2004 ISUZU TF SERIES engine remove

ENGINE SPEED CONTROL SYSTEM (6VE1 3.5L) 6H-3
4. Remove the accelerator control cable from the
throttle.




RTW46HMH000101

Inspection
Check the following items and replace the control
cable if any abnormality is found.
 The control cable should move smoothly.
 The control cable should not be bent or kinked.
 The control cable should not be damage o
r
corrosion.
Installation
1. Install the accelerator control cable to accelerator
control pedal and dash panel.
2. Install the accelerator control cable to throttle.
Attach T-END and inner cable to throttle cam o
f
engine.
3. Install accelerator control cable to accelerato
r
bracket.
1) Rotate the ratchet ring in direction an arrow 90

until both white marking are aligned.
2) Confirm marking of outer cap must be uppe
r
side.
3) Slider the lock in direction B.
4) Confirm ratchet ring is locked.

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) 6-9
Abnormal Noise Due to Hydraulic Lash Adjuster
Should abnormal noise due to the hydraulic lash
adjuster trouble be heard immediately after the engine
is started, inspect as follows:

Condition Possible cause Correction
Abnormal noise is heard Air contaminated Bleed
HLA is spongy Check ball valve broken Repair
Safety valve in cylinder head
broken Replace
Valve clearance is not zero HLA inside stick Replace HLA assembly

Troubleshooting Procedure
Short out each spark plug in sequence using insulated
spark plug wire removers. Locate cylinder with
defective bearing by listening for abnormal noise that
stops when spark plug is shorted out.

Condition Possible cause Correction
Noise from connecting rods or
from connecting rod bearings
(Faulty connecting rods or
connecting rod bearings usually
make an abnormal noise slightly
higher than the crank bearing
noise, which becomes more
evident when engine is
accelerated) Bearing or crankshaft pin worn Replace connecting rod bearings
and crankshaft or regrind
crankshaft and install the under
size bearing
Crankpin out of round Replace connecting rod bearings
and crankshaft or regrind
crankshaft and install the under
size bearing
Connecting rod bent Correct or replace
Connecting rod bearing seized Replace connecting rod bearings
and crankshaft or regrind
crankshaft and install the under
size bearing

Troubleshooting Procedure
Abnormal noise stops when the spark plug on the
cylinder with defective parts is shorted out.

Condition Possible cause Correction
Piston and cylinder
(Faulty piston or cylinder usually
makes a combined mechanical
thumping noise which increases
when engine is suddenly
accelerated but diminishes
gradually as the engine warms up) Piston clearance increased due to
cylinder wear Replace piston and cylinder body
Piston seized Replace piston and cylinder body
Piston ring broken Replace piston and cylinder body
Piston defective Replace pistons and others

ENGINE DIAGNOSIS (C24SE) 6-11
Abnormal Combustion
Condition Possible cause Correction
Trouble in fuel injection system Fuel pressure control valve
defective Replace
Fuel filter clogged Replace
Fuel pump clogged Clean or replace
Fuel tank or fuel pipe clogged Clean or replace
Fuel injector clogged Clean or replace
Fuel pump relay defective Replace
Power supply cable for fuel pump
loosely connected or defective Reconnect, correct or replace
Manifold Absolute Pressure
Sensor circuit open or shorted Correct or replace
Manifold Absolute Pressure
Sensor defective Replace
Engine Coolant Temperature
(ECT) Sensor circuit open or
shorted Correct or replace
ECT Sensor defective Replace
Throttle Position Sensor
adjustment incorrect Reconnect
Throttle Position Sensor defective Replace
Throttle Position Sensor
connector loosely connected Reconnect
Vehicle Speed Sensor cable
loosely connected or defective Correct or replace
Vehicle Speed Sensor loosely
fixed Fix tightly
Vehicle Speed Sensor in wrong
contact or defective Replace
Engine Control Module cable
loosely connected or defective Correct or replace
Trouble in emission control
system Heated Oxygen Sensor circuit
open (If applicable) Correct or replace
Heated Oxygen Sensor defective
(If applicable) Replace
Signal vacuum hose loosely fitted
or defective Correct or replace
ECT Sensor circuit open or
shorted Correct or replace
ECT Sensor defective Replace
Evaporative Emission Control
system (If applicable) Refer to Section 6E
Trouble in ignition system - Refer to "Engine Lacks Power"
Trouble in cylinder head parts Carbon deposits in combustion
chamber Remove carbon
Carbon deposit on valve, valve
seat and valve guide Remove carbon

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

6A-4 ENGINE MECHANICAL (C24SE)
GENERAL DESCRIPTION

Engine Cleanliness And Care
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances
that are measured in the thousandths of a millimeter (ten thousandths of an inch). Accordingly, when any internal
engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that
proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is
considered standard shop practice even if not specifically stated.

A liberal coating of engine oil should be applied to all friction areas during assembly to protect and lubricate
the surfaces on initial operation.

Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft journal
bearings are removed for service, they should be retained in order.


At the time of installation, they should be installed in the same locations and with the same mating surfaced as
when removed.

Battery cables should be disconnected before any major work is performed on the engine. Failure to
disconnect cables may result in damage to wire harness or other electrical parts.

The four cylinders of this engine are identified by numbers; cylinders 1, 2, 3 and 4, as counted from crankshaft
pulley.
General Information on Engine Service
The following information on engine service should be noted carefully, as it is important in preventing damage and

ENGINE MECHANICAL (C24SE) 6A-5
contributing to reliable engine performance:

When raising or supporting the engine for any reason, do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump strainer, jacking against the oil pan may cause damage to the
oil pick up unit.

The 12-volt electrical system is capable of damaging circuits. When performing any work where electrical
terminals could possible be grounded, the ground cable of the battery should be disconnected at the battery.

Any time the intake air duct or air cleaner is removed, the intake opening should be covered. This will protect
against accidental entrance of foreign material into the cylinder which could cause extensive damage when
the engine is started.

Cylinder Block
The cylinder block is made of cast iron. The crankshaft is supported by five bearings. The bearing cap is made of
nodular cast iron.

Cylinder Head
The cylinder head is made of aluminum alloy casting with a spark plug in the center.

Valve Train
Valve system is a single over head camshaft.
The valves clearance adjustment are hydraulic.
Hydraulic valve lifter adjustment, no adjustment necessary.

Intake Manifold
The intake manifold is made of aluminum alloy.

Exhaust Manifold
The exhaust manifold is made of high Si-Mo nodular iron.

Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade that meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made of cast hardened steel. The connecting rod bearings are
made of modular cast iron. The connecting rod bearings are made of steel backed with tri-metal babbitt metal.

Crankshaft and Bearings
The crank shaft is made of modular cast iron. Pins and journal are graded for correct size selection for their bearing.