2004 ISUZU TF SERIES belt

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.




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

6G-10 ENGINE LUBRICATION (6VE1 3.5L)
 Tighten fixing bolts to the specified torque.
Torque : 25 N




m (2.5 kg




m/18 lb ft)



051RW001
2. Install oil pipe with O-ring, tighten fixing bolt to the
specified torque.
Torque : 10 N




m (1.0 kg




m/7 lb ft)
3. Install oil strainer with O-ring, tighten fixing bolt to
the specified torque.
Torque : 25 N




m (2.5 kg




m/18 lb ft)
4. Install oil filter assembly and tighten bolts to the
specified torque.
Torque : 25 N




m (2.5 kg




m/18 lb ft)





050RW001
Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter


5. Install timing pulley on crankshaft.
Install timing belt.
 Refer to installation procedure for Timing Belt in
this manual.
6. Install crankshaft pulley.
 Refer to install procedure for Crankshaft Pulley
in this manual.
7. Install crankcase assembly.
 Refer to installation procedure for Oil Pan and
Crankcase in this manual.
8. Refill engine oil until full level on engine oil dipstick.

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.

6G-12 ENGINE LUBRICATION (6VE1 3.5L)
Main Data and Specifications
General Specifications

Item Specifications
Oil capacity 5.3 liters

Torque Specifications
Crankcase, Oil pan, Timing belt tensioner, Timing pulley, timing belt cover, Oil pump, Oil gallery, Oil strainer
N




m (kg




m/lb ft)




RTW46GLF000101

6-8 ENGINE DIAGNOSIS (C24SE)
Condition Possible cause Correction
Engine overheating Level of Engine Coolant too low Replenish
Thermo switch or fan motor
defective Replace
Thermostat defective Replace
Engine Coolant pump defective Correct or replace
Radiator clogged Clean or replace
Radiator filter cap defective Replace
Level of oil in engine crankcase
too low or wrong oil in engine Change or replenish
Resistance in exhaust system
increased Clean exhaust system or replace
defective parts
Throttle Position Sensor
adjustment incorrect Adjust Wide Open Throttle switch
setting
Throttle Position Sensor circuit
open or shorted Correct or replace
Cylinder head gasket damaged Replace
Cooling Fan clutch defective Replace
Fan belt slipping Adjust tension of V-belt or replace
V-belt
Engine overcooling Thermostat defective Replace (Use a thermostat set to
open at 92
C (197.6
F))
Engine lacks compression - Refer to Hard Start
Others Tire inflation pressure abnormal Adjust to recommend pressures
Brake drag Adjust
Clutch slipping Adjust or replace
Level of oil in engine crankcase
too high Correct level of engine oil

Engine Noisy
Abnormal engine noise often consists of various
noises originating in rotating parts, sliding parts and
other moving parts of the engine. It is, therefore,
advisable to locate the source of noise systematically.

Condition Possible cause Correction
Noise from crank journals or from
crank bearings
(Faulty crank journals and crank
bearings usually make dull noise
that becomes more evident when
accelerating) Oil clearance increased due to
worn crank journals or crank
bearings Replace crank bearings and
crankshaft or regrind crankshaft
and install the over size bearing
Crankshaft out of round Replace crank bearings and
crankshaft or regrind crankshaft
and install the over size bearing
Crank bearing seized Replace crank bearings and
crankshaft or regrind crankshaft
and install the over size bearing

6-10 ENGINE DIAGNOSIS (C24SE)
Troubleshooting Procedure

Condition Possible cause Correction
Piston pin noise
(Piston makes noise each time it
goes up and down) Piston pin or piston pin hole worn Replace piston, piston pin and
connecting rod assy

Troubleshooting Procedure
The slapping sound stops when spark plug on bad
cylinder is shorted out.

Condition Possible cause Correction
Timing belt noise Timing belt tension is incorrect Replace pusher or adjust the
tension pulley or replace timing
belt
Tensioner bearing defective Replace
Timing belt defective Replace
Timing wheels defective Replace
Timing belt comes in contact with
timing cover Replace timing belt and timing
cover
Valve noise Valve and valve guide seized Replace valve and valve guide
Valve spring broken Replace
Valve seat off-positioned Correct
Crankshaft noise Crankshaft end play excessive
(noise occurs when clutch is
engaged) Replace thrust bearing
Engine knocking Preignition due to use of spark
plugs of inadequate heat range Install Spark Plugs of adequate
heat range
Fuel too low in octane rating Replace fuel
Wide Open Throttle enrichment
system failure Refer to Section 6E
Selection of transmission gear
incorrect Caution operator or incorrect gear
selection
Engine overheating Refer to "Engine Lacks Power"
Others Water pump defective Replace
V-belt slipping Adjust tension of V-belt or replace
V-belt

ENGINE MECHANICAL (C24SE) 6A-1
SECTION 6A
ENGINE MECHANICAL
CONTENTS
PAGE
General Description......................................................................................................... 6A- 4
ENGINE PICTORIAL .................................................................................................... 6A- 6
Main Data and Specification ........................................................................................... 6A-11
CRANKCASE VENTILATION SYSTEM ....................................................................... 6A-16
ENGINE ASSEMBLY & LOOSE PARTS ..................................................................... 6A-17
OPERATIONS ON ENGINE AGGREGATES .................................................................... 6A-18
Engine Damping Blocks(Engine without Transmission)......................................... 6A-18
Toothed Belt and Timing Check ............................................................................... 6A-21
Toothed Belt Tension, Adjust .................................................................................... 6A-23
Toothed Belt, Replace ................................................................................................ 6A-24
OPERATIONS ON INSTALLED ENGINE ......................................................................... 6A-26
Gasket, Exhaust Manifold, Cylinder Head ................................................................ 6A-26
Gasket, Intake Manifold, Cylinder Head .................................................................... 6A-26
Seal Ring, Camshaft Housing, Timing Side .............................................................. 6A-27
Seal Ring, Thermostat Housing, Cylinder Head ....................................................... 6A-27
Seal Ring - Front Camshaft Housing, Replace ......................................................... 6A-28
Toother Belt Rear Cover ............................................................................................. 6A-30
Toother Belt Tension Roller ....................................................................................... 6A-31
COMPONENT PARTS ...................................................................................................... 6A-32
Cylinder Head .............................................................................................................. 6A-32
Hydraulic Valve Lifter.................................................................................................. 6A-33
OPERATIONS ON CYLINDER HEAD AND CAMSHAFT HOUSING ............................... 6A-34
Camshaft...................................................................................................................... 6A-34
Camshaft Housing Removal and Installation ........................................................... 6A-35
Cylinder Head .............................................................................................................. 6A-35
Hydraulic Valve Lifers, Replace ................................................................................. 6A-37
Camshaft Housing, Replace....................................................................................... 6A-37