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Isuzu TF Series 6VE1 3.5L Engine Workshop Manual Section 6

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Complete Isuzu TF Series 6VE1 3.5L Engine Workshop Manual Section 6 β€” engine mechanical, cooling, fuel, electrical, ignition, emissions, exhaust, lubrication, speed control and induction in one PDF.

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Description

Isuzu TF Series 6VE1 3.5L Engine Workshop Manual β€” Section 6

The Isuzu TF Series 6VE1 3.5L Engine Workshop Manual Section 6 is the complete engine service section for the 6VE1 3.5-litre V6 gasoline engine used in Isuzu TF Series vehicles. Published under document number TF6VE-WE-0431, this workshop manual covers every major engine system in detail β€” mechanical overhaul, cooling, fuel delivery, ignition, starting and charging, driveability and emissions, exhaust, lubrication, speed control, and induction. It is written for technicians and experienced owners who need manufacturer procedures, torque values, diagnostic flow charts, and component specifications for the 6VE1 engine.

File Details

  • Manual type: Engine Workshop Manual (Section 6)
  • Brand: Isuzu
  • Series: TF Series
  • Engine: 6VE1 3.5L V6 gasoline
  • Document number: TF6VE-WE-0431
  • Language: English
  • Page count: 582 pages
  • File format: PDF

Chapters Covered

The Isuzu TF Series 6VE1 engine workshop manual is organised into ten engine sections, each with removal, installation, inspection, repair, reassembly, specifications, and special tool listings.

  • Engine Mechanical (6A) β€” Service precaution; general description; engine diagnosis; cylinder head covers LH/RH; common chamber; exhaust manifolds LH/RH; crankshaft pulley; timing belt; camshaft; cylinder head; valve stem oil controller, valve spring and valve guide; piston, piston ring and connecting rod; crankshaft and main bearings; rear oil seal; engine assembly; full cylinder head overhaul; valve train overhaul; camshaft overhaul; crankshaft overhaul; piston and connecting rod overhaul; cylinder block overhaul; main data and specifications; special tools.
  • Engine Cooling (6B) β€” Service precaution; general description; diagnosis; draining and refilling; water pump; thermostat; radiator; drive belt and cooling fan; main data and specifications; special tool.
  • Engine Fuel (6C) β€” Service precaution; fuel metering; fuel filter; in-tank fuel filter; fuel pump flow test; fuel pump; fuel tube and quick-connector fittings; fuel pump relay; fuel tank; filler neck; fuel gauge unit; fuel filler cap; main data and specifications; special tool.
  • Engine Electrical (6D1) β€” Battery general description; diagnosis; battery charging; jump starting; battery removal and installation; main data and specifications.
  • Ignition System (6D2) β€” General description; diagnosis; ignition coil; spark plug; crankshaft position sensor; main data and specifications.
  • Starting and Charging System (6D3) β€” Starting system; starter removal, disassembly, inspection and reassembly; charging system; generator removal, disassembly, inspection and reassembly; bench test; main data and specifications.
  • Driveability and Emissions (6E) β€” Abbreviation charts; component locator; ECM circuit diagram; ground point charts; connector list; relay and fuse; ECM wiring diagrams; ECM connector pin assignment and output signal; general description for ECM and sensors; fuel metering; electronic ignition system; evaporative emission system; EGR system; ISUZU Strategy Based Diagnostics; general service information; On-Board Diagnostic (OBD) system check; full DTC charts; symptom diagnosis; on-vehicle service procedures; special tools.
  • Engine Exhaust (6F) β€” General description; three-way catalytic converter and centre exhaust pipe; exhaust silencer and rear exhaust pipe; main data and specifications.
  • Engine Lubrication (6G) β€” General description; oil pump disassembly, inspection and reassembly; oil pan and crankcase removal and installation; oil pump oil seal; main data and specification.
  • Engine Speed Control System (6H) β€” Accelerator pedal control cable removal, inspection and installation.
  • Induction (6J) β€” Air cleaner element removal, inspection and installation.

IMAGES PREVIEW

Isuzu TF Series 6VE1 3.5L Engine Workshop Manual Section 6 β€” PDF page 1 preview
Isuzu TF Series 6VE1 3.5L Engine Workshop Manual Section 6 β€” PDF page 45 preview
Isuzu TF Series 6VE1 3.5L Engine Workshop Manual Section 6 β€” PDF page 104 preview

Across these ten sections, the Isuzu TF Series 6VE1 workshop manual gives a technician the complete engine service picture. Engine Mechanical (6A) alone spans well over 100 pages of procedures and specifications for the 3.5L V6, including the aluminium die-cast cylinder block with cast-in cylinder liners, the pent-roof combustion chamber cylinder heads, the four-cam four-valve DOHC valve train, and the timing belt drive with its specific alignment and tensioning steps. Driveability and Emissions (6E) is the largest single section, covering every diagnostic trouble code the 6VE1 ECM can set β€” from MAF, IAT, ECT, TPS, O2 sensor, injector, ignition coil, CKP, CMP, EGR, EVAP, IAC, VSS, CAN bus, and immobilizer circuits β€” with step-by-step diagnostic charts and reference values.

Engine Diagnosis and Troubleshooting

The manual opens with a detailed engine diagnosis section that walks through hard starting, starting motor faults, ignition trouble, fuel system faults, and engine compression testing before moving into system-specific chapters. Symptom tables cover rough idling, engine stalling, hesitation, lack of power, abnormal combustion, excessive fuel consumption, oil leaks, lubrication problems, and engine noise β€” each with possible causes and recommended actions. The compression test procedure gives the exact steps for disabling ignition and fuel, checking cranking speed, and comparing results against the 1000 kPa (145 psi) limit. For rough running and misfire complaints, the manual breaks down ignition coil, spark plug, fuel injector, MAF, ECT, IAT, TPS, and ECM causes with clear diagnostic direction.

What This Manual Enables You To Do

Whether you are rebuilding a 6VE1 3.5L engine, chasing an intermittent misfire, replacing a timing belt, or diagnosing a CHECK ENGINE lamp, the Isuzu TF Series 6VE1 3.5L Engine Workshop Manual Section 6 puts the factory procedures at your fingertips.

Complete PDF Bookmark Tree

Complete Bookmarks

The complete bookmarks in the β€œIsuzu TF Series 6VE1 3.5L Engine Workshop Manual Section 6” are as follows:

TOPp. 1
SECTION 6Ap. 3
Service Precautionp. 4
General Descriptionp. 5
Engine Diagnosisp. 6
Cylinder Head Cover LHp. 23
Removalp. 23
Installationp. 23
Cylinder Head Cover RHp. 25
Removalp. 25
Installationp. 25
Common Chamberp. 26
Removalp. 26
Installationp. 27
Exhaust Manifold LHp. 28
Removalp. 28
Installationp. 28
Exhaust Manifold RHp. 29
Removalp. 29
Installationp. 29
Crankshaft Pulleyp. 30
Removalp. 30
Installationp. 30
Timing Beltp. 31
Removalp. 31
Installationp. 32
Camshaftp. 36
Removalp. 36
Installationp. 36
Cylinder Headp. 39
Removalp. 39
Installationp. 39
Valve Stem Oil Controller, Valve Spring and Valve Guidep. 41
Removalp. 41
Installationp. 41
Piston, Piston Ring and Connecting Rodp. 42
Removalp. 42
Installationp. 43
Crankshaft and Main Bearingsp. 45
Removalp. 45
Installationp. 46
Rear Oil Sealp. 50
Removalp. 50
Installationp. 50
Engine Assemblyp. 51
Removalp. 51
Installationp. 51
Cylinder Headp. 54
Cylinder Head and Associated Partsp. 54
Disassemblyp. 55
Cleanp. 55
Inspection and Repairp. 55
Reassemblyp. 56
Valve Spring, Oil Controller, Valve, Valve Guidep. 58
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Partsp. 58
Disassemblyp. 59
Inspection and Repairp. 59
Reassemblyp. 63
Camshaftp. 66
Camshaft and Associated Partsp. 66
Disassemblyp. 66
Inspection and Repairp. 67
Reassemblyp. 69
Crankshaftp. 73
Crankshaft and Associated Partsp. 73
Disassemblyp. 73
Inspection and Repairp. 75
Reassemblyp. 77
Piston and Connecting Rodp. 81
Piston, Connecting Rod and Associate Partsp. 81
Disassemblyp. 81
Inspection and Repairp. 82
Reassemblyp. 86
Cylinder Blockp. 89
Cylinder Block and Associated Partsp. 89
Disassemblyp. 90
Inspection and Repairp. 90
Reassemblyp. 91
Main Data and Specificationp. 95
Special Toolp. 101
SECTION 6Bp. 103
Service Precautionp. 103
General Descriptionp. 104
Diagnosisp. 107
Draining and Refilling Cooling Systemp. 108
Water Pumpp. 109
Water Pump and Associated Partsp. 109
Removalp. 109
Inspectionp. 109
Installationp. 109
Thermostatp. 111
Thermostat and Associated Partsp. 111
Removalp. 111
Inspectionp. 111
Installationp. 111
Radiatorp. 112
Radiator and Associated Partsp. 112
Removalp. 113
Inspectionp. 113
Installationp. 114
Drive Belt and Cooling Fanp. 117
Drive Belt and Associated Partsp. 117
Inspectionp. 117
Installationp. 117
Main Data and Specificationsp. 118
Special Toolsp. 120
SECTION 6Cp. 121
Service Precautionp. 121
General Descriptionp. 122
Fuel Meteringp. 123
Fuel Filterp. 124
Removalp. 124
Inspectionp. 124
Installationp. 124
Inspectionp. 124
In‐Tank Fuel Filterp. 124
Fuel Pump Flow Testp. 125
Fuel Pumpp. 126
Fuel Pump and Associated Partsp. 126
Removalp. 126
Installationp. 127
Fuel Tube / Quick ‐ Connector Fittingsp. 128
Precautionsp. 128
Cautions During Workp. 128
Removalp. 128
Reuse of Quick‐Connectorp. 129
Assembling Advicep. 129
Fuel Pump Relayp. 130
General Descriptionp. 130
Fuel Tankp. 131
Fuel Tank and Associated Partsp. 131
Removalp. 132
Installationp. 132
Filler Neckp. 133
Removalp. 133
Installationp. 133
Fuel Gauge Unitp. 133
Removal and Installationp. 133
Fuel Filler Capp. 134
General Descriptionp. 134
Inspectionp. 134
Main Data and Specificationsp. 135
Special Toolsp. 136
SECTION 6D1p. 137
Service Precautionp. 137
Batteryp. 138
General Descriptionp. 138
Diagnosisp. 138
Battery Chargingp. 139
Jump Startingp. 139
Battery Removalp. 140
Battery Installationp. 140
Main Data and Specificationsp. 141
SECTION 6D2p. 143
Service Precautionp. 143
General Descriptionp. 144
Diagnosisp. 144
Ignition Coilp. 145
Removalp. 145
Inspection and Repairp. 145
Installationp. 145
Spark Plugp. 146
Inspectionp. 146
Replacement spark plugsp. 146
Crankshaft Position Sensorp. 147
Removalp. 147
Installationp. 147
Main Data and Specificationsp. 148
SECTION 6D3p. 151
Service Precautionp. 151
Starting Systemp. 152
General Descriptionp. 152
Diagnosisp. 154
Starterp. 155
Removalp. 155
Installationp. 155
Disassembled Viewp. 156
Disassemblyp. 157
Inspection and Repairp. 159
Reassemblyp. 162
Main Data and Specificationsp. 163
Charging Systemp. 165
General Descriptionp. 165
General On‐Vehicle Inspectionp. 165
Generatorp. 166
Removalp. 166
Inspectionp. 166
Installationp. 166
Disassembled Viewp. 167
Disassemblyp. 167
Inspection and Repairp. 170
Reassemblyp. 172
Bench Testp. 172
Main Data and Specificationsp. 173
SECTION 6Ep. 175
ABBREVIATION CHARTSp. 179
COMPONENT LOCATORp. 180
ENGINE COMPONENT LOCATOR TABLEp. 180
ECM CIRCUIT DIAGRAMp. 184
GROUND POINT CHART GENERAL EXPORT (LHD) (1/4)p. 187
GROUND POINT CHART GENERAL EXPORT (LHD) (2/4)p. 188
GROUND POINT CHART GENERAL EXPORT (LHD) (3/4)p. 189
GROUND POINT CHART GENERAL EXPORT (LHD) (4/4)p. 190
GROUND POINT CHART GENERAL EXPORT (RHD) (1/4)p. 191
GROUND POINT CHART GENERAL EXPORT (RHD) (2/4)p. 192
GROUND POINT CHART GENERAL EXPORT (RHD) (3/4)p. 193
GROUND POINT CHART GENERAL EXPORT (RHD) (4/4)p. 194
LOCATIONp. 195
CABLE HARNESS & CONNECTOR LOCATIONp. 196
CONNECTOR LISTp. 201
RELAY AND FUSEp. 204
RELAY AND FUSE BOX LOCATION (LHD & RHD)p. 204
RELAY AND FUSE BOX LOCATION (LHD & RHD)p. 205
FUSE & RELAY LOCATION (LHD & RHD)p. 206
ECM WIRING DIAGRAM (1/10)p. 207
ECM WIRING DIAGRAM (2/10)p. 208
ECM WIRING DIAGRAM (3/10)p. 209
ECM WIRING DIAGRAM (4/10)p. 210
ECM WIRING DIAGRAM (5/10)p. 211
ECM WIRING DIAGRAM (6/10)p. 212
ECM WIRING DIAGRAM (7/10)p. 213
ECM WIRING DIAGRAM (8/10)p. 214
ECM WIRING DIAGRAM (9/10)p. 215
ECM WIRING DIAGRAM (10/10)p. 216
ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNALp. 217
GENERAL DESCRIPTION FOR ECM AND SENSORSp. 225
Mass Air Flow (MAF) Sensor & Intake Air Temperature (IAT) Sensorp. 226
Throttle Position Sensor (TPS)p. 226
Idle Air Control (IAC) Valvep. 227
Camshaft Position (CMP) Sensorp. 227
Crankshaft Position (CKP) Sensorp. 228
Engine Coolant Temperature (ECT) Sensorp. 228
Vehicle Speed Sensor (VSS)p. 229
Heated Oxygen (O2) Sensorp. 229
GENERAL DESCRIPTION FOR FUEL METERINGp. 230
GENERAL DESCRIPTION FOR ELECTRONIC IGNITION SYSTEM IGNITION COILS & CONTROLp. 232
GENERAL DESCRIPTION FOR EVAPORATIVE EMISSION SYSTEMp. 235
GENERAL DESCRIPTION FOR EXHAUST GAS RECIRCULATION (EGR) SYSTEMp. 236
ISUZU STRATEGY BASED DIAGNOSTICSp. 237
Diagnostic Thought Processp. 238
1. Verify the Complaintp. 238
2. Perform Preliminary Checksp. 238
3. Check Bulletins and Troubleshooting Hintsp. 239
4. Perform Service Manual Diagnostic Checksp. 239
5a and 5b. Perform Service Manual Diagnostic Proceduresp. 239
5c. Technician Self Diagnosesp. 239
5d. Intermittent Diagnosisp. 240
Symptom Simulation Testsp. 241
5e. Vehicle Operates as Designedp. 242
6. Re-examine the complaintp. 242
7. Repair and Verify Fixp. 242
GENERAL SERVICE INFORMATIONp. 243
Aftermarket Electrical and Vacuum Equipmentp. 243
Electrostatic Discharge Damagep. 243
Visual/Physical Engine Compartment Inspectionp. 244
Basic Knowledge of Tools Requiredp. 245
Serial Data Communicationsp. 245
On-Board Diagnostic (OBD)p. 245
Comprehensive Component Monitor Diagnostic Operationp. 245
The Diagnostic Executivep. 246
Verifying Vehicle Repairp. 247
Reading Flash Diagnostic Trouble Codesp. 247
Reading Diagnostic Trouble Codes Using a TECH 2p. 247
On-Board Diagnosis (Self-Diagnosis)p. 248
Diagnosis with TECH 2p. 249
TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA)p. 253
TYPICAL SCAN DATA & DEFINITIONS (O2 SENSOR DATA)p. 255
MISCELLANEOUS TESTp. 257
PLOTTING SNAPSHOT GRAPHp. 259
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)p. 260
Flow Chart for Snapshot Replay (Plotting Graph)p. 261
SNAPSHOT DISPLAY WITH TIS2000p. 262
SERVICE PROGRAMMING SYSTEM (SPS)p. 265
HOW TO USE BREAKER BOXp. 268
ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECKp. 271
NO CHECK ENGINE LAMP (MIL)p. 275
CHECK ENGINE LAMP (MIL) β€œON" STEADYp. 278
FUEL INJECTOR COIL TEST PROCEDURE AND FUEL INJECTOR BALANCE TEST PROCEDUREp. 280
FUEL SYSTEM ELECTRICAL TESTp. 285
FUEL SYSTEM DIAGNOSISp. 290
A/C SYSTEM CIRCUIT DIAGNOSISp. 296
ECM DIAGNOSTIC TROUBLE CODES (DTC)p. 304
MULTIPLE DTC SETS TROUBLESHOOTING AIDSp. 316
DIAGNOSTIC TROUBLE CODE (DTC) P0101 (FLASH CODE 61) MASS AIR FLOW SENSOR CIRCUIT RANGE/PERFORMANCEp. 319
DIAGNOSTIC TROUBLE CODE (DTC) P0102 (FLASH CODE 61) MASS AIR FLOW SENSOR CIRCUIT LOW INPUTp. 323
DIAGNOSTIC TROUBLE CODE (DTC) P0103 (FLASH CODE 61) MASS AIR FLOW SENSOR CIRCUIT HIGH INPUTp. 328
DIAGNOSTIC TROUBLE CODE (DTC) P0112 (FLASH CODE 23) INTAKE AIR TEMPERATURE (IAT) SENSOR LOW INPUTp. 332
DIAGNOSTIC TROUBLE CODE (DTC) P0113 (FLASH CODE 23) INTAKE AIR TEMPERATURE (IAT) SENSOR HIGH INPUTp. 337
DIAGNOSTIC TROUBLE CODE (DTC) P0117 (FLASH CODE 14) ENGINE COOLANT TEMPERATURE (ECT) SENSOR LOW INPUTp. 342
DIAGNOSTIC TROUBLE CODE (DTC) P0118 (FLASH CODE 14) ENGINE COOLANT TEMPERATURE (ECT) SENSOR HIGH INPUTp. 347
DIAGNOSTIC TROUBLE CODE (DTC) P0121 (FLASH CODE 21) THROTTLE POSITION SENSOR (TPS) CIRCUIT RANGE/PERFORMANCEp. 353
DIAGNOSTIC TROUBLE CODE (DTC) P0122 (FLASH CODE 21) THROTTLE POSITION SENSOR CIRCUIT LOW INPUTp. 357
DIAGNOSTIC TROUBLE CODE (DTC) P0123 (FLASH CODE 21) THROTTLE POSITION SENSOR CIRCUIT HIGH INPUTp. 362
DIAGNOSTIC TROUBLE CODE (DTC) P0131 (FLASH CODE 15) O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)p. 367
DIAGNOSTIC TROUBLE CODE (DTC) P0151 (FLASH CODE 15) O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 1)p. 367
DIAGNOSTIC TROUBLE CODE (DTC) P0132 (FLASH CODE 15) O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)p. 375
DIAGNOSTIC TROUBLE CODE (DTC) P0152 (FLASH CODE 15) O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 1)p. 375
DIAGNOSTIC TROUBLE CODE (DTC) P0134 (FLASH CODE 15) O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)p. 381
DIAGNOSTIC TROUBLE CODE (DTC) P0154 (FLASH CODE 15) O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 2 SENSOR 1)p. 381
DIAGNOSTIC TROUBLE CODE (DTC) P0171 (FLASH CODE 44) O2 SENSOR SYSTEM TOO LEAN (BANK 1)p. 385
DIAGNOSTIC TROUBLE CODE (DTC) P0174 (FLASH CODE 44) O2 SENSOR SYSTEM TOO LEAN (BANK 2)p. 385
DIAGNOSTIC TROUBLE CODE (DTC) P0172 (FLASH CODE 45) O2 SENSOR SYSTEM TOO RICH (BANK 1)p. 390
DIAGNOSTIC TROUBLE CODE (DTC) P0175 (FLASH CODE 44) O2 SENSOR SYSTEM TOO RICH (BANK 2)p. 390
DIAGNOSTIC TROUBLE CODE (DTC) P1171 (FLASH CODE 44) FUEL SUPPLY SYSTEM LEAN DURING POWER ENRICHMENT (Bank 1)p. 395
DIAGNOSTIC TROUBLE CODE (DTC) P1172 (FLASH CODE 44) FUEL SUPPLY SYSTEM LEAN DURING POWER ENRICHMENT (Bank 2)p. 395
DIAGNOSTIC TROUBLE CODE (DTC) P0201 (FLASH CODE 31) INJECTOR 1 CONTROL CIRCUITp. 400
DIAGNOSTIC TROUBLE CODE (DTC) P0202 (FLASH CODE 31) INJECTOR 2 CONTROL CIRCUITp. 400
DIAGNOSTIC TROUBLE CODE (DTC) P0203 (FLASH CODE 31) INJECTOR 3 CONTROL CIRCUITp. 400
DIAGNOSTIC TROUBLE CODE (DTC) P0204 (FLASH CODE 31) INJECTOR 4 CONTROL CIRCUITp. 400
DIAGNOSTIC TROUBLE CODE (DTC) P0205 (FLASH CODE 31) INJECTOR 5 CONTROL CIRCUITp. 400
DIAGNOSTIC TROUBLE CODE (DTC) P0206 (FLASH CODE 31) INJECTOR 6 CONTROL CIRCUITp. 400
DIAGNOSTIC TROUBLE CODE (DTC) P0336 (FLASH CODE 29) CRANKSHAFT POSITION SENSOR CIRCUIT RANGE/PERFORMANCE (58X)p. 408
DIAGNOSTIC TROUBLE CODE (DTC) P0337 (FLASH CODE 29) CRANKSHAFT POSITION SENSOR CIRCUIT NO SIGNAL (58X)p. 408
DIAGNOSTIC TROUBLE CODE (DTC) P0341(FLASH CODE 41) CAMSHAFT POSITION SENSOR CIRCUIT RANGE/PERFORMANCEp. 417
DIAGNOSTIC TROUBLE CODE (DTC) P0342 (FLASH CODE 41) CAMSHAFT POSITION SENSOR CIRCUIT NO SIGNALp. 417
DIAGNOSTIC TROUBLE CODE (DTC) P0351 (FLASH CODE 42) IGNITION 1 CONTROL CIRCUITp. 423
DIAGNOSTIC TROUBLE CODE (DTC) P0352 (FLASH CODE 42) IGNITION 2 CONTROL CIRCUITp. 423
DIAGNOSTIC TROUBLE CODE (DTC) P0353 (FLASH CODE 42) IGNITION 3 CONTROL CIRCUITp. 423
DIAGNOSTIC TROUBLE CODE (DTC) P0354 (FLASH CODE 42) IGNITION 4 CONTROL CIRCUITp. 423
DIAGNOSTIC TROUBLE CODE (DTC) P0355 (FLASH CODE 42) IGNITION 5 CONTROL CIRCUITp. 423
DIAGNOSTIC TROUBLE CODE (DTC) P0356 (FLASH CODE 42) IGNITION 6 CONTROL CIRCUITp. 423
DIAGNOSTIC TROUBLE CODE (DTC) P0404 (FLASH CODE 32) EGR CIRCUIT RANGE/PERFOMANCE (OPEN VALVE)p. 432
DIAGNOSTIC TROUBLE CODE (DTC) P1404 (FLASH CODE 32) EGR CIRCUIT RANGE/PERFOMANCE (CLOSED VALVE)p. 432
DIAGNOSTIC TROUBLE CODE (DTC) P0405 (FLASH CODE 32) EGR CIRCUIT LOWp. 437
DIAGNOSTIC TROUBLE CODE (DTC) P0406 (FLASH CODE 32) EGR CIRCUIT HIGHp. 442
DIAGNOSTIC TROUBLE CODE (DTC) P0444 EVAP PURGE SOLENOID VALVE CIRCUIT LOW VOLTAGEp. 448
DIAGNOSTIC TROUBLE CODE (DTC) P0445 EVAP PURGE SOLENOID VALVE CIRCUIT HIGH VOLTAGEp. 448
DIAGNOSTIC TROUBLE CODE (DTC) P0500 (FLASH CODE 24) VEHICLE SPEED SENSOR (VSS) CIRCUIT RANGE/PERFORMANCEp. 453
DIAGNOSTIC TROUBLE CODE (DTC) P0562 (FLASH CODE 66) SYSTEM VOLTAGE LOWp. 462
DIAGNOSTIC TROUBLE CODE (DTC) P0563 (FLASH CODE 66) SYSTEM VOLTAGE HIGHp. 465
DIAGNOSTIC TROUBLE CODE (DTC) P0601 (FLASH CODE 51) CONTROL MODULE MEMORY CHECKSUMp. 467
DIAGNOSTIC TROUBLE CODE (DTC) P0602 ECU PROGRAMMING ERRORp. 469
DIAGNOSTIC TROUBLE CODE (DTC) P1508 (FLASH CODE 22) IDLE AIR CONTROL SYSTEM LOW/CLOSEDp. 470
DIAGNOSTIC TROUBLE CODE (DTC) P1509 (FLASH CODE 22) IDLE AIR CONTROL SYSTEM HIGH/OPENp. 470
DIAGNOSTIC TROUBLE CODE (DTC) P1601 (FLASH CODE 65) CAN BUS OFFp. 478
DIAGNOSTIC TROUBLE CODE (DTC) U2104 (FLASH CODE 67) CAN BUS RESET COUNTER OVER-RUNp. 484
DIAGNOSTIC TROUBLE CODE (DTC) P1626 IMMOBILIZER NO SIGNALp. 491
DIAGNOSTIC TROUBLE CODE (DTC) P1631 IMMOBILIZER WRONG SIGNALp. 497
DIAGNOSTIC TROUBLE CODE (DTC) P1648 WRONG SECURITY CODE ENTEREDp. 499
DIAGNOSTIC TROUBLE CODE (DTC) P1649 IMMOBILIZER FUNCTION NOT PROGRAMMEDp. 501
SYMPTOM DIAGNOSISp. 503
PRELIMINARY CHECKSp. 503
VISUAL/PHYSICAL CHECKp. 503
INTERMITTENTp. 503
ENGINE CRANKS BUT WILL NOT RUNp. 505
HARD START SYMPTOMp. 508
ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING SYMPTOMp. 511
SURGES AND/OR CHUGS SYMPTOMp. 515
HESITATION, SAG, STUMBLE SYMPTOMp. 519
CUTS OUT, MISSES SYMPTOMp. 523
LACK OF POWER, SLUGGISH OR SPONGY SYMPTOMp. 526
DETONATION/SPARK KNOCK SYMPTOMp. 530
POOR FUEL ECONOMY SYMPTOMp. 533
EXCESSIVE EXHAUST EMISSIONS OR ODORS SYMPTOMp. 536
DIESELING, RUN-ON SYMPTOMp. 539
BACKFIRE SYMPTOMp. 540
ON-VEHICLE SERVICE PROCEDUREp. 542
ENGINE CONTROL MODULE (ECM)p. 542
CRANKSHAFT POSITION (CKP)SENSORp. 543
CAMSHAFT POSITION (CMP) SENSORp. 543
ENGINE COOLANT TEMPERATURE (ECT) SENSORp. 544
MASS AIR FLOW (MAF) SENSOR & INTAKE AIR TEMPERATURE (IAT) SENSORp. 544
THROTTLE POSITION SENSOR (TPS)p. 545
IDLE AIR CONTROL (IAC) VALVEp. 545
HEATED OXYGEN SENSOR (HO2S)p. 546
EVAP CANISTER PURGE VALVE SOLENOIDp. 547
FUEL PRESSURE RELIEFp. 548
FUEL RAIL ASSEMBLYp. 548
FUEL INJECTORSp. 549
FUEL PRESSURE REGULATORp. 551
IGNITION COILp. 553
SPARK PLUGSp. 554
Special Toolsp. 556
SECTION 6Fp. 557
Service Precautionp. 557
General Descriptionp. 558
Three Way Catalytic Converter and Center Exhaust Pipep. 560
Three Way Catalytic Converter and Center Exhaust Pipe and Associated Partsp. 560
Removalp. 560
Installationp. 560
Exhaust Silencer and Rear Exhaust Pipep. 561
Exhaust Silencer & Tail Pipe and Associated Partsp. 561
Removalp. 561
Installationp. 561
Main Data and Specificationsp. 562
SECTION 6Gp. 563
Service Precautionp. 563
General Descriptionp. 564
Oil Pumpp. 565
Oil Pump and Associated Partsp. 565
Disassemblyp. 566
Inspection and Repairp. 566
Reassemblyp. 567
Oil Pan and Crankcasep. 569
Removalp. 569
Installationp. 569
Oil Pumpp. 571
Removalp. 571
Installationp. 571
Oil Pump Oil Sealp. 573
Removalp. 573
Installationp. 573
Main Data and Specificationsp. 574
SECTION 6Hp. 575
Service Precautionp. 575
Accelerator Pedal Control Cablep. 576
Removalp. 576
Inspectionp. 577
Installationp. 577
SECTION 6Jp. 579
Service Precautionp. 579
Air Cleanerp. 580
Removalp. 580
Inspectionp. 580
Installationp. 580

Engine repair and overhaul. The manual supports complete tear-down and rebuild of the 6VE1 engine: cylinder head removal and disassembly, valve guide and valve seat replacement, camshaft inspection and installation, piston and connecting rod removal and reassembly, crankshaft and main bearing selection with plastigage procedures, rear oil seal replacement, and engine assembly removal and installation. Every procedure includes torque values, tightening sequences, and inspection limits.

Diagnostics and troubleshooting. Section 6E covers OBD system checks, DTC reading with flash codes or a Tech 2 scan tool, typical scan data and definitions, snapshot graphing, and symptom diagnosis for hard start, rough idle, hesitation, lack of power, poor fuel economy, backfire, and more. The DTC charts list setting conditions, fail-safe actions, recovery conditions, related failure parts, and ECM pin numbers.

Maintenance and specification work. Cooling system draining and refilling, thermostat testing, water pump service, drive belt routing, fuel filter and fuel pump service, fuel tank removal, ignition coil and spark plug service, starter and generator overhaul, oil pump service, and accelerator cable adjustment are all covered with the correct sequences and clearances.

Because this is a downloadable PDF, there is no shipping and no waiting. The file can be viewed on a phone, tablet, laptop, or desktop, and individual pages can be printed for use in the workshop. Having the correct Isuzu procedures and specifications on hand reduces the risk of damage from guessed torque values, wrong clearances, or missed diagnostic steps β€” and makes every job on the 6VE1 3.5L engine faster and more accurate.

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