procedure for Crankshaf
t
Pulley in this manual.
5. Remove timing belt.
 Refer to removal procedure for Timing Belt in
this manual.
6. Remove timing pulley from crankshaft.
7. Remove four fixing bolts from oil filter assembly.
8. Remove oil strainer fixing bolts, remove oil straine
r
assembly with O-ring.
9. Remove three bolts from oil pipe and O-ring.
10. Remove eight oil pump fixing bolts, then oil pump
assembly.
11. Remove sealant from mounting surface of oil pump
assembly, cylinder block and take care not to
damage mounting surfaces of oil pump and cylinde
r
block.
Installation
1. Install oil pump assembly
 Apply sealant (TB-1207B or equivalent) to the oil
pump mounting surfaces as shown in the
illustration.
 The oil pump assembly must be installed within
5 minutes after sealant application before the
sealant hardens.
NOTE: Do not apply sealant to the oil ports.




051RW002
 Use 5–8840–2287–0 installer when installing
new oil seal.
 Apply engine oil to oil seal lip.
 Install oil pump assembly to the cylinder block.
NOTE: Do not damage oil seal during installation of oil
pump assembly.





015RS001

ENGINE LUBRICATION (6VE1 3.5L) 6G-11
Oil Pump Oil Seal
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove crankshaft pulley.
 Refer to removal procedure for Crankshaf
t
Pulley in this manual.
4. Remove timing belt.
 Refer to removal procedure for Timing Belt in
this manual.
5. Remove timing pulley from crankshaft.
6. Remove oil pump oil seal using a sealer puller.
NOTE: Take care not to damage sealing surfaces of oil
pump and crankshaft when removing oil seal.

Installation
1. Install oil pump oil seal, apply engine oil to oil seal
lip, then install oil seal using 5–8840–2287–0
installer.





015RS001
2. Install timing pulley to crankshaft.
3. Install timing belt.
 Refer to installation procedure for Timing Belt in
this manual.
4. Install crankshaft pulley.
 Refer to installation procedure for Crankshaf
t
Pulley in this manual.
5. Refill engine oil until full level.

6H-2 ENGINE SPEED CONTROL SYSTEM (6VE1 3.5L)
Accelerator Pedal Control Cable



RTW46HLF000101

Removal
1. Disconnect the accelerator control cable from the
accelerator pedal and dash panel.
2. Remove the cable clips.
3. Remove the accelerator control cable from
accelerator control cable bracket.
1) Slide the lock in direction A
2) Rotate the ratchet ring in indirection an arro
w
90
.

ENGINE SPEED CONTROL SYSTEM (6VE1 3.5L) 6H-3
4. Remove the accelerator control cable from the
throttle.




RTW46HMH000101

Inspection
Check the following items and replace the control
cable if any abnormality is found.
 The control cable should move smoothly.
 The control cable should not be bent or kinked.
 The control cable should not be damage o
r
corrosion.
Installation
1. Install the accelerator control cable to accelerator
control pedal and dash panel.
2. Install the accelerator control cable to throttle.
Attach T-END and inner cable to throttle cam o
f
engine.
3. Install accelerator control cable to accelerato
r
bracket.
1) Rotate the ratchet ring in direction an arrow 90

until both white marking are aligned.
2) Confirm marking of outer cap must be uppe
r
side.
3) Slider the lock in direction B.
4) Confirm ratchet ring is locked.

ENGINE DIAGNOSIS (C24SE) 6-3
3.Trouble in Fuel System
Condition Possible cause Correction
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
faulty Refer to "Electronic Fuel Injection"
section
4.Engine Lacks Compression
Condition Possible cause Correction
Engine lacks compression Spark plug loosely fitted or spark
plug gasket defective Tighten to specified torque or
replace gasket
Spark plug wire incorrect Connect properly or replace
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 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 gauge
needle reaches the maximum level. Note the
reading.
9. Repeat the test with each cylinder.
The pressure difference between the individual
cylinders should not exceed 100kPa (14.5 psi).

ENGINE DIAGNOSIS (C24SE) 6-9
Abnormal Noise Due to Hydraulic Lash Adjuster
Should abnormal noise due to the hydraulic lash
adjuster trouble be heard immediately after the engine
is started, inspect as follows:

Condition Possible cause Correction
Abnormal noise is heard Air contaminated Bleed
HLA is spongy Check ball valve broken Repair
Safety valve in cylinder head
broken Replace
Valve clearance is not zero HLA inside stick Replace HLA assembly

Troubleshooting Procedure
Short out each spark plug in sequence using insulated
spark plug wire removers. Locate cylinder with
defective bearing by listening for abnormal noise that
stops when spark plug is shorted out.

Condition Possible cause Correction
Noise from connecting rods or
from connecting rod bearings
(Faulty connecting rods or
connecting rod bearings usually
make an abnormal noise slightly
higher than the crank bearing
noise, which becomes more
evident when engine is
accelerated) Bearing or crankshaft pin worn Replace connecting rod bearings
and crankshaft or regrind
crankshaft and install the under
size bearing
Crankpin out of round Replace connecting rod bearings
and crankshaft or regrind
crankshaft and install the under
size bearing
Connecting rod bent Correct or replace
Connecting rod bearing seized Replace connecting rod bearings
and crankshaft or regrind
crankshaft and install the under
size bearing

Troubleshooting Procedure
Abnormal noise stops when the spark plug on the
cylinder with defective parts is shorted out.

Condition Possible cause Correction
Piston and cylinder
(Faulty piston or cylinder usually
makes a combined mechanical
thumping noise which increases
when engine is suddenly
accelerated but diminishes
gradually as the engine warms up) Piston clearance increased due to
cylinder wear Replace piston and cylinder body
Piston seized Replace piston and cylinder body
Piston ring broken Replace piston and cylinder body
Piston defective Replace pistons and others

ENGINE DIAGNOSIS (C24SE) 6-11
Abnormal Combustion
Condition Possible cause Correction
Trouble in fuel injection system Fuel pressure control valve
defective Replace
Fuel filter clogged Replace
Fuel pump clogged Clean or replace
Fuel tank or fuel pipe clogged Clean or replace
Fuel injector clogged Clean or replace
Fuel pump relay defective Replace
Power supply cable for fuel pump
loosely connected or defective Reconnect, correct or replace
Manifold Absolute Pressure
Sensor circuit open or shorted Correct or replace
Manifold Absolute Pressure
Sensor defective Replace
Engine Coolant Temperature
(ECT) Sensor circuit open or
shorted Correct or replace
ECT Sensor defective Replace
Throttle Position Sensor
adjustment incorrect Reconnect
Throttle Position Sensor defective Replace
Throttle Position Sensor
connector loosely connected Reconnect
Vehicle Speed Sensor cable
loosely connected or defective Correct or replace
Vehicle Speed Sensor loosely
fixed Fix tightly
Vehicle Speed Sensor in wrong
contact or defective Replace
Engine Control Module cable
loosely connected or defective Correct or replace
Trouble in emission control
system Heated Oxygen Sensor circuit
open (If applicable) Correct or replace
Heated Oxygen Sensor defective
(If applicable) Replace
Signal vacuum hose loosely fitted
or defective Correct or replace
ECT Sensor circuit open or
shorted Correct or replace
ECT Sensor defective Replace
Evaporative Emission Control
system (If applicable) Refer to Section 6E
Trouble in ignition system - Refer to "Engine Lacks Power"
Trouble in cylinder head parts Carbon deposits in combustion
chamber Remove carbon
Carbon deposit on valve, valve
seat and valve guide Remove carbon