2004 ISUZU TF SERIES Fuel sensor

ENGINE MECHANICAL (6VE1 3.5L) 6A-15
Abnormal Combustion
Symptom Possible Cause Action
Trouble in fuel system Fuel pressure control valve defectiveReplace
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
broken or poor connections Reconnect, correct or replace
Mass Airflow (MAF) Sensor circuit
open or defective Correct or replace
MAF Sensor defective Replace
Engine Coolant Temperature (ECT)
Sensor circuit open or shorted Correct or replace
ECT Sensor defective Replace
Throttle Position Sensor adjustment
incorrect Readjust
Throttle Position Sensor defective Replace
Throttle Position Sensor connector
poor connections Reconnect
Vehicle Speed Sensor cable poor
connections 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 poor
connections or defective Correct or replace

6A-20 ENGINE MECHANICAL (6VE1 3.5L)
Malfunction Indicator Lamp
The instrument panel “CHECK ENGINE" Malfunction
Indicator Lamp (MIL) illuminates by self diagnostic
system when the system checks the starting of engine,
or senses malfunctions. ”CHECK ENGINE" MIL does
not illuminate at the starting of engine

Symptom Possible Cause Action
“CHECK ENGINE" MIL does not
illuminate at the starting of engine Bulb defective Replace
MIL circuit open Correct or replace
Command signal circuit to operate
self diagnostic system shorted Correct or replace
Engine Control Module (ECM) cable
loosely connected, disconnected or
defective Correct or replace
ECM defective Replace
“CHECK ENGINE" MIL illuminates,
and stays on Deterioration of heated oxygen
sensor internal element Replace
Heated oxygen sensor connector
terminal improper contact Reconnect properly
Heated oxygen sensor lead wire
shorted Correct
Heated oxygen sensor circuit open Correct or replace
Deterioration of engine coolant
temperature sensor internal element Replace
Engine coolant temperature sensor
connector terminal improper contact Reconnect properly
Engine coolant temperature sensor
lead wire shorted Correct
Engine coolant temperature sensor
circuit open Correct or replace
Throttle position sensor open or
shorted circuits Correct or replace
Deterioration of crankshaft position
sensor Replace
Crankshaft position sensor circuit
open or shorted Correct or replace
Vehicle speed sensor circuit open Correct or replace
Intake air temperature sensor circuit
open or shorted Correct or replace
Fuel injector circuit open or shorted Correct or replace
ECM driver transistor defective Replace ECM
Malfunctioning of ECM RAM
(Random Access Memory) or ROM
(Read Only Memory) Replace ECM

ENGINE MECHANICAL (6VE1 3.5L) 6A-21
Cylinder Head Cover LH
Removal
1. Disconnect battery ground cable.
2. Disconnect positive crankcase ventilation hose.
3. Remove camshaft angle sensor connector.
4. Remove ground cable fixing bolt on cylinder head
cover.
5. Ignition coil connector and ignition coil.

Disconnect the three connectors from the
ignition coils.

Remove harness bracket bolt on cylinder head
cover.

Remove fixing bolts on ignition coils.









060RW078
Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assemblies

6. Remove fixing bolt for fuel injector harness
bracket.

7. Remove eight fixing bolts, then the cylinder head
cover.






010RW001
Installation
1. Install cylinder head cover.

Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.

Apply sealant (TB-1207B or equivalent) of bead
diameter 2-3 mm at eight place of arched area
of camshaft bracket on front and rear sides.

The cylinder head cover must be installed with
in 5 minutes after sealant application to preven
t
hardening of sealant.

Tighten bolts to the specified torque.
Torque : 9 N




m (0.9 kg




m/7 lb ft)




010RW006

6A-22 ENGINE MECHANICAL (6VE1 3.5L)
2. Install fuel injection harness bracket and tighten
bolt to the specified torque.
Torque : 8 N




m (0.8 kg




m/8 lb ft)
3. Connect ignition coil connector and ignition coil,
then tighten bolt to the specified torque.
Torque : 4 N




m (0.4 kg




m/3 lb ft)


060RW078
Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assembly

4. Connect ground cable and tighten bolts to the
specified torque.
Torque : 8 N




m (0.8 kg




m/6 lb ft)
5. Connect camshaft angle sensor connector.
6. Install positive crankcase ventilation hose.

6A-24 ENGINE MECHANICAL (6VE1 3.5L)
Common Chamber
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner duct assembly.
3. Remove the ECM.

Disconnect the two connectors from the ECM.

Remove fixing bolts on the common chamber.

Remove fixing bolts for ground cable.




060RW025
4. Remove the accelerator control cable from
accelerator control cable bracket.

Slide the lock in direction A

Rotate the ratchet ring in indirection an arro
w
90




RTW46ASH000201
Legend
(1) Cable Bracket
(2) Ratchet ring
(3) Outer Cap
(4) Lock
(5) Paint Mark
(6) Arrow Mark

5. Remove the accelerator control cable from the
throttle.
6. Disconnect vacuum booster hose from common
chamber.
7. Disconnect connector from manifold absolute
pressure sensor, idle air control valve, throttle
position sensor, solenoid valve, electric vacuum
sensing valve.
8. Disconnect vacuum hose on canister VSV and
positive crankcase ventilation hose, fuel rail
assembly with pressure control valve bracket.
9. Remove ventilation hose from throttle valve and
intake duct and remove water hose.
10. Remove exhaust gas recirculation valve assembly
fixing bolt and nut on common chamber.
11. Remove two bolts from common chamber rea
r
side for remove fuel hose bracket.
12. Remove common chamber four bolts and fou
r
nuts then remove the common chamber.



025RW001
Legend
(1) Common Chamber
(2) Throttle Valve Assembly
(3) Bolt

13. Remove the four throttle body fixing bolts.

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 FUEL (6VE1 3.5L) 6C-3
Fuel Metering
The Engine Control Module (ECM) is in complete
control of this fuel delivery system during normal driving
conditions.
The intake manifold function, like that of a diesel, is
used only to let air into the engine. The fuel is injected
by separate injectors that are mounted over the intake
manifold.
The Barometric Pressure (BARO) sensor measures the
changes in the barometric pressure which result from
engine load and speed changes, which the BARO
sensor converts to a voltage output.
This sensor generates the voltage to change
corresponding to the flow of the air drawn into the
engine.
The changing voltage is transformed into an electric
signal and provided to the ECM.
With receipt of the signals sent from the BARO sensor,
Intake Air Temperature sensor and others, the ECM
determines an appropriate fuel injection pulse width
feeding such information to the fuel injector valves to
effect an appropriate air/fuel ratio.
The Multiport Fuel Injection system utilizes an injection
system where the injectors turn on at every crankshaf
t
revolution. The ECM controls the injector on time so
that the correct amount of fuel is metered depending on
driving conditions.
Two interchangeable “O" rings are used on the injecto
r
that must be replaced when the injectors are removed.
The fuel rail is attached to the top of the intake manifold
and supplies fuel to all the injectors.
Fuel is recirculated through the rail continually while the
engine is running. This removes air and vapors from the
fuel as well as keeping the fuel cool during hot weathe
r
operation.
The fuel pressure control valve that is mounted on the
fuel rail maintains a pressure differential across the
injectors under all operating conditions. It is
accomplished by controlling the amount of fuel that is
recirculated back to the fuel tank based on engine
demand.
See Section “Driveability and Emission" for more
information and diagnosis.