2002 ISUZU AXIOM Service Repair Manual

rear entertainment fuel open gas tank driver seat adjustment adding oil lights

Page 809 of 2100

ISUZU AXIOM 2002 Service Repair Manual 5D2±4
PARKING BRAKE SYSTEM (4X2 Model)
Removal
1. Remove rear wheels (1) and drums (2).
2. Remove bolt (3) (4) (5).
3. Remove nut (6).
4. Remove nut (7) and retainer (8).
5. Remove rear brake shoe as

5D2±4
PARKING BRAKE SYSTEM (4X2 Model)
Removal
1. Remove rear wheels (1) and drums (2).
2. Remove bolt (3) (4) (5).
3. Remove nut (6).
4. Remove nut (7) and retainer (8).
5. Remove rear brake shoe assemblies. Refer to
ªBrake
Lining Assembly and Associated Partsº in Power
Assisted Brake System
section.
6. Use offset box wrench (13 mm hex.) to compress the
locking lugs on the cable, then remove the rear cable
(9) from the Backing plate.
311RS012
Legend
(1) Offset Box Wrench
Installation
1. Install rear cable (9).
2. Install retainer (8).
3. Tighten nut (7) to the specified torque.
Torque : 41 N´m (30 lb ft)
To adjust the parking brake, refer to
Parking Brake
Adjustment
in this section.
4. Tighten nut (6) to the specified torque.
Torque : 15 N´m (11 lb ft)
5. Tighten bolt (5) (4) (3) to the specified torque.
Torque : 6.5 N´m (57 lb in)
6. Install rear drums (2) and wheels (1).
Parking Brake Adjustment
NOTE: All brakes are self adjusting. Brakes are adjusted
by repeated stepping on the brake pedal. (After stepping
on the pedal and releasing it, the rear auto±adjuster, in the
rear brake, produces a clicking sound. The same
operation should be repeated until the sound
disappears.)
Take the following steps after overhauling the rear brake
assembly.
1. Move the parking brake lever to its fully released
position.
2. Parking cable must be loosened sufficiently. (Loosen
the adjust nut and the lock nut.).
3. Repeat stepping on the brake pedal firmly, and
releasing it until the clicking sound can no longer be
heard.
If the difference between the brake drum inside
diameter and diameter of the brake shoes is adjusted
to be 0.5 mm, the number of times for depressing the
brake pedal can be reduced.
4. Remove the drum. Measure the brake drum inside
diameter and diameter of the brake shoes.
Shoe clearance: 0.25 mm to 0.40 mm
(0.0098 in to 0.0157 in)
If incorrect, check the brake auto±adjusting system.
5. Rotate the adjust nut of hand brake lever until all slack
disappears from the cable. Set the adjust nut.
6. Applying about 30 kg (66 lb) of force, pull the parking
brake lever to its fully set position three or four times.
7. If the parking brake is properly adjusted, the travel
between the fully disengaged position and the fully
engaged position will be 6 notches.
If the traveling range is not within these limits, repeat
steps 1 through 5 again .
After adjusting has been done, check to see if the rear
wheel rotates smoothly without drag when turned by
hand.

Page 810 of 2100

ISUZU AXIOM 2002 Service Repair Manual PARKING BRAKE SYSTEM (4X2 Model)
5D2±5
Main Data and Specifications
General Specifications
Model
TypeLeading±Trailing
Drum inside diameter295 mm (11.6 in)
Parking brake lever stroke6±8 notches
Whe

Page 811 of 2100

ISUZU AXIOM 2002 Service Repair Manual 6A±1
ENGINE MECHANICAL (6VE1 3.5L)
AXIOM
ENGINE
CONTENTS
Engine Mechanical 6A. . . . . . . . . . . . . . . . . . . . . .
Engine Cooling 6B. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Fu

6A±1
ENGINE MECHANICAL (6VE1 3.5L)
AXIOM
ENGINE
CONTENTS
Engine Mechanical 6A. . . . . . . . . . . . . . . . . . . . . .
Engine Cooling 6B. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Fuel 6C. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Electrical 6D1. . . . . . . . . . . . . . . . . . . . . . . .
Ignition System 6D2. . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Charging System 6D3. . . . . . . . . . . . Driveability and Emissions 6E. . . . . . . . . . . . . . . .
Engine Exhaust 6F. . . . . . . . . . . . . . . . . . . . . . . . .
Engine Lubrication 6G. . . . . . . . . . . . . . . . . . . . . .
Engine Speed Control System 6H. . . . . . . . . . . .
Induction 6J. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE MECHANICAL (6VE1 3.5L)
CONTENTS
Service Precaution 6A±2. . . . . . . . . . . . . . . . . . . . . .
General Description 6A±3. . . . . . . . . . . . . . . . . . . . .
Engine Diagnosis 6A±4. . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover LH 6A±19. . . . . . . . . . . . . . . . .
Removal 6A±19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Cover RH 6A±21. . . . . . . . . . . . . . . . .
Removal 6A±21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±21. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Common Chamber 6A±22. . . . . . . . . . . . . . . . . . . . . .
Removal 6A±22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold LH 6A±24. . . . . . . . . . . . . . . . . . . . .
Removal 6A±24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold RH 6A±25. . . . . . . . . . . . . . . . . . . .
Removal 6A±25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Pulley 6A±26. . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing Belt 6A±27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 6A±32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 6A±35. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Stem Oil Controller , Valve Spring
and Valve Guide 6A±37. . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±37. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston, Piston Ring and Connecting Rod 6A±38. . . Removal 6A±38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±39. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Main Bearings 6A±40. . . . . . . . . . . .
Removal 6A±40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Seal 6A±45. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±45. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±45. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Assembly 6A±46. . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A±46. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A±47. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 6A±49. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head and Associated Parts 6A±49. . . . .
Disassembly 6A±50. . . . . . . . . . . . . . . . . . . . . . . . . .
Clean 6A±50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A±50. . . . . . . . . . . . . . . . . .
Reassembly 6A±51. . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring, Oil Controller, Valve, Valve
Guide 6A±53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Spring, Oil Controller, Valve, Valve
Guide and Associated Parts 6A±53. . . . . . . . . . . .
Disassembly 6A±53. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A±54. . . . . . . . . . . . . . . . . .
Reassembly 6A±57. . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 6A±60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft and Associated Parts 6A±60. . . . . . . . .
Disassembly 6A±60. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A±61. . . . . . . . . . . . . . . . . .
Reassembly 6A±63. . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft 6A±67. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft and Associated Parts 6A±67. . . . . . . .
Disassembly 6A±67. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair for Bearings 6A±68. . . . . .
Inspection and Repair for Crankshaft 6A±70. . . . .
Reassembly 6A±71. . . . . . . . . . . . . . . . . . . . . . . . . .

Page 812 of 2100

ISUZU AXIOM 2002 Service Repair Manual 6A±2
ENGINE MECHANICAL (6VE1 3.5L)
Piston and Connecting Rod 6A±75. . . . . . . . . . . . . . .
Piston, Connecting Rod and Associate
Parts 6A±75. . . . . . . . . . . . . . . . . . . . . . . . . .

6A±2
ENGINE MECHANICAL (6VE1 3.5L)
Piston and Connecting Rod 6A±75. . . . . . . . . . . . . . .
Piston, Connecting Rod and Associate
Parts 6A±75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 6A±75. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A±76. . . . . . . . . . . . . . . . . .
Reassembly 6A±80. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block 6A±82. . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block and Associated Parts 6A±82. . . . .
Disassembly 6A±82. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A±83. . . . . . . . . . . . . . . . . .
Reassembly 6A±84. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specification 6A±87. . . . . . . . . . . . . .
Special Tool 6A±93. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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, REFER 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, or 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.

Page 813 of 2100

ISUZU AXIOM 2002 Service Repair Manual 6A±3
ENGINE MECHANICAL (6VE1 3.5L)
General Description
Engine Cleanliness And Care
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are

6A±3
ENGINE MECHANICAL (6VE1 3.5L)
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
millimeter (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.
The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.
General Information on Engine Service
The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance.
When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
damage to the oil pick±up unit.
The 12±volt electrical system is capable of damaging
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the
battery.
Any time the intake air duct or air cleaner is removed,
the intake opening should be covered. This will
protect against accidental entrance of foreign
material into the cylinder which could cause extensive
damage when the engine is started.
Cylinder Block
The cylinder block is made of aluminum die±cast casting
for 75V±type six cylinders. It has a rear plate integrated
structure and employs a deep skirt. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width is different
between No.2, No.3 and No.1, No.4; the width of No.3
bearing on the body side is different in order to support the
thrust bearing. The bearing cap is made of nodular cast
iron and each bearing cap uses four bolts and two side
bolts.
Cylinder Head
The cylinder head, made of aluminum alloy casting
employs a pent±roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V±type design. The ports are cross±flow
type.
Valve Train
Intake and exhaust camshaft on both banks are driven
with a camshaft drive gear by the timing belt. The valves
are operated by the camshaft and the valve clearance is
adjusted to select suitable thickness shim.
Intake Manifold
The intake manifold system is composed of the aluminum
cast common chamber and intake manifold attached with
six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade that
meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin made
of chromium steel is offset 1mm toward the thrust side,
and the thrust pressure of piston to the cylinder wall varies
gradually as the piston travels. The connecting rods are
made of forged steel. The connecting rod bearings are
graded for correct size selection.
Crankshaft and Bearings
The crankshaft is made of Ductile cast±iron. Pins and
journals are graded for correct size selection for their
bearing.

Page 814 of 2100

ISUZU AXIOM 2002 Service Repair Manual 6A±4
ENGINE MECHANICAL (6VE1 3.5L)
Engine Diagnosis
First of all the engine diagnose to check the fuel quantity,
the engine level and the engine coolant level.
Hard Starting
1. Starting Motor Does No

6A±4
ENGINE MECHANICAL (6VE1 3.5L)
Engine Diagnosis
First of all the engine diagnose to check the fuel quantity,
the engine level and the engine coolant level.
Hard Starting
1. Starting Motor Does Not Turn Over
Troubleshooting Procedure
Turn on headlights and starter switch.
Condition
Possible causeCorrection
Headlights go out or dim
considerably
Battery run down or under chargedRecharge or replace battery
considerablyTerminals poorly connectedClean battery posts and terminals
and connect properly
Starting motor coil circuit shortedOverhaul or replace
Starting motor defectiveOverhaul or replace
2. Ignition Trouble Ð Starting Motor Turns Over But Engine Does Not Start
Spark Test
Disconnect an ignition coil from any spark plug. Connect
the spark plug tester (For example J±26792), start the
engine, and check if a spark is generated in the spark plugtester. Before starting the engine, make sure that the
spark plug tester is properly grounded. To avoid electrical
shock, do not touch the part where insulation of the
ignition coil is broken while the engine is running.
Condition
Possible causeCorrection
Spark jumps across gapSpark plug defectiveClean, adjust spark gap or replace
Ignition timing incorrectRefer to Ignition System
Fuel not reaching fuel injector(s) or
engineRefer to item 3 (Trouble in fuel
system)
Valve timing incorrectAdjust
Engine lacks compressionRefer to item 4 (Engine lacks
compression)
No sparking takes placeIgnition coil disconnected or brokenConnect properly or replace
Electronic Ignition System with
moduleReplace
Poor connections in engine harnessCorrect
Powertrain Control Module cable
disconnected or defectiveCorrect or replace
3. Trouble In Fuel System
Condition
Possible causeCorrection
Starting motor turns over and spark
occurs but engine does not start
Fuel tank emptyFill
occurs but engine does not start.Water in fuel systemClean
Fuel filter cloggedReplace filter
Fuel pipe cloggedClean or replace
Fuel pump defectiveReplace
Fuel pump circuit openCorrect or replace
Evaporative Emission Control
System circuit cloggedCorrect or replace
Multiport Fuel Injection System faultyRefer to ªElectronic Fuel Injectionº
section

Page 815 of 2100

ISUZU AXIOM 2002 Service Repair Manual 6A±5
ENGINE MECHANICAL (6VE1 3.5L)
4. Engine Lacks Compression
Condition
Possible causeCorrection
Engine lacks compressionSpark plug loosely fitted or spark
plug gasket defectiveTighten to specified

Page 816 of 2100

ISUZU AXIOM 2002 Service Repair Manual 6A±6
ENGINE MECHANICAL (6VE1 3.5L)
Rough Engine Idling or Engine Stalling
ConditionPossible causeCorrection
Trouble in fuel injection systemThrottle shutting off incompleteCorrect or replace
Throttle

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