belt ISUZU TF SERIES 2004 Manual Online

ENGINE COOLING (6VE1 3.5L) 6B-15
Drive Belt and Cooling Fan
Drive Belt and Associated Parts



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Legend (4) Water Pump and Cooling Fan Pulley
(1) Crankshaft Pulley (5) Idle Pulley
(2) Generator (6) Tension Pulley
(3) Power Steering Pump (7) Drive Belt


The drive belt adjustment is not required as automatic
drive belt tensioner is equipped.
Inspection
Check drive belt for wear or damage, and replace with a
new one as necessary.
Installation
Install cooling fan assembly and tighten bolts/nuts to the
specified torque.
Torque : 25 N




m (2.5 kg




m/18 lb ft) for fan pulley
and fan bracket.
Torque : 10 N




m (1.0 kg




m/7 lb ft) for fan and
clutch assembly.
NOTE: Fan belts for 6VE1 Gasoline Engine mounted on
98MY (UX) have been brought into one. As a result, the
rotating direction of a fan belt is opposite to the direction
of cooling fan for 92 to 97MY 6VD1 with no
interchangeability.
Therefore, incorrect installation of a fan may cause the
air for cooling to flow in the opposite direction, this
resulting in the poor performance of the air-conditione
r
and a rise temperature in engine cooling water.

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-15
Charging System
General Description
The IC integral regulator charging system and its main
components are connected as shown in illustration.
The regulator is a solid state type and it is mounted
along with the brush holder assembly inside the
generator installed on the rear end cover.
The generator does not require particular maintenance
such as voltage adjustment.
The rectifier connected to the stator coil has eigh
t
diodes to transform AC voltage into DC voltage.
This DC voltage is connected to the output terminal o
f
generator.

General On–Vehicle Inspection
The operating condition of charging system is indicated
by the charge warning lamp. The warning lamp comes
on when the starter switch is turned to “ON" position.
The charging system operates normally if the lamp
goes off when the engine starts.
If the warning lamp shows abnormality or i
f
undercharged or overcharged battery condition is
suspected, perform diagnosis by checking the charging
system as follows:
1. Check visually the belt and wiring connector.
2. With the engine stopped, turn the stator switch to
“ON" position and observe the warning lamp.
If lamp does not come on:
Disconnect wiring connector from generator, and
ground the terminal “L" on connector side.
If lamp comes on:
Repair or replace the generator.




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6D3-16 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Generator
Removal
1. Disconnect battery ground cable.
2. Move drive belt tensioner to loose side using
wrench then remove drive belt (1).
3. Disconnect the wire from terminal “B" and
disconnect the connector (4).
4. Remove generator fixing bolt (3).
5. Remove generator assembly (2).





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Inspection
1. Disconnect the wiring connector from generator.
2. With the engine stopped, turn starter switch to “ON"
and connect a voltmeter between connecto
r
terminal L (2) and ground or between terminal IG (1)
and ground.




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If voltage is not present, the line between battery
and connector is disconnected and so requires
repair.
3. Reconnect the wiring connector to the generator,
run the engine at middle speed, and turn off all
electrical devices other than engine.
4. Measure battery voltage. If it exceeds 16V, repair o
r
replace the generator.
5. Connect an ammeter to output terminal o
f
generator, and measure output current under load
by turning on the other electrical devices (eg.,
headlights). At this time, the voltage must not be
less than 13V.
Installation
1. Install generator assembly to the position to be
installed.
2. Install generator assembly and tighten the fixing
bolts to the specified torque.
Torque:
M10 bolt: 52 N




m (5.3 kg




m/38 lb ft)
M8 bolt: 25 N




m (2.5 kg




m/18 lb ft)
3. Connect wiring harness connector and direc
t
terminal “B".
4. Move drive belt tensioner to loose side using
wrench, then install drive belt to normal position.
5. Reconnect battery ground cable.

6E-332 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Step Action Value (s) Yes No
8
1. Using a Tech 2, display the IAC value.
2. Check for a faulty, plugged, or sticking IAC
operation.
Was the problem found?
- Verify repair Go to Step 9
9
Check the CKP sensor signal or installation condition.
Refer to DTC P0336 "Crankshaft Position Sensor
Circuit Range/Performance" and DTC P0337
"Crankshaft Position Sensor Circuit No Signal".
Was a problem found?
- Verify repair Go to Step 10
10
Check for proper ignition voltage output with the spark
tester.
Was a problem found?
- Verify repair Go to Step 11
11
1. Remove the spark plugs and check for gas or oil
fouling cracks, wear, improper gap, burned
electrodes, heavy deposits, or improper heat
range.
2. If spark plugs are fouled, the cause of fouling must
be determined before replacing the spark plugs.
Was a problem found?
- Verify repair Go to Step 12
12
Check the fuel pressure. Refer to Fuel System
Diagnosis.
Was a problem found?
- Verify repair Go to Step 13
13
Perform the procedure in Fuel System Pressure Test
to determine if there is a problem with fuel delivery.
Was a problem found?
- Verify repair Go to Step 14
14
Visually/physically check the vacuum hose for splits,
kinks and proper connections and routing.
Was a problem found?
- Verify repair Go to Step 15
15
Check the exhaust system for a possible restriction:

Damaged or collapsed pipes.

Internal muffler failure.
Was a problem found?
- Verify repair Go to Step 16
16
Check for the following engine mechanical problems
(refer to Engine Mechanical section):

Low compression.

Leaking cylinder head gaskets.

Worn camshaft.

Camshaft drive belt slipped or stripped.
Was a problem found?
- Verify repair Go to Step 17

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-335
Step Action Value (s) Yes No
10
1. Remove the spark plugs and check for gas or oil
fouling cracks, wear, improper gap, burned
electrodes, heavy deposits, or improper heat
range.
2. If spark plugs are fouled, the cause of fouling must
be determined before replacing the spark plugs.
Was a problem found?
- Verify repair Go to Step 11
11
Check for water or alcohol contaminated fuel.
Was a problem found?
- Verify repair Go to Step 12
12
Perform the procedure in Fuel System Pressure Test
to determine if there is a problem with fuel delivery.
Refer to 6E-116 page.
Was a problem found?
- Verify repair Go to Step 13
13
1. Check the injector connectors.
2. If any of the connectors are connected at an
improper cylinder, connect as necessary.
Was a problem found?
- Verify repair Go to Step 14
14
Check for the following engine mechanical problems
(refer to Engine Mechanical section):

Low compression.

Leaking cylinder head gaskets.

Worn camshaft.

Camshaft drive belt slipped or stripped.
Was a problem found?
- Verify repair Go to Step 15
15
1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:

Visual/physical inspection.

Tech 2 data.

All electrical connections within a suspected circuit
and/or system.
Was a problem found?
- Verify repair Go to Step 16
16
Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the "SPS (Service Programming System)".
Was the problem solved?
- Verify repair Go to Step 17

6E-340 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Step Action Value (s) Yes No
22
Check the ECM grounds to verify that they are clean
and tight. Refer to the ECM wiring diagrams.
Was a problem found?
- Verify repair Go to Step 23
23
1. Check for faulty engine mounts.
2. If a problem is found, repair as necessary.
Was a problem found?
- Verify repair Go to Step 24
24
Check for the following engine mechanical problems
(refer to Engine Mechanical section):

Low compression.

Leaking cylinder head gaskets.

Worn camshaft.

Sticking or leaking valves. -Valve timing.

Broken valve springs.

Camshaft drive belt slipped or stripped.
Was a problem found?
- Verify repair Go to Step 25
25
1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:

Visual/physical inspection.

Tech 2 data.

All electrical connections within a suspected circuit
and/or system.
Was a problem found?
- Verify repair Go to Step 26
26
Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the "SPS (Service Programming System)".
Was the problem solved?
- Verify repair Go to Step 27
27
Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual. Following
ECM programming, the immobilizer system (if
equipped) must be linked to the ECM. Refer to section
11 “Immobilizer System-ECM replacement” for the
ECM/Immobilizer linking procedure.
- Verify repair -

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-351
Step Action Value (s) Yes No
17
Check for the following engine mechanical problems
(refer to Engine Mechanical Section):

Low compression. -Leaking cylinder head gaskets.

Worn camshaft. -Sticking or leaking valves.

Valve timing. -Broken valve springs.

Camshaft drive belt slipped or stripped.
Was a problem found?
- Verify repair Go to Step 18
18
1. Check for faulty engine mounts.
2. If a problem is found, repair as necessary.
Was a problem found?
- Verify repair Go to Step 19
19
1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:

Visual/physical inspection.

Tech 2 data.

All electrical connections within a suspected circuit
and/or system.
Was a problem found?
- Verify repair Go to Step 20
20
Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the "SPS (Service Programming System)".
Was the problem solved?
- Verify repair Go to Step 21
21
Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual. Following
ECM programming, the immobilizer system (if
equipped) must be linked to the ECM. Refer to section
11 “Immobilizer System-ECM replacement” for the
ECM/Immobilizer linking procedure.
- Verify repair -

6E-354 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Step Action Value (s) Yes No
15
Check items that can cause the engine to run lean. Refer to
DTC P0171 "O2 Sensor System Too Lean (Bank 1)" or DTC
P0174 "O2 Sensor System Tool Lean (Bank 2)".
Was a problem found?
- Verify repair Go to Step 16
16
Check for proper ignition voltage output with the spark tester.
Was a problem found?
- Verify repair Go to Step 17
17
Check the ignition coils for cracks or carbon tracking. If a
problem is found, repair as necessary.
Was a problem found?
- Verify repair Go to Step 18
18
1. Remove the spark plugs and check for gas or oil fouling
cracks, wear, improper gap, burned electrodes, heavy
deposits, or improper heat range.
2. If spark plugs are fouled, the cause of fouling must be
determined before replacing the spark plugs.
Was a problem found?
- Verify repair Go to Step 19
19
Visually/physically check the vacuum hose for splits, kinks and
proper connections and routing.
Was a problem found?
- Verify repair Go to Step 20
20
Check the exhaust system for a possible restriction:

Damaged or collapsed pipes.

Internal muffler failure.
Was a problem found?
- Verify repair Go to Step 21
21
Check the torque converter clutch (TCC) for proper operation
(if A/T model). If a problem is found, repair as necessary.
Was a problem found?
- Verify repair Go to Step 22
22
Check for the following engine mechanical problems (refer to
Engine Mechanical Section):

Low compression.

Leaking cylinder head gaskets.

Worn camshaft.

Sticking or leaking valves.

Valve timing.

Broken valve springs.

Camshaft drive belt slipped or stripped.
Was a problem found?
- Verify repair Go to Step 23
23
1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no malfunctions
have been found, review/inspect the following:

Visual/physical inspection.

Tech 2 data.

All electrical connections within a suspected circuit and/or
system.
Was a problem found?
- Verify repair Go to Step 24

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-367
Step Action Value (s) Yes No
10
Check for the following engine mechanical problems
(refer to Engine Mechanical):

Low compression.

Leaking cylinder head gaskets.

Worn camshaft.

Sticking or leaking valves.

Valve timing.

Broken valve springs.

Camshaft drive belt slipped or stripped.
Was a problem found?
- Verify repair Go to Step 11
11
Check the intake and exhaust manifold for casting
flash. Refer to Engine Mechanical.
Was a problem found?
- Verify repair Go to Step 12
12
1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:

Visual/physical inspection.

Tech 2 data.

All electrical connections within a suspected circuit
and/or system.
Was a problem found?
- Verify repair Go to Step 13
13
Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the "SPS (Service Programming System)".
Was the problem solved?
- Verify repair Go to Step 14
14
Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual. Following
ECM programming, the Immobilizer system (if
equipped) must be linked to the ECM. Refer to section
11 “Immobilizer System-ECM replacement” for the
ECM/Immobilizer linking procedure.
- Verify repair -

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.




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 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.





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