2004 ISUZU TF SERIES fuel

ENGINE FUEL (6VE1 3.5L) 6C-11
Fuel Tank
Fuel Tank and Associated Parts




RTW46FLF000301

Legend (7) Fuel Filler Hose
(1) Bolt; Fuel Tank (8)Fuel Tube/Quick Connector
(2) Fuel Tank Band (9)
(3) Rear Side Shield Evapo Tube / Quick Connector – Only Specified
Model
(4) Side Shield (10)Fuel Filter
(5) Retainer (11)Band; Under Shield
(6) Fuel Tank (12)Under Shield

6C-12 ENGINE FUEL (6VE1 3.5L)
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission".
1. Disconnect battery ground cable.
2. Loosen slowly the fuel filler cap.
NOTE: To prevent spouting out fuel to change the
pressure in the fuel tank.
NOTE: Cover opening of the filler neck to prevent any
dust entering.
3. Jack up the vehicle.
4. Support underneath of the fuel tank with a lifter.
5. Remove the inner liner of the wheel house on rea
r
left side.
6. Remove fasten bolt to the filler neck from the
body.
7. Disconnect the quick connector (8) into the fuel
tube from the fuel pipe and the evapo tube from
evapo joint connector.
NOTE: Cover the quick connector to prevent any dus
t
entering and fuel leaking.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in
this section when performing any repairs.
8. Remove fasten bolt (1) to the tank band and the
tank band (2).
9. Disconnect the pump and sender connector on the
fuel pump and remove the harness from weld clip
on the fuel tank.
10. Lower the fuel tank (6).
NOTE: When the fuel tank is lowered from the vehicle,
don’t scratch each hose and tube by around other pars.


Installation
1. Rise the fuel tank into position.
NOTE: Ensure hoses and tubes do not foul on othe
r
component.
2. Connect the pump and sender connector to the
fuel pump and install harness to into the plastic clip
welded to the top of the fuel tank..
NOTE: The connector must be certainly connected
against stopper.
Ensure tank band anchor mates with guide hole on
frame.
3. Install the tank band to fasten bolt.
Torque: 68 N




m (6.9kg




m/50 lb ft)
NOTE: The anchor of the tank band must be certainly
installed to guide hole on frame.
4. Connect the quick connector from the fuel tube to
the fuel pipe and the evapo tube from evapo join
t
connector.
NOTE: Pull off the left checker into the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in
this section when performing any repairs.
5. Install the filler neck to the body by bolt.
6. Install the inner liner of the wheel house on rea
r
side.
7. Remove lifter to support underneath of the fuel
tank.
8. Put back the vehicle.
9. Tigten the filler cap until at least three clicks are
heard.
10. Connect the battery ground cable.

ENGINE FUEL (6VE1 3.5L) 6C-13
Filler Neck
Removal
1. Remove the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.
2. Put a marking the following point as the filler neck
assembly is restored.

Each joint area of the hose (to restore axial
direction and insertion length of the hose)

Each fasten area of the clamp (to restore axial
direction and position of the clamp)

Each bolt in the clamp (to restore fasten length
of bolt in the clamp)

The band clip (to restore position and fasten
length of the band clip)
NOTE: Cover end of each hose and pipe to prevent any
dust entering.
Installation
1. Align each marking and restore the following point.

Each joint area of the hose (Restore axial
direction and insertion length of the hose)

Each fasten area of the clamp (Restore axial
direction and position of the clamp)

Each bolt in the clamp (Restore fasten length o
f
bolt in the clamp)
Torque: 2.5 N




m (0.25 kg




m / 2 lb ft) … filler neck
side except flat deck model.

The band clip (Restore position and fasten
length of the band clip)
2. Install the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.


Fuel Gauge Unit
Removal and Installation
As for removal and installation of the Fuel Gauge Unit,
refer to “Fuel Tank" of this section 6C as the fuel gauge
unit is combined with the fuel pump and sende
r
assembly.

6C-14 ENGINE FUEL (6VE1 3.5L)
Fuel Filler Cap
General Description
A vacuum valve and pressure valve are built into the
fuel filler cap which adjusts the fuel pressure in the fuel
tank to prevent fuel tank damage.



RTW36CSH000401
Legend
(1) Pressure Valve
(2) Vacuum Valve
(3) Seal Ring

Inspection
The fuel filler cap must be inspected for seal condition.
The fuel filler cap must be replaced if found defective
CAUTION: A replacement fuel filler cap must be the
same as the original. The fuel filler cap valve was
designed primarily for this application and must be
replaced with the same type or decreased engine
performance may occur.

ENGINE FUEL (6VE1 3.5L) 6C-15
Main Data and Specifications
Torque Specification
N




m (kg




m/ lb ft)




RTW46FMF000601

6C-16 ENGINE FUEL (6VE1 3.5L)
Special Tools

ILLUSTRATION PART NO.
PART NAME


5–8840–2602–0
(J–39765)
Remover; fuel pump
retainer

6D2-4 IGNITION SYSTEM (6VE1 3.5L)
Spark Plug
Inspection
Poor spark plug condition adversely affects engine
performance. Carefully inspect each spark plug
following the procedure outlined below.
1. Remove the spark plug.
2. Check the plug for dirt and other foreign material.
If the plug is extremely dirty, the fuel and electrical
systems must be checked.
3. If necessary, clean the spark plugs by placing them
in a spark plug cleaning machine for no more than
20 seconds.
4. Check the electrode and insulator for wear and/o
r
cracking. If there is significant wear or cracking, the
plug must be replaced.
5. Check the gasket for damage. Replace the gasket i
f
necessary.
6. Measure the insulation resistance with a 500-vol
t
megaohm meter. Replace the plug if the resistance
is less than the specified value.
Insulation resistance: 50 M





or more




011RS010

7. Check the spark plug gap. Replace the spark plug
the if gap is not as specified.
Standard: 1.0–1.1 mm (0.04–0.043 in)
Limit: 1.3 mm (0.05 in)





011RS011
 Do not attempt to adjust the gap of an old spark
plug. Replace the plug and adjust the gap of the
new plug if required.
 Take care not to damage the spark plug tip
during handling.
8. Tighten the spark plugs to the specified torque.
Torque: 18 N




m (1.8 kg




m/13 lb ft)
Replacement spark plugs
 Under normal conditions (no problem with the fuel
and/or electrical systems), use replacement spark
plugs with a low heat value (hot-type plug).
 If insulator and electrode scorching is significant,
use replacement spark plugs with a high heat value
(cold-type plug).

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-1
ENGINE
3.5L ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS


ABBREVIATION CHARTS ................................ 6E-5
COMPONENT LOCATOR ................................. 6E-6
ENGINE COMPONENT LOCATOR TABLE .. 6E-6
ECM CIRCUIT DIAGRAM ................................. 6E-10
GROUND POINT CHART G.EXP (LHD)
WITHOUT EUROPE, ISRAEL, TURKEY (1/4). 6E-13
GROUND POINT CHART G.EXP (LHD) (2/4) .. 6E-14
GROUND POINT CHART G.EXP (LHD) (3/4) .. 6E-15
GROUND POINT CHART G.EXP (LHD) (4/4) .. 6E-16
GROUND POINT CHART G.EXP (RHD) (1/4) . 6E-17
GROUND POINT CHART G.EXP (RHD) (2/4) . 6E-18
GROUND POINT CHART G.EXP (RHD) (3/4) . 6E-19
GROUND POINT CHART G.EXP (RHD) (4/4) . 6E-20
LOCATION ........................................................ 6E-21
CABLE HARNESS & CONNECTOR
LOCATION ....................................................... 6E-22
CONNECTOR LIST ........................................... 6E-27
RELAY AND FUSE ............................................ 6E-30
RELAY AND FUSE BOX LOCATION
(LHD&RHD) ................................................... 6E-30
RELAY AND FUSE BOX LOCATION
(LHD&RHD) ................................................... 6E-31
FUSE AND RELAY LOCATION
(LHD&RHD) ................................................... 6E-32
ECM WIRING DIAGRAM (1/10) ........................ 6E-33
ECM WIRING DIAGRAM (2/10) ........................ 6E-34
ECM WIRING DIAGRAM (3/10) ........................ 6E-35
ECM WIRING DIAGRAM (4/10) ........................ 6E-36
ECM WIRING DIAGRAM (5/10) ........................ 6E-37
ECM WIRING DIAGRAM (6/10) ........................ 6E-38
ECM WIRING DIAGRAM (7/10) ........................ 6E-39
ECM WIRING DIAGRAM (8/10) ........................ 6E-40
ECM WIRING DIAGRAM (9/10) ........................ 6E-41
ECM WIRING DIAGRAM (10/10) ...................... 6E-42
ECM CONNECTOR PIN ASSIGNMENT
& OUTPUT SIGNAL ......................................... 6E-43
GENERAL DESCRIPTION FOR ECM AND
SENSORS ........................................................ 6E-51

Mass Air Flow (MAF) Sensor & Intake Air
Temperature (IAT) Sensor ............................. 6E-52
Throttle Position Sensor (TPS)....................... 6E-52
Idle Air Control (IAC) Valve ............................ 6E-53
Camshaft Position (CMP) Sensor .................. 6E-53
Crankshaft Position (CKP) Sensor ................. 6E-54
Engine Coolant Temperature (ECT) Sensor .. 6E-54
Vehicle Speed Sensor (VSS) ......................... 6E-55
Heated Oxygen (O
2) Sensor........................... 6E-55
GENERAL DESCRIPTION FOR FUEL
METERING....................................................... 6E-56
GENERAL DESCRIPTION FOR ELECTRONIC
IGNITION SYSTEM IGNITION
COILS & CONTROL ......................................... 6E-58
GENERAL DESCRIPTION FOR EVAPORATIVE
EMISSION SYSTEM ........................................ 6E-61
GENERAL DESCRIPRION FOR EXHAUST
GAS RECIRCULATION (EGR) SYSTEM......... 6E-62
ISUZU STRATEGY BASED DIAGNOSTICS .... 6E-63
Diagnostic Thought Process .......................... 6E-64
1. Verify the Complaint ................................... 6E-64
2. Perform Preliminary Checks....................... 6E-64
3. Check Bulletins and Troubleshooting
Hints ........................................................... 6E-65
4. Perform Service Manual Diagnostic
Checks ....................................................... 6E-65
5a and 5b. Perform Service Manual
Diagnostic Procedures ............................... 6E-65
5c. Technician Self Diagnoses ....................... 6E-65
5d. Intermittent Diagnosis............................ 6E-66
Symptom Simulation Tests.......................... 6E-67
5e. Vehicle Operates as Designed ................. 6E-68
6. Re-Examine the Complaint ........................ 6E-68
7. Repair and Verify Fix .................................. 6E-68
GENERAL SERVICE INFORMATION .............. 6E-69
Aftermarket Electrical and Vacuum
Equipment ..................................................... 6E-69
Electrostatic Discharge Damage .................... 6E-69