ISUZU Petrol Engine 6VD1 3.2L Workshop Service Repair Manual 3.2
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ISUZU Petrol Engine 6VD1 3.2L Workshop Service Repair Manual 3.2
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 milli meter (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 surfaces 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. 0 The six cylinders of this engine are identified by numbers.
TABLE OF CONTENTS:
ISUZU Petrol Engine 6VD1 3.2L Workshop Service Repair Manual 3.2
INDEX........................................................................................................ 0 Sec.6A ENGINE MECHANICAL................................................................................... 1 Service Precaution....................................................................................... 2 General Description...................................................................................... 3 Engine Diagnosis......................................................................................... 4 Cylinder Head Cover LH................................................................................... 17 Removal.............................................................................................. 17 Installation......................................................................................... 18 Cylinder Head Cover RH................................................................................... 19 Removal.............................................................................................. 19 Installation......................................................................................... 19 Common Chamber........................................................................................... 20 Removal.............................................................................................. 20 Installation......................................................................................... 20 Exhaust Manifold LH...................................................................................... 22 Removal.............................................................................................. 22 Installation......................................................................................... 22 Exhaust Manifold RH...................................................................................... 23 Removal.............................................................................................. 23 Installation......................................................................................... 23 Crankshaft Pulley........................................................................................ 24 Removal.............................................................................................. 24 Installation......................................................................................... 24 Timing Belt.............................................................................................. 25 Removal.............................................................................................. 25 Installation......................................................................................... 26 Camshaft................................................................................................. 30 Removal.............................................................................................. 30 Installation......................................................................................... 31 Cylinder Head............................................................................................ 33 Removal.............................................................................................. 33 Installation......................................................................................... 33 Valve Stem Oil Controller , Valve Spring and Valve Guide................................................. 35 Removal.............................................................................................. 35 Installation......................................................................................... 35 Piston, Piston Ring and Connecting Rod................................................................... 36 Removal.............................................................................................. 36 Installation......................................................................................... 37 Crankshaft and Main Bearings............................................................................. 38 Removal.............................................................................................. 38 Installation......................................................................................... 39 Rear Oil Seal............................................................................................ 43 Removal.............................................................................................. 43 Installation......................................................................................... 43 Engine Assembly.......................................................................................... 44 Removal.............................................................................................. 44 Installation......................................................................................... 45 Cylinder Head............................................................................................ 48 Cylinder Head and Associated Parts................................................................... 48 Disassembly.......................................................................................... 48 Clean................................................................................................ 49 Inspection and Repair................................................................................ 49 Reassembly........................................................................................... 50 Valve Spring, Oil Controller, Valve, Valve Guide......................................................... 52 Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts................................ 52 Disassembly.......................................................................................... 52 Inspection and Repair................................................................................ 53 Reassembly........................................................................................... 56 Camshaft................................................................................................. 59 Camshaft and Associated Parts........................................................................ 59 Disassembly.......................................................................................... 59 Inspection and Repair................................................................................ 60 Reassembly........................................................................................... 62 Crankshaft............................................................................................... 65 Crankshaft and Associated Parts...................................................................... 65 Disassembly.......................................................................................... 65 Inspection and Repair................................................................................ 66 Inspection and Repair................................................................................ 67 Reassembly........................................................................................... 69 Piston and Connecting Rod................................................................................ 73 Piston, Connecting Rod and Associate Parts........................................................... 73 Disassembly.......................................................................................... 73 Inspection and Repair................................................................................ 74 Reassembly........................................................................................... 78 Cylinder Block........................................................................................... 81 Cylinder Block and Associated Parts.................................................................. 81 Disassembly.......................................................................................... 81 Inspection and Repair................................................................................ 82 Reassembly........................................................................................... 83 Main Data and Specification.............................................................................. 86 Special Tool............................................................................................. 92 Sec.6B ENGINE COOLING...................................................................................... 94 Service Precaution....................................................................................... 94 General Description...................................................................................... 95 Diagnosis................................................................................................ 97 Draining and Refilling Cooling System.................................................................... 98 Water Pump............................................................................................... 99 Water Pump and Associated Parts...................................................................... 99 Removal.............................................................................................. 99 Inspection........................................................................................... 99 Installation......................................................................................... 99 Thermostat...............................................................................................100 Thermostat and Associated Parts......................................................................100 Removal..............................................................................................100 Inspection...........................................................................................100 Installation.........................................................................................100 Radiator.................................................................................................101 Radiator and Associated Parts........................................................................101 Removal..............................................................................................101 Inspection...........................................................................................102 Installation.........................................................................................103 Drive Belt and Cooling Fan...............................................................................105 Drive Belt and Associated Parts......................................................................105 Inspection...........................................................................................105 Installation.........................................................................................105 Main Data and Specifications.............................................................................106 Special Tool.............................................................................................107 Sec.6C ENGINE FUEL.........................................................................................108 Service Precaution.......................................................................................108 General Description......................................................................................109 Fuel Metering............................................................................................110 Fuel Filter..............................................................................................111 Removal..............................................................................................111 Inspection...........................................................................................111 Installation.........................................................................................111 Inspection...........................................................................................111 In‐Tank Fuel Filter..................................................................................111 Fuel Pump Flow Test..................................................................................111 Fuel Pump................................................................................................112 Fuel Pump and Associated Parts.......................................................................112 Removal..............................................................................................112 Installation.........................................................................................112 Fuel Pump Relay..........................................................................................113 General Description..................................................................................113 Fuel Tank................................................................................................113 Fuel Tank and Associated Parts.......................................................................113 Removal..............................................................................................113 Installation.........................................................................................114 Fuel Gauge Unit..........................................................................................114 Removal and Installation.............................................................................114 Fuel Filler Cap..........................................................................................114 General Description..................................................................................114 Inspection...........................................................................................114 Main Data and Specifications.............................................................................115 Sec.6D1 ENGINE ELECTRICAL...................................................................................116 Service Precaution.......................................................................................116 Battery..................................................................................................117 General Description......................................................................................117 Diagnosis................................................................................................117 Battery Charging.....................................................................................118 Jump Starting........................................................................................118 Battery Removal......................................................................................119 Battery Installation.................................................................................119 Main Data and Specifications.........................................................................120 Sec.6D2 IGNITION SYSTEM.....................................................................................121 Service Precaution.......................................................................................121 General Description......................................................................................122 Diagnosis................................................................................................122 Ignition Coil............................................................................................123 Removal..............................................................................................123 Inspection and Repair................................................................................123 Installation.........................................................................................123 Spark Plug...............................................................................................124 Removal..............................................................................................124 Inspection and Repair................................................................................124 Installation.........................................................................................124 Crankshaft Angle Sensor..................................................................................125 Removal..............................................................................................125 Installation.........................................................................................125 Main Data and Specifications.............................................................................126 Sec.6D3 STARTING AND CHARGING SYSTEM........................................................................127 Service Precaution.......................................................................................127 Starting System..........................................................................................128 General Description......................................................................................128 Diagnosis................................................................................................130 Starter..................................................................................................131 Removal..............................................................................................131 Installation.........................................................................................131 Disassembled View....................................................................................132 Disassembly..........................................................................................133 Inspection and Repair................................................................................135 Reassembly...........................................................................................139 Main Data and Specifications.........................................................................141 Charging System..........................................................................................143 General Description......................................................................................143 General On‐Vehicle Inspection............................................................................143 Generator................................................................................................144 Removal..............................................................................................144 Inspection...........................................................................................144 Installation.........................................................................................144 Disassembled View....................................................................................145 Disassembly..........................................................................................145 Inspection and Repair................................................................................148 Reassembly...........................................................................................150 Bench Test...........................................................................................150 Main Data and Specifications.........................................................................151 Sec.6E DRIVEABILITY AND EMISSIONS..........................................................................152 Specification............................................................................................155 Tightening Specifications............................................................................155 Diagrams and Schematics..................................................................................156 ECM Wiring Diagram (1 of 6)..........................................................................156 ECM Wiring Diagram (2 of 6)..........................................................................157 ECM Wiring Diagram (3 of 6)..........................................................................158 ECM Wiring Diagram (4 of 6)..........................................................................159 ECM Wiring Diagram (5 of 6)..........................................................................160 ECM Wiring Diagram (6 of 6)..........................................................................161 ECM Pinouts..............................................................................................162 ECM Pinout Table, 40-Way Connector ‐ “A”.............................................................162 ECM Pinout Table, 40-Way Connector ‐ “B”.............................................................163 Component Locators...................................................................................164 Engine Component Locator Table.......................................................................165 Undercarriage Component Locator......................................................................166 Sensors and Miscellaneous Component Locators.........................................................167 Fuse and Relay Panel (Underhood Electrical Center).......................................................169 Diagnosis................................................................................................170 Strategy-Based Diagnostics...........................................................................170 Strategy-Based Diagnostics...........................................................................170 DTC Stored...........................................................................................170 No DTC...............................................................................................170 No Matching Symptom..................................................................................170 Intermittents........................................................................................170 No Trouble Found.....................................................................................170 Verifying Vehicle Repair.............................................................................170 General Service Information..............................................................................171 Maitenance Schedule..................................................................................171 Visual/Physical Engine Compartment Inspection........................................................171 Basic Knowledge of Tools Required....................................................................171 Seral Data Communications................................................................................172 Class II Serial Data Communications..................................................................172 On-Board Diagnostic Tests................................................................................172 On-Board Diagnostic Tests............................................................................172 Comprehensive Component Monitor Diagnostic Operation.................................................172 System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations....173 Common OBD Terms.....................................................................................173 The Diagnostic Executive.............................................................................173 DTC Types............................................................................................174 Verifying Vehicle Repair.............................................................................175 Reading Flash Diagnostic Trouble Codes...............................................................175 Reading Diagnostic Trouble Codes Using a TECH 2......................................................176 On-Board Diagnosis (Self-Diagnosis)..................................................................176 Tech 2 Scan Tool.....................................................................................178 Getting Started......................................................................................179 DTC Modes............................................................................................181 DTC Information Mode.................................................................................181 Primary System-Based Diagnostics.........................................................................181 Primary System-Based Diagnostics.....................................................................181 Fuel Control Heated Oxygen Sensors...................................................................181 HO2S Heater..........................................................................................181 Fuel Trim System Monitor Diagnostic Operation............................................................182 On-Board Diagnostic (OBD) System Check...................................................................183 A/C Clutch Control Circuit Diagnosis.....................................................................185 Electronic Ignition System Diagnosis.....................................................................191 Visual Check of The Evaporative Emission Canister........................................................191 Fuel Metering System Check...............................................................................191 Idle Air Control (IAC) Valve.............................................................................191 Fuel System Pressure Test................................................................................191 Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure...............................191 Engine Control Module ECM Diagnosis......................................................................196 Multiple ECM Information Sensor DTCS Set.................................................................196 Tech 2 Data Definitions and Ranges.......................................................................199 Typical Scan Data Values.................................................................................200 No Malfunction Indicator Lamp (MIL)......................................................................204 Malfunction Indicator Lamp (MIL) “ON” Steady.............................................................207 Engine Cranks But Will Not Run...........................................................................210 Fuel System Electrical Test..............................................................................215 Fuel System Diagnosis....................................................................................218 Idle Air Control (IAC) System Check......................................................................223 Barometric Pressure (BARO) Output Check..................................................................226 ECM Diagnostic Trouble Codes.............................................................................228 Diagnostic Trouble Code (DTC) P0101 (Flash DTC=61) MAF System............................................230 Diagnostic Trouble Code (DTC) P0102 (Flash DTC=61) MAF Sensor Circuit Low Frequency......................233 Diagnostic Trouble Code (DTC) P0103 (Flash DTC=61) MAF Sensor Circuit High Frequency.....................236 Diagnostic Trouble Code (DTC) P0107 (Flash DTC=33) BARO Sensor Circuit Low Voltage.......................238 Diagnostic Trouble Code (DTC) P0108 (Flash DTC=33) BARO Sensor Circuit Hight Voltage.....................241 Diagnostic Trouble Code (DTC) P0112 (Flash DTC=23) IAT Sensor Circuit Low Voltage........................244 Diagnostic Trouble Code (DTC) P0113 (Flash DTC=23) IAT Sensor Circuit High Voltage.......................247 Diagnostic Trouble Code (DTC) P0117 (Flash DTC=14) ECT Sensor Circuit Low Voltage........................250 Diagnostic Trouble Code (DTC) P0118 (Flash DTC=14) ECT Sensor Circuit High Voltage.......................252 Diagnostic Trouble Code (DTC) P0121 (Flash DTC=21) TP System Performance.................................255 Diagnostic Trouble Code (DTC) P0122 (Flash DTC=21) TP Sensor Circuit Low Voltage.........................258 Diagnostic Trouble Code (DTC) P0123 (Flash DTC=21) TP Sensor Circuit High Voltage........................261 Diagnostic Trouble Code (DTC) P0131 (Flash DTC=15) HO2S Circuit Low Voltage..............................264 Diagnostic Trouble Code (DTC) P0132 (Flash DTC) HO2S Circuit High Voltage................................267 Diagnostic Trouble Code (DTC) P0134 (Flash DTC=15) HO2S Circuit Insufficient Activity....................270 Diagnostic Trouble Code (DTC) P0171 (Flash DTC=44) Fuel Trim System Too Lean.............................273 Diagnostic Trouble Code (DTC) P0172 (Flash DTC=45) Fuel Trim System Rich.................................277 Diagnostic Trouble Code (DTC) P0201 (Flash DTC=31) Injector 1 Control Circuit............................281 Diagnostic Trouble Code (DTC) P0202 (Flash DTC=31) Injector 2 Control Circuit............................284 Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit...........................................287 Diagnostic Trouble Code (DTC) P0204 (Flash DTC=31) Injector 4 Control Circuit............................290 Diagnostic Trouble Code (DTC) P0205 (Flash DTC=31) Injector 5 Control Circuit............................293 Diagnostic Trouble Code (DTC) P0206 (Flash DTC=31) Injector 6 Control Circuit............................296 Diagnostic Trouble Code (DTC) P0336 (Flash DTC=29) CKP Reference Signal Circuit..........................299 Diagnostic Trouble Code (DTC) P0337 (Flash DTC=29) CKP Sensor Circuit Low Frequency......................301 Diagnostic Trouble Code (DTC) P0341 (Flash DTC=41) CMP Sensor Circuit Performamce........................303 Diagnostic Trouble Code (DTC) P0342 (Flash DTC=41) CMP Sensor Circuit Low................................306 Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit...........................................310 Diagnostic Trouble Code (DTC) P0352 (Flash DTC=42) Ignition 2 Control Circuit............................313 Diagnostic Trouble Code (DTC) P0353 (Flash DTC=42) Ignition 3 Control Circuit............................316 Diagnostic Trouble Code (DTC) P0354 (Flash DTC=42) Ignition 4 Control Circuit............................319 Diagnostic Trouble Code (DTC) P0355 (Flash DTC=42) Ignition 5 Control Circuit............................322 Diagnostic Trouble Code (DTC) P0356 (Flash DTC=42) Ignition 6 Control Circuit............................325 Diagnostic Trouble Code (DTC) P0502 (Flash DTC=24) VSS No Signal.........................................328 Diagnostic Trouble Code (DTC) P0562 (Flash DTC=66) System Voltage Low....................................331 Diagnostic Trouble Code (DTC) P0563 (Flash DTC=66) System Voltage High...................................332 Diagnostic Trouble Code (DTC) P0601 (Flash DTC=51) ECM Memory............................................333 Diagnostic Trouble Code (DTC) P1171 (Flash DTC=44) Fuel System Lean Dueing Acceleration..................334 Diagnostic Trouble Code (DTC) P1508 (Flash DTC=22) IAC System Low RPM....................................337 Diagnostic Trouble Code (DTC) P1509 (Flash DTC=22) IAC System High RPM...................................340 Symptom Diagnosis........................................................................................343 Default Matrix Table.....................................................................................366 Camshaft Position (CMP) Sensor...........................................................................369 Crankshaft Position (CKP) Sensor.........................................................................370 Engine Coolant Temperature (ECT) Sensor..................................................................370 Heated Oxygen Sensor (HO2S)..............................................................................371 Intake Air Temperature (IAT) Sensor......................................................................373 Mass Air Flow (MAF) Sensor...............................................................................373 Barometric Pressure (BARO) Sensor........................................................................374 Malfunction Indicator Lamp (MIL).........................................................................374 Engine Control Module (ECM) .............................................................................374 EEPROM...................................................................................................375 Power Steering Pressure (PSP) Switch.....................................................................375 Throttle Position (TP) Sensor............................................................................376 Vehicle Speed Sensor (VSS)...............................................................................377 Air Cleaner/Air Filter...................................................................................378 Idle Air Control (IAC) Valve.............................................................................379 Common Chamber...........................................................................................380 Accelerator Cable Assembly...............................................................................380 Accelerator Pedal Replacement............................................................................382 Fuel Fillter Cap.........................................................................................384 Fuel Filter..............................................................................................384 Fuel Gauge Unit..........................................................................................386 Fuel Injectors...........................................................................................386 Fuel Pressure Regulator..................................................................................387 Fuel Metering System.....................................................................................389 Fuel Pump Assembly.......................................................................................389 Fuel Pump Relay..........................................................................................389 Fuel Rail Assembly.......................................................................................390 Fuel Tank................................................................................................391 Throttle Body (TB).......................................................................................391 Electronic Ignition System...............................................................................392 Catalytic Converter......................................................................................393 Air Conditioning Relay...................................................................................393 EVAP Canister Hoses......................................................................................393 EVAP Canister............................................................................................393 EVAP Canister Purge Solenoid.............................................................................394 Fuel Tank Vent Valve.....................................................................................395 Positive Crankcase Ventilation (PCV) Valve...............................................................395 Wiring and Connectors....................................................................................395 Wire Harness Repair: Twisted Shielded Cable..............................................................396 Twisted Leads............................................................................................396 Weather-Pack Connector...................................................................................398 Com-Pack III.............................................................................................399 Metri-Pack...............................................................................................399 General Description (ECM and Sensors)....................................................................401 General Description (Air Induction)......................................................................406 General Description (Fuel Metering)......................................................................406 General Description (Electronic Ignition System).........................................................409 A/C Clutch Diagnosis.....................................................................................412 General Description (Evaporative (EVAP) Emission System).................................................413 Diagnosis................................................................................................414 Special Tools............................................................................................416 Sec.6F ENGINE EXHAUST......................................................................................419 Service Precaution.......................................................................................419 General Description......................................................................................420 Three Way Catalytic Converter and Forked Exhaust Pipe....................................................421 Three Way Catalytic Converter and Front Exhaust Pipe and Associated Parts............................421 Removal..............................................................................................421 Installation.........................................................................................421 Exhaust Silencer.........................................................................................422 Exhaust Silencer and Associated Parts................................................................422 Removal..............................................................................................422 Installation.........................................................................................422 Rear Exhaust pipe........................................................................................423 Rear Exhaust pipe and Associated Parts...............................................................423 Removal..............................................................................................423 Installation.........................................................................................423 Main Data and Specifications.............................................................................424 Sec.6G ENGINE LUBRICATION..................................................................................425 Service Precaution.......................................................................................425 General Description......................................................................................426 Oil Pump.................................................................................................427 Oil Pump and Associated Parts........................................................................427 Disassembly..........................................................................................427 Inspection and Repair................................................................................428 Reassembly...........................................................................................429 Oil Pan and Crankcase....................................................................................431 Removal..............................................................................................431 Installation.........................................................................................431 Oil Pump.................................................................................................434 Removal..............................................................................................434 Installation.........................................................................................434 Oil Pump Oil Seal........................................................................................436 Removal..............................................................................................436 Installation.........................................................................................436 Main Data and Specification..............................................................................437 Sec.6H ENGINE SPEED CONTROL SYSTEM.........................................................................438 Service Precaution.......................................................................................438 Accelerator Pedal Control Cable..........................................................................439 Removal..............................................................................................439 Installation.........................................................................................439 Inspection...........................................................................................439 Accelerator Pedal........................................................................................440 Accelerator Pedal and Associated Parts...............................................................440 Removal..............................................................................................440 Installation.........................................................................................440 Sec.6J INDUCTION...........................................................................................441 Service Precaution.......................................................................................441 Air Cleaner Element......................................................................................442 Removal..............................................................................................442 Inspection...........................................................................................442 Installation.........................................................................................442
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
Maxwell Caleb –
I had it printed on line. It took quite a while but got it done.