2004 ISUZU TF SERIES cooling

6A-28 ENGINE MECHANICAL (6VE1 3.5L)
Crankshaft Pulley
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.


850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Serpentine Belt

5. Remove cooling fan assembly four fixing nuts,
then the cooling fan assembly.
6. Remove crankshaft pulley assembly using
5884001330 crankshaft holder, hold crankshaf
t
pulley then remove center bolt and pulley.
Installation
1. Install crankshaft pulley using 5884001330
crankshaft holder, hold the crankshaft pulley and
tighten center bolt to the specified torque.
Torque: 167 N




m (17.0 kg




m/123 lb ft)
2. Install cooling fan assembly and tighten bolts/nuts
to the specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft) for fan pulley
and fan bracket.
Torque: 10 N




m (1.0 kg




m/88.5 lb in) for fan and
clutch assembly.
3. Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
4. Install radiator upper fan shroud.
5. Install air cleaner assembly.

ENGINE MECHANICAL (6VE1 3.5L) 6A-29
Timing Belt
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using
wrench then remove drive belt.


850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt

5. Remove cooling fan assembly four nuts, then the
cooling fan assembly.
6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.
10. Remove crankshaft pulley assembly using
5884001330 crankshaft holder, hold crankshaf
t
pulley remove center bolt, then the pulley.
11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover 13. Remove pusher.
CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.




014RW011
Legend
(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin

14. Remove timing belt.
CAUTION:
1. Do not bend or twist the belt, otherwise its
core could be damaged. The belt should not be
bent at a radius less than 30 mm.
2. Do not allow oil or other chemical substances
to come in contact with the belt. They will
shorten the life.
3. Do not attempt to pry or stretch the belt with a
screw driver or any other tool during
installation.
4. Store timing belt in a cool and dark place.
Never expose the belt direct sunlight or heat.

ENGINE MECHANICAL (6VE1 3.5L) 6A-33
4. Install crankshaft pulley using 5-8840-0133-0, hold
the crankshaft pulley and tighten center bolt to the
specified torque.
Torque: 167 N




m (17.0 kg




m/123 lb ft)
5. Install fan pulley bracket and tighten fixing bolts to
the specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft)
6. Install power steering pump assembly and tighten
to the specified torque.
Torque:
M8 bolt: 25 N




m (2.5 kg




m/18 lb ft)
M10 bolt: 43 N




m (4.4 kg




m/32 lb ft)
7. Install cooling fan assembly and tighten bolts/nuts
to the specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft) for fan pulley
and fan bracket.
Torque: 10 N




m (1.0 kg




m/7 lb ft) for fan and
clutch assembly.
8. Move drive belt tensioner to loose side using
wrench, then install drive belt to normal position.


850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt

9. Install radiator upper fan shroud.
10. Install air cleaner assembly.

ENGINE MECHANICAL (6VE1 3.5L) 6A-49
Engine Assembly
Removal

P1010068
1. Disconnect battery ground and positive cable.
2. Remove battery.
3. Make alignment mark on the engine hood and
hinges before removal in order to return the hood
to original position exactly.
4. Remove engine hood.
5. Drain radiator coolant.
6. Disconnect accelerator cable and automatic cruise
control cable from throttle valve on common
chamber.
7. Remove the ECM.

Disconnect the two connectors from the ECM.

. Remove fixing bolts on the common chamber.

Remove fixing bolts for ground cable.
8. Disconnect air duct with air cleaner cover.
9. Remove air cleaner assembly.
10. Disconnect canister vacuum hose.
11. Disconnect vacuum booster hose.
12. Disconnect three engine harness connectors.
13. Disconnect harness connector to transmission (lef
t
front side of engine compartment), disconnect shift
on the fly harness connector from front side o
f
front axle and remove transmission harness
bracket from engine left side.
14. Disconnect ground cable between engine and
frame.
15. Disconnect bonding cable connector on the back
of right dash panel.
16. Disconnect bonding cable terminal on the lef
t
bank.

17. Disconnect starter harness connector from starter.
18. Disconnect generator harness connector from
generator.
19. Disconnect coolant reserve tank hose from
radiator.
20. Remove radiator upper and lower hoses.
21. Remove upper fan shroud.
22. Remove cooling fan assembly four fixing nuts,
then the cooling fan assembly.
23. Move drive belt tensioner to loose side using
wrench then remove drive belt.
24. Remove power steering pump fixing bolts, then
power steering pump. Place the power steering
pump along with piping on the body side.
25. Remove air conditioning compressor fixing bolts
from bracket and place the compressor along with
piping on the body side.
26. Remove four O2 sensor harness connectors (two
each bank) from exhaust front pipe.
27. Remove three exhaust pipe fixing nuts from each
bank.
28. Remove two exhaust pipe fixing nuts from each
exhaust pipe, then move exhaust pipe to rear side
of vehicle.
29. Remove flywheel dust covers.
30. Disconnect two heater hoses from engine.
31. Disconnect fuel hose from right side o
f
transmission.
CAUTION: Plug fuel pipe on engine side and fuel
hose from fuel tank.
32. Remove transmission assembly. Refer to
Transmission section in this manual.
33. Support the engine by engine hoist.
34. Remove two left side engine mount fixing bolts
from engine mount on chassis side.
35. Remove two right side engine mount fixing bolts
from engine mount on chassis side.
36. Remove engine assembly.
Installation
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Also take care that dowel positions are
different between the manual transmission and the
automatic transmission. Otherweise, the
transmission may be damaged.

6A-50 ENGINE MECHANICAL (6VE1 3.5L)





012RS009
1. Install engine assembly. Tighten engine mount
fixing bolts to frame to the specified torque.
Torque: 41 N




m (4.2 kg




m/30 lb ft)
2. Reconnect fuel hose to fuel pipe on engine.
3. Install transmission assembly. Refer to
Transmission section in this manual.
4. Reconnect two heater hoses to engine.
5. Install flywheel dust covers.
6. Install exhaust pipe and temporally tighten two
(each bank) rear exhaust flange nuts then tighten
three stud nuts (each bank) between exhaus
t
manifold and exhaust pipe, finally tighten rear side
stud nuts to the specified torque.
Torque: 67 N




m (6.8 kg




m/49 lb ft)






LTW36FSH000101
7. Reconnect O2 sensor connector.
8. Install cooling fan assembly and tighten bolts/nuts
to the specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft) for fan pulley
and fan bracket.
Torque : 10 N




m (1.0 kg




m/7 lb ft) for fan and
clutch assembly.
9. Install air conditioner compressor to engine and
tighten to the specified torque.
Torque : 43 N




m (4.4 kg




m/32 lb ft)
10. Install power steering pump, tighten fixing bolt to
the specified torque.
Torque :
M8 bolts : 25 N




m (2.5 kg




m/18 lb ft)
M10 bolts : 43 N




m (4.4 kg




m/32 lb ft)
11. Move drive belt tensioner to loose side using
wrench, then install drive belt to normal position.



850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt

12. Install upper fan shroud.
13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back o
f
right dash panel.

ENGINE COOLING (6VE1 3.5L) 6B-1
ENGINE
ENGINE COOLING (6VE1 3.5L)
CONTENTS

Service Precaution............................................. 6B–1
General Description ........................................... 6B–2
Diagnosis ........................................................... 6B–5
Draining and Refilling Cooling System .............. 6B–6
Water Pump ...................................................... 6B–7
Water Pump and Associated Parts ................ 6B–7
Removal ......................................................... 6B–7
Inspection ....................................................... 6B–7
Installation....................................................... 6B–7
Thermostat ........................................................ 6B–9
Thermostat and Associated Parts .................. 6B–9
Removal ......................................................... 6B–9
Inspection ....................................................... 6B–9

Installation ...................................................... 6B–9
Radiator ............................................................. 6B–10
Radiator and Associated Parts ....................... 6B–10
Removal ......................................................... 6B–11
Inspection ....................................................... 6B–11
Installation ...................................................... 6B–12
Drive Belt and Cooling Fan ................................ 6B–15
Drive Belt and Associated Parts ..................... 6B–15
Inspection ....................................................... 6B–15
Installation ...................................................... 6B–15
Main Data and Specifications ............................ 6B–16
Special Tool .................................................... 6B–18


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.

6B-2 ENGINE COOLING (6VE1 3.5L)
General Description



030RW001
Legend (7)Cylinder Head
(1) Water Pump (8) Right Bank
(2) Thermostat (9) Throttle Body
(3) Radiator (10) Cylinder Block
(4) Reserve Tank (11) Cylinder Head
(5) Cooling Fan (12) Left Bank
(6) Cylinder Block (13) Heater


The engine cooling system consists of the radiator, the
water pump, the cooling fan, and the thermostat.
To quickly increase cold engine coolant temperature fo
r
smooth engine operation, the coolant is circulated by
the water pump and thermostat through the bypass
hose and back to the cylinder body.
The coolant does not circulate through the radiator.
When the coolant temperature reaches specified value,
the thermostat will begin to open and a gradually
increasing amount of coolant will circulate through the
radiator.
The thermostat will be fully open when the coolan
t
temperature reaches specified value. All of the coolant
is now circulating through the radiator for effective
engine cooling.

ENGINE COOLING (6VE1 3.5L) 6B-3
Water Pump
The EC pump is a centrifugal impeller type and is driven
by a timing belt.


030RS001
Thermostat
The thermostat is a wax pellet type with a air hole(1)
and is installed in the thermostat housing.


031RW002
Radiator
The radiator is a tube type with corrugated fins. In order
to raise the boiling point of the coolant, the radiator is
fitted with a cap in which the valve is operated at 93.3


122.7 kPa (13.5
17.8 psi) pressure. (No oil cooler
provided for M/T)


110RS001
Antifreeze Solution
 Calculating mixing ratio






F06RW005