2004 ISUZU TF SERIES relay

6E-230 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Step Action Value (s) Yes No
7
Using the DVM and check the injector power supply
circuit.
1. Ignition "On", engine "Off".
2. Disconnect the injector connector for the affected
cylinder.
3. Check the circuit for open circuit.
Was the DVM indicated specified value?
E-6/E-7/E-8/E-9/
E-51/E-52
V



Battery voltage
Go to Step 9
Go to Step 8
8
Repair the open or short to ground circuit between the
ECM main relay and injector for the affected cylinder.
Is the action complete?
- Verify repair -
9
Using the DVM and check the injector signal circuit.
Breaker box is available:
1. Ignition "Off", engine "Off".
2. Install the breaker box as type A (ECM
disconnected).
Refer to 6E-95 page.
3. Disconnect the injector connector for the affected
cylinder.
4. Check the circuit for open or short to ground circuit.
Was the problem found?
A36
Breaker Box


E-6


No.1 Cylinder

B3
Breaker Box


E-7


No.2 Cylinder

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-261
Step Action Value (s) Yes No
8
Repair the open or short to ground circuit between the
ECM main relay and EGR valve.
Is the action complete?
- Verify repair -
9

Using the DVM and check the EGR valve solenoid
signal circuit.
Breaker box is available:
1. Ignition "Off", engine "Off".
2. Install the breaker box as type A (ECM
disconnected).
Refer to 6E-95 page.
3. Disconnect EGR valve connector.
4. Check the circuit for open, short to sensor ground
or short to ground circuit.
Was the problem found?
A5A22


Breaker Box
E-76







Breaker box is not available:
1. Ignition "Off", engine "Off".
2. Disconnect the EGR valve connector and ECM
connector.
3. Check the circuit for open, short to sensor ground
or short to ground circuit.
Was the problem found?
E-60(A)




E-76









-

Repair faulty
harness and
verify repair

Go to Step 10

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-299
Step Action Value (s) Yes No
6
Remove the IAC Valve and visually check.
Was the problem found?
- Go to Step 12 Go to Step 7
7
Using the DVM and check the IAC Valve coil at IAC
Valve.
1. Ignition "Off", engine "Off".
2. Disconnect the IAC Valve connector.
3. Check the coil resistance.
Does the tester indicate standard resistance as shown
in the following table?
IAC Valve














Measurement Terminal Resistance ()
1 - 2 Approximately 50
2 - 3 Approximately 50
1 – 3 Approximately 100
4 - 5 Approximately 50
5 - 6 Approximately 50
4 - 6 Approximately 100
-
Go to Step 8
Go to Step 12
8
Using the DVM and check the IAC Valve power supply
circuit.
1. Ignition "Off", engine "Off".

2. Disconnect the IAC Valve connector and ECM
main relay
3. Check the circuit for open circuit.
Was the problem found?
X-13E-70











-
Repair faulty
harness and
verify repair
Go to Step 9

6E-374 3.5L ENGINE DRIVEABILITY AND EMISSIONS
FUEL PRESSURE RELIEF
Caution:
To reduce the risk of the fire and personal injury, it
is necessary to relive the fuel system pressure
before servicing the fuel system components.
Caution:
After relieving the fuel system pressure, a small
amount of fuel may be released when servicing fuel
lines or connections. Reduce the chance o
f
personal injury by covering the fuel line fitting with
a short towel before disconnecting the fittings. The
towel will absorb any fuel that may leak out. When
the disconnect is completed, place the towel in an
approved container.

1. Remove the fuel filler cap.
2. Remove the fuel pump relay.
3. Start the engine and allow it to stall.
4. Crank the engine for about 30 seconds.
5. Disconnect the negative battery cable.



FUEL RAIL ASSEMBLY

Removal Procedure
NOTE:
 Do not attempt to remove the fuel inlet fitting on
the fuel rail. It is staked in place. Removing the
fuel inlet fitting will result in damage to the fuel
rail or the internal O-ring seal.
 Use care when removing the fuel rail assembly in
order to prevent damage to the injector electrical
connector terminals and the injector spray tips.
 Fittings should be capped and holes plugged
during servicing to prevent dirt and othe
r
contaminants from entering open lines and
passages.
Important: Before removal, the fuel rail assembly may
be cleaned with a spray type engine cleaner. Follow the
spray package instructions. Do not immerse the fuel
rails in liquid cleaning solvent.
1. Depressurize the fuel system. Refer to Fuel
Pressure Relief Procedure in this Section.
2. Disconnect the negative battery cable.
3. Remove the engine cover.
4. Disconnect the accelerator pedal cable from throttle
body and cable bracket.

5. Disconnect the connectors from, solenoid valve,
sensing valve.
6. Disconnect the vacuum hose on canister solenoid
and positive crankcase ventilation hose.
7. Remove the common chamber Refer to the
common chamber in Engine Mechanical.
1. Lift up carefully on the fuel injectors. Do no
t
separate the fuel injectors from the fuel rail.
2. If an injector becomes separated from the fuel
rail, the infector O-ring seals and the retaine
r
clip must be replaced.
3. Drain residual fuel into an approved container.




060RW044
8. If removal of the fuel pressure regulator is
necessary, refer to Fuel Pressure Regulator.
9. If removal of the fuel injectors is necessary, refer to
Fuel Injectors.

Installation Procedure
1. If the fuel injectors were removed, install them.
Refer to Fuel Injectors.
2. If the fuel pressure regulator was removed, install
it. Refer to Fuel Pressure Regulator.

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-377
FUEL PRESSURE REGULATOR

Removal Procedure
CAUTION: To reduce the risk of fire and personal
injury, it is necessary to relieve the fuel system
pressure before servicing the fuel system
components.
CAUTION: After relieving the system pressure, a
small amount of fuel may be released when
servicing fuel lines or connections. Reduce the
chance of personal injury by covering the fuel line
fittings with a shop towel before disconnecting the
fittings. The towels will absorb any fuel that may
leak out. When the disconnect is completed, place
the towel in an approved container.
NOTE: Compressed air must never be used to test
or clean a fuel pressure regulator, as damage to the
fuel pressure regulator may result.
NOTE: To prevent damage to the fuel pressure
regulator, do not immerse the pressure regulator in
solvent.
1. Depressurize the fuel system. Refer to Fue
l
Pressure Relief Procedure.
2. Disconnect the negative battery cable.
3. Remove the fuel pump relay. Refer to Fuel Pump
Relay.
4. Remove the pressure regulator hose from the fuel
pressure regulator.
5. Remove the two bolts from the protector tha
t
secures the common chamber.



060RW066

6. Remove the fuel pressure regulator attaching
screw.




060RW116
7. Remove the fuel pressure regulator from the fuel
rail.

Disassembly Procedure
1. Remove the O-ring from the fuel pressure regulator.
2. Remove the fuel return line from the fuel pressure
regulator.
3. Remove the O-ring from the fuel return line.
 The O-ring may be left inside the fuel pressure
regulator instead of on the fuel return line.




060RW116

6E-378 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Assembly Procedure
1. Install a new O-ring on the fuel return line.
2. Install the fuel return line on the fuel pressure
regulator.
Do not over-tighten the swivel nut on the fuel pressure
regulator. The fuel pressure regulator can be damaged
and fuel may leak if the swivel nut is over-tightened.
3. Tighten the swivel nut.
4. Install a new O-ring on the fuel pressure regulator.

Installation Procedure
1. Install the fuel pressure regulator attaching screw.
Tighten
 Tighten the fuel pressure regulator attaching scre
w
to 3 Nm (0.3 kgm/26 lb in.).




060RW116
2. Install the fuel pressure regulator on the fuel rail.

3. Install the two bolts to the protector that secures
the common chamber.



060RW066
4. Install the pressure regulator hose to the fuel
pressure regulator.
5. Install the fuel pump relay. Refer to Fuel Pump
Relay.
6. Connect the negative battery cable.
7. Crank the engine until it starts. Cranking the engine
may take longer than usual due to trapped air in the
fuel lines.

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.