check engine ISUZU TF SERIES 2004 Workshop Manual

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

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-379
IGNITION COIL

Removal Procedure
1. Disconnect battery ground cable.
2. Ignition coil connector and ignition coil.
 Disconnect three connector from ignition coil.
 Remove harness bracket bolt on cylinder head
cover.
 Remove fixing bolts on ignition coil.




060RW001
Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assembly


Inspection Procedure
Check the ignition coil assembly for insulation. Check
terminals for corrosion or damage, and replace as
necessary.
Measuring resistance of ignition coil assembly.


Terminal No. Limit
1 to 2 Without 0 ohm or infinity
maximum ohm.
1 to 3 Same as above
2 to 3 Same as above


Measure resistance of ignition coil assembly, and
replace the ignition coil assembly if its value exceeds
the standard.





060RW006

Installation Procedure
1. Install the ignition coil assembly (3).
Connect ignition coil connector (1) and ignition coil
(3), then tighten bolt (2) to the specified torque.
Torque: 4 N




m (0.4 kg




m/35 lb in)





060RW001
2. Connect battery ground cable.

6E-380 3.5L ENGINE DRIVEABILITY AND EMISSIONS
SPARK PLUGS

Removal Procedure
1. Remove spark plugs.

Inspection Procedure
The spark plug affects entire engine performance and
therefore its inspection is very important.
 Check electrode and insulator for presence o
f
cracks, and replace if any.
 Check electrode for wear, and replace if necessary.
 Check gasket for damage, and replace if necessary.
 Measure insulation resistance with an ohmmeter,
and replace if faulty.
 Adjust spark plug gap to 1.0 mm (0.04 in)

1.1 mm
(0.043 in).
 Check fuel and electrical systems if spark plug is
extremely dirty.
 Use spark plugs having low heat value (hot type
plug) if fuel and electrical systems are normal.
 Use spark plugs having high heat value (cold type
plug) if insulator and electrode are extremely
burned.
Sooty Spark Plugs
Much deposit of carbon or oil on the electrode and
insulator of spark plug reduces the engine performance.
Possible causes:
 Too rich mixture
 Presence of oil in combustion chamber
 Incorrectly adjusted spark plug gap
Burning Electrodes
This fault is characterized by scorched or heavily
oxidized electrode or blistered insulator nose.
Possible causes:
 Too lean mixture
 Improper heat value

Measuring Insulation Resistance
 Measure insulation resistance using a 500 volt
megaohm meter.
 Replace spark plugs if measured value is out o
f
standard.
Insulation resistance: 50 M
  or more




011RS010
Cleaning Spark Plugs
 Clean spark plugs with a spark plug cleaner.
 Raise the ground electrode to an angle of 45 to 60
degrees. If electrode is wet, dry it before cleaning.

After spark plug is thoroughly cleaned, check
insulator for presence of cracks.
 Clean threads and metal body with a wire brush.
 File the electrode tip if electrode is extremely worn.

6F-2 ENGINE EXHAUST (6VE1 3.5L)
General Description



RTW46FLF000101
Legend (3) Three Way Catalytic Converter
(1) Front Exhaust Pipe LH (4) Center Exhaust Pipe
(2) Front Exhaust Pipe RH (5) Exhaust Silencer & Tail Pipe


When inspecting or replacing exhaust system
components, make sure there is adequate clearance
from all points on the underbody to prevent overheating
the floor pan and possible damage to the passenge
r
compartment insulation and trim materials.
Check complete exhaust system and nearby body
areas and rear compartment lid for broken, damaged,
missing or mispositioned parts, open seams, holes,
loose connections or other deterioration which could
permit exhaust fumes to seep into the rea
r
compartment or passenger compartment. Dust or water
in the rear compartment may be an indication of a
problem in one of these areas. Any faulty areas should
be corrected immediately.

Hangers
Various types of hangers are used to support exhaust
system(s). These include conventional rubber straps,
rubber rings, and rubber blocks.
The installation of exhaust system supports is very
important, as improperly installed supports can cause
annoying vibrations which can be difficult to diagnose.
Three Way Catalytic Converter
The three way catalytic converter is an emission control
device added to the exhaust system to reduce
pollutants from the exhaust gas stream.

ENGINE EXHAUST (6VE1 3.5L) 6F-3
CAUTION: The catalytic converter requires the use
of unleaded fuel only.
Periodic maintenance of the exhaust system is no
t
required. If the vehicle is raised for other service, it is
advisable to check the condition of the complete
exhaust system.
A dual bed monolith catalytic converter is used in
combination with three way catalytic converter.
Catalytic Converter Types:
Three way (Reduction/Oxidation) catalyst
The catalyst coating on the three way (reduction)
converter contains platinum and rhodium which lowers
the levels of nitrous oxide (NOx) as well as
hydrocarbons (HC) and carbon monoxide (Co).
Gasket
The gasket must be replaced whenever a new exhaust
pipe, muffler or catalytic converter is installed.

6G-4 ENGINE LUBRICATION (6VE1 3.5L)
Disassembly
1. Remove crankshaft timing pulley.
2. Remove crankcase with oil pan.
3. Remove oil pipe.
4. Remove oil strainer.
5. Remove oil pump assembly.
6. Remove plug.
7. Remove spring.
8. Remove relief valve.
9. Remove oil pump cover.
10. Remove driven gear.
11. Remove drive gear.
12. Remove oil seal.
13. Remove O-ring.
Inspection and Repair
CAUTION: Make necessary correction or parts
replacement if wear, damage or any other abnormal
conditions are found during inspection.
Relief Valve (8)
 Check to see that the relief valve slides freely.
 The oil pump must be replaced if the relief valve
does not slide freely.
 Replace the spring and/or the oil pump assembly
(5) if the spring is damaged or badly worn.





051RS002
Body (14) and Gears (10, 11)
The pump assembly must be replaced if one or more of
the conditions below is discovered during inspection.
 Badly worn or damaged driven gear (10).
 Badly worn drive gear (11) driving face.
 Badly scratched or scored body sliding face (14) o
r
driven gear (10).
 Badly worn or damaged gear teeth.
Measure the clearance between the body and the
driven gear with a feeler gauge.
Standard : 0.10 mm–0.18 mm
(0.0039 in.–0.0070 in)
Limit : 0.20mm (0.0079 in)





051RS004
 Measure the clearance between the drive gear and
driven gear with a feeler gauge.
Standard : 0.11 mm–0.24 mm
(0.0043 in–0.0094 in)
Limit : 0.35mm (0.0138 in)




051RS003

ENGINE LUBRICATION (6VE1 3.5L) 6G-5
 Measure the side clearance with a precision straight
edge and a feeler gauge.
Clearance
Standard : 0.03 mm–0.09 mm
(0.0011 in–0.0035 in)
Limit : 0.15mm (0.0059 in)







051RS005
Oil Strainer
Check the oil strainer for cracking and scoring. If
cracking and scoring are found, the oil strainer must be
replaced.





051RS006

Reassembly
1. Install drive gear (11).
2. Install driven gear (10).
3. Install oil pump cover (9) and first, loosely tighten all
of the attaching screws. Next, tighten the attaching
screws to the specified torque.
Torque : 10 N




m (1.0 kg




m/7 lb ft)
After installation, check that the gear rotates
smoothly.
4. Install relief valve (8) and apply engine oil to the
relief valve and spring (7).
5. Install spring (7).
6. Install the plug (6).
Torque : 8 N




m (0.8 kg




m/6 lb ft)






051RS007
7. Install oil pump assembly (5).
 Carefully remove any oil from the cylinder body
and the pump. Apply sealant (TB–1207B o
r
equivalent) to the pump fitting face as shown in
illustration. Take care that sealant is not applied
to oil port surfaces. The oil pump assembly
must be installed within 5 minutes after sealan
t
application to prevent premature hardening o
f
sealant.
CAUTION: Do not apply an excessive amount o
f
sealant to the contact surface. Applying too much
sealant will overflow the contact surfaces. This
could cause serious damage to the engine.
 Attach oil pump assembly to cylinder body.
 Tighten the oil pump fixing bolts.
Torque : 25 N




m (2.6 kg




m/18 lb ft)

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) 6-1
SECTION 6
ENGINE DIAGNOSIS
CONTENTS
PAGE
Engine Diagnosis............................................................................................................... 6- 2
Hard Starting ................................................................................................................. 6- 2
Engine Compression Test Procedure ......................................................................... 6- 3
Rough Engine Idling or Engine Stalling ...................................................................... 6- 4
Rough Engine Running ................................................................................................ 6- 5
Hesitation....................................................................................................................... 6- 6
Engine Lacks Power ..................................................................................................... 6- 7
Engine Noisy ................................................................................................................. 6- 8
Abnormal Noise Due to Hydraulic Lash Adjustor ...................................................... 6- 9
Troubleshooting Procedure ......................................................................................... 6- 9
Abnormal Combustion.................................................................................................. 6-11
Engine Oil Consumption Excessive ............................................................................ 6-12
Fuel Consumption Excessive ...................................................................................... 6-13
Oil Problems .................................................................................................................. 6-13
Engine Oil Pressure Check .......................................................................................... 6-13
Malfunction Indicator Lamp ......................................................................................... 6-14

6-2 ENGINE DIAGNOSIS (C24SE)
Engine Diagnosis
Hard Starting
1.Starting Motor Does Not Turn Over
Trouble Shooting Procedure
Turn on headlights and starter switch.
Condition Possible cause Correction
Headlights go out or dim
considerably Battery run down or under
charged Recharge or replace battery
Terminals poorly connected Clean battery posts and terminals
and connect properly
Starting motor coil circuit shorted Overhaul or replace
Starting motor defective Overhaul or replace
2.Ignition Trouble - Starting Motor Turns Over But Engine Does Not Start
Spark Test
Disconnect a high tension cable from any spark plug.
Connect the spark plug tester (use commercially
available tool), crank the engine, and check if a spark is
generated in the spark plug tester. Before cranking the
engine, make sure that the spark plug tester is properly
grounded. To avoid electrical shock, do not touch the
high tension cable while the engine is running.

Condition Possible cause Correction
Spark jumps across gap Spark plug defective Clean, adjust spark gap or replace
Spark plug wire in correct Connect properly or replace
Ignition timing incorrect Refer to Ignition System
Fuel not reaching fuel injector(s)
or engine Refer to item 3 (Trouble in fuel
system)
Valve timing incorrect Adjust
Engine lacks compression Refer to item 4 (Engine lacks
compression)
No sparking takes place Ignition coil disconnected or
broken Connect properly or replace
Electronic Ignition System with
module Replace
Poor connections in engine
harness Correct
Engine Control Module cable
disconnected or defective Correct or replace