Isuzu 6VE1 3.5L Engine Factory Workshop Manual

A complete factory service and repair manual for the Isuzu 6VE1 3.5L V6 engine, designed for professional mechanics and car enthusiasts. This engine was widely used in Isuzu Trooper, Rodeo, Axiom and other models of the early 2000s.

The Service manual covers all major engine systems and contains step-by-step instructions, specifications, diagrams, tables and diagnostic procedures.

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Engine mechanical (6VE1 3.5l) Download

Engine cooling (6VE1 3.5l) Download

Engine fuel (6VE1 3.5l) Download

Engine electrical (6VE1 3.5l) Download

Ignition system (6VE1 3.5l) Download

Starting and charging system (6VE1 3.5l) Download

Driveability and emissions( 6VE1 3.5l) Download

Engine exhaust (6VE1 3.5l) Download

Engine lubrication (6VE1 3.5l) Download

Engine speed control system (6VE1 3.5l) Download

Induction (6VE1 3.5l) Download

1. Increased oil consumption

Description: the engine tends to "eat oil", especially at high mileage.

Causes: wear of oil scraper rings, valve guides, seals.

Solution: major overhaul of the cylinder head or complete engine overhaul.

2. Valve cover gasket leak

Symptoms: oil smell, smudges on the block and cylinder head.

Causes: rubber aging, incorrect installation.

Solution: replacing cylinder head cover gaskets (often both at once).

3. Engine overheating

Causes: faulty thermostat, clogged radiator, coolant leaks.

Consequences: cylinder head damage, broken cylinder head gasket.

Solution: checking the cooling system, replacing the thermostat and/or radiator.

4. Unstable idling

Causes: dirty throttle body, faulty idle air control sensor (IACV), air leak.

Solution: clean throttle body, check vacuum hoses, replace sensors.

5. Knocking or unusual noises

Possible sources: worn timing belt (chain, tensioner), connecting rod bearings.

Solution: check timing chain tensioner, disassemble engine if necessary.

6. P0300 (multiple misfires)

Causes: ignition coils, spark plugs, air leak, faulty injectors.

Solution: diagnose cylinders, check ignition system.

7. EGR system malfunctions

Symptoms: detonation, unstable idling.

Causes: jammed EGR valve, clogged channels.

Solution: Cleaning or replacing the EGR valve.

8. Coolant leaks

Often appear in the intake manifold area or under the thermostat.

Possible causes: aging gaskets, cracks in the pipes.