2004 ISUZU TF SERIES wiring

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-343
Step Action Value (s) Yes No
13
Check items that can cause the engine to run rich.
Refer to DTC P0172 "O2 Sensor System Too Rich
(Bank 1)" or DTC P0175 "O2 Sensor System Too Rich
(Bank 2)".
Was a problem found?
- Verify repair Go to Step 15
14
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 15
15
Check for proper ignition voltage output with the spark
tester.
Was a problem found?
- Verify repair Go to Step 16
16
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 17
17
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 18
18
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 19
19
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 20
20
Visually/physically check the vacuum hose for splits,
kinks and proper connections and routing.
Was a problem found?
- Verify repair Go to Step 21
21
Check the exhaust system for a possible restriction:

Damaged or collapsed pipes.

Internal muffler failure.
Was a problem found?
- Verify repair Go to Step 22

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-347
Step Action Value (s) Yes No
13
Check items that can cause the engine to run rich.
Refer to DTC P0172 "O2 Sensor System Too Rich
(Bank 1)" or DTC P0175 "O2 Sensor System Too Rich
(Bank 2)".
Was a problem found?
- Verify repair Go to Step 15
14
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 15
15
Check for proper ignition voltage output with the spark
tester.
Was a problem found?
- Verify repair Go to Step 16
16
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 17
17
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 18
18
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 19
19
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 20
20
Visually/physically check the vacuum hose for splits,
kinks and proper connections and routing.
Was a problem found?
- Verify repair Go to Step 21
21
Check the exhaust system for a possible restriction:

Damaged or collapsed pipes.

Internal muffler failure.
Was a problem found?
- Verify repair Go to Step 22

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-349
CUTS OUT, MISSES SYMPTOM

DEFINITIONS: Steady pulsation or jerking that follows
engine speed; usually more pronounced as engine load
increases.




time rpm



Step Action Value (s) Yes No
1
Was the "On-Board Diagnostic (OBD) System Check"
performed?
- Go to Step 2 Go to On Board
Diagnostic (OBD)
System Check
2
1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom?
- Verify repair Go to Step 3
3
Was a visually/physical check performed?
- Go to Step 4 Go to Visual /
physical Check.
4
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 5
5
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 6
6
Monitor "B1S1 (Bank 1 Sensor 1) Status" and "B2S1
(Bank 2 Sensor 1) Status" on the Tech 2.
Is the "B1S1 (Bank 1 Sensor 1) Status" or "B2S1
(Bank 2 Sensor 1) Status" in the rich condition?
- Go to Step 7 Go to Step 8
7
Check items that can cause the engine to run rich.
Refer to DTC P0172 "O2 Sensor System Too Rich
(Bank 1)" or DTC P0175 "O2 Sensor System Too Rich
(Bank 2)".
Was a problem found?
- Verify repair Go to Step 9
8
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 9

ENGINE EXHAUST (6VE1 3.5L) 6F-1
ENGINE
ENGINE EXHAUST (6VE1 3.5L)
CONTENTS

Service Precaution................................................. 6F-1
General Description............................................... 6F-2
Three Way Catalytic Converter and Center
Exhaust Pipe.......................................................... 6F-3
Three Way Catalytic Converter and Center
Exhaust Pipe and Associated Parts................ 6F-3
Removal............................................................... 6F-3

Installation............................................................. 6F-3
Exhaust Silencer and Rear Exhaust Pipe........... 6F-4
Exhaust Silencer and Rear Exhaust Pipe and
Associated Parts................................................. 6F-4
Removal................................................................ 6F-4
Installation............................................................. 6F-4
Main Data and Specifications................................ 6F-5


Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.


CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

ENGINE LUBRICATION (6VE1 3.5L) 6G-1
ENGINE
ENGINE LUBRICATION (6VE1 3.5L)
CONTENTS

Service Precaution................................................. 6G-1
General Description............................................... 6G-2
Oil Pump.................................................................. 6G-3
Oil Pump and Associated Parts........................ 6G-3
Disassembly........................................................ 6G-4
Inspection and Repair........................................ 6G-4
Reassembly......................................................... 6G-5
Oil Pan and Crankcase.......................................... 6G-7
Removal............................................................... 6G-7

Installation............................................................. 6G-7
Oil Pump.................................................................. 6G-9
Removal................................................................ 6G-9
Installation............................................................. 6G-9
Oil Pump Oil Seal.................................................... 6G-11
Removal................................................................ 6G-11
Installation............................................................. 6G-11
Main Data and Specification.................................. 6G-12


Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.


CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners o
r
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

ENGINE SPEED CONTROL SYSTEM (6VE1 3.5L) 6H-1
ENGINE
ENGINE SPEED CONTROL SYSTEM (6VE1 3.5L)
CONTENTS

Service Precaution................................................. 6H-1
Accelerator Pedal Control Cable.......................... 6H-2
Removal............................................................... 6H-2
Inspection............................................................. 6H-2
Installation............................................................ 6H-3




Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.


CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners o
r
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

INDUCTION (6VE1 3.5L) 6J-1
ENGINE
INDUCTION (6VE1 3.5L)
CONTENTS

Service Precaution................................................. 6J-1
Air Cleaner Element............................................... 6J-2
Removal............................................................... 6J-2

Inspection............................................................. 6J-2
Installation............................................................. 6J-2


Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.


CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners o
r
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

ENGINE MECHANICAL (C24SE) 6A-59






Bypass Valve
Removal
1. Remove oil filter.
2. Remove bypass valve by cutting thread in locking disc
with M 10 tap (3rd stage), turning in M 10 bolt and taking
out bypass valve from seating.
Installation
1. Install bypass valve using drift (diameter approx.
15mm/0.6in.).






Oil Filter
Removal
1. Remove oil filter using commercially available tool.

Installation
1. Install oil filter by hand and oil seal ring.
2. Fill up engine oil while preventing overflow.



Oil Pump
Removal
1. Remove rear toothed belt cover, and oil pan according to
the corresponding operations.
2. Remove oil filter, wiring plug from oil pressure switch, oil
pump from cylinder block, and oil pressure switch from
oil pump.









Clean
Sealing surfaces

Installation
1. Install oil pressure switch to oil pump, oil pump to cylinder
block, oil pan, bearing bridge wiring plug, oil filter and
toothed belt cover.

Tighten (Torque)
Oil pressure switch to oil pump - 30 N

m (3.2 kgf

m)
Oil pump to cylinder block - 6 N

m (0.6 kgf

m)
Oil intake pipe to oil pump - 8 N

m (0.8 kgf

m)
Intake pipe bracket to cylinder block - 8 N

m (0.8 kgf

m)
*Insert bolts with Locktite (Refer to General Description
Recommended Liguid Gasket)