2004 ISUZU TF SERIES check oil

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.

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 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

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) 6-13
Fuel Consumption Excessive
Condition Possible cause Correction
Trouble in fuel system Mixture too rich or too lean due to
trouble in fuel injection system Refer to "Abnormal Combustion"
Fuel cut function does not act Refer to "Abnormal Combustion"
Trouble in ignition system Misfiring or abnormal combustion
due to trouble in ignition system Refer to Hard Start or Abnormal
Combustion Troubleshooting
Guide
Others Engine idle speed too high Reset Idle Air Control Valve
Returning of accelerator control
sluggish Correct
Fuel system leakage Correct or replace
Clutch slipping Correct
Brake drag Correct
Selection of transmission gear
incorrect Caution operator of incorrect gear
selection
Oil Problems
Condition Possible cause Correction
Oil pressure too low Wrong oil in use Replace with correct engine oil
Relief valve sticking Replace
Oil pump not operating properly Correct or replace
Oil pump strainer clogged Clean or replace strainer
Oil pump worn Replace
Oil pressure gauge defective Correct or replace
Crankshaft bearing or connecting
rod bearing worn Replace
Oil contamination Wrong oil in use Replace with new engine oil
Oil filter clogged Replace oil filter
Cylinder head gasket damage Replace gasket
Burned gases leaking Replace piston and piston rings or
rebore cylinders
Oil not reaching valve system Oil passage in cylinder head or
cylinder body clogged Clean or correct

Engine Oil Pressure Check
1. Check for dirt, gasoline or water in the engine
oil.
a. Check the viscosity of the oil.
b. Change the oil if the viscosity is outside the
specified standard.
c. Refer to the "Maintenance and Lubrication"
section of this manual.
2. Check the engine oil level.
The level should fall somewhere between the
"ADD" and the "FULL" marks on the oil level
dipstick.
If the oil level does not reach the "ADD" mark on
the oil level dipstick, engine oil must be added. 3. Remove the oil pressure unit.
4. Install an oil pressure gauge.
5. Start the engine and allow the engine to reach
normal operating temperature (About 80
C).
6. Measure the oil pressure.
Oil pressure should be:
150 kPa(21.8 psi) at idle speed.
7. Stop the engine.
8. Remove the oil pressure gauge
9. Install the oil pressure unit.
10. Start the engine and check for leaks.

6A-2 ENGINE MECHANICAL (C24SE)
PAGE
Camshaft Housing, Check for Plance Surface ......................................................... 6A-39
Cylinder Head, Removal and Installation .................................................................. 6A-39
Cylinder Head, Disassemble and Assemble ............................................................. 6A-42
Valve, Grind ................................................................................................................. 6A-44
Valve Guide, Ream ..................................................................................................... 6A-44
Valve Seating, Mill ....................................................................................................... 6A-45
Cylinder Head, Overhaul............................................................................................. 6A-45
Flywheel ....................................................................................................................... 6A-46
Starter Ring Gear(Manual Transmission) ................................................................. 6A-47
Seal Ring, Crankshaft ................................................................................................. 6A-48
Seal Ring, Crankshaft Rear ........................................................................................ 6A-48
Oil Pan and Bearing Bridge........................................................................................ 6A-49
OPERATIONS ON CRANK DRIVE ................................................................................... 6A-51
Con-Rod Bearing......................................................................................................... 6A-51
Piston with Con-Rod ................................................................................................... 6A-51
Con-Rod ....................................................................................................................... 6A-52
Pistion Rings ............................................................................................................... 6A-53
OPERATIONS ON REMOVED ENGINE ........................................................................... 6A-55
Crankshaft ................................................................................................................... 6A-55
Bearing Free Play Measurement ................................................................................ 6A-57
Plastigage Method ...................................................................................................... 6A-57
Micrometer and gauge method .................................................................................. 6A-58
Bypass Valve ............................................................................................................... 6A-59
Oil Filter ....................................................................................................................... 6A-59
Oil Pump ...................................................................................................................... 6A-59
Oil Pump Safety Valve ................................................................................................ 6A-60
Oil Pump(Overhaul) .................................................................................................... 6A-60
OPERATIONS ON OIL CIRCULATION ............................................................................ 6A-61
Cylinder Head Safety Valve ........................................................................................ 6A-61
OPERATIONS ON COOLING SYSYTEM ......................................................................... 6A-63
Cooling System, Check for Leakes ........................................................................... 6A-63
Cooling System, Fill Up and Bleed ............................................................................ 6A-63
Refill Coolant ............................................................................................................... 6A-64
Ignition Timing, Check................................................................................................ 6A-64