2002 ISUZU AXIOM air conditioning

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±123
Sun Sensor
865R200002
Legend
(1) Sun Sensor
(2) Center Cluster Upper
Removal
1. Disconnect the battery ground cable.
2. Remove the center cluster upper.
3. Disconnect the sun sensor connector.
4. Remove the sun sensor.
Installation
To install, follow the removal step in the reverse order.
Duct Sensor
874R200010
Legend
(1) Sensor Part
(2) Evaporator Core
(3) Duct Sensor Assembly
(4) Evaporator Assembly
Removal
1. Disconnect the battery ground cable.
2. Remove the evaporator assembly.

Refer to
evaporator assembly in this section.
3. Remove the duct sensor assembly.
Installation
To install, follow the removal step in the reverse order.

1A±124
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Mode Actuator
840R200005
Legend
(1) Driver Knee Bolster Assembly
(2) Instrument Panel Driver Lower Cover
Assembly
(3) Actuator Rod
(4) Mode Actuator
Removal
1. Disconnect the battery ground cable.
2. Remove the instrument panel driver lower cover
assembly.
3. Remove the driver knee bolster assembly.

Refer to the
Instrument Panel Assembly in Body
Structure section.
4. Remove the actuator rod.
5. Remove the mode actuator.
Installation
To install, follow the remove step in the reverse order.
Mix Actuator
840R200006
Legend
(1) Center Cluster Upper
(2) Center Cluster
(3) Knee Pad (RH)
(4) Actuator Rod
(5) Mix Actuator
(6) Knee Pad (LH)
(7) Audio & Switch Assembly
Removal
1. Disconnect the battery ground cable.
2. Remove the knee pad (R/RH).
3. Remove the center cluster upper.
4. Remove the center cluster.

Refer to the
Instrument Panel Assembly in Body
Structure section.
5. Disconnect the six connectors.
6. Remove the Audio & Switch Assembly.
7. Remove the actuator rod.
8. Remove the mix actuator.
Installation
To install, follow the remove step in the reverse order.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±125
Intake Actuator
873R200003
Legend
(1) Evaporator Assembly
(2) Intake Actuator
(3) Intake Actuator Connector
Removal
1. Disconnect the battery ground cable.
2. Discharge and recover refrigerant.

Refer to
Refrigerant Recovery in this section.
3. Remove the evaporator assembly.

Refer to
Evaporator Assembly section.
4. Disconnect the intake actuator connector.
5. Remove the intake actuator.
Installation
To install, follow the remove step in the reverse order.

6A±46
ENGINE MECHANICAL (6VE1 3.5L)
Engine Assembly
Removal
035R200001
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 Ion sensing module harness connectors,
and manifold absolute pressure sensor harness
connectors from sensor on common chamber.
7. Disconnect throttle position sensor harness
connectors from throttle body.
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 (left
front side of engine compartment), disconnect shift
on the fly harness connector from front side of 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 left 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 O
2 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 hoses from right side of transmission.
CAUTION: Plug fuel pipes on engine side and fuel
hoses 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.

6A±50
ENGINE MECHANICAL (6VE1 3.5L)
Disassembly
NOTE:

During disassembly, be sure that the valve train
components are kept together and identified so that
they can be reinstalled in their original locations.

Before removing the cylinder head from the engine
and before disassembling the valve mechanism,
perform a compression test and note the results.
1. Remove camshaft drive gear pulley fixing bolt (3),
then pulley (4).
2. Remove camshaft bearing cap fixing bolt (5),
camshaft bearing cap (6), then camshaft exhaust (7),
and intake side (8).
3. Remove tappet with shim (11).
4. Use the J±8062 valve spring compressor and
J±42898 valve spring compressor adapter to remove
the split collar (12), valve spring with upper seat (13)
and valve (14).
014RW042
5. Remove spark plug (1).
CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use surface conditioning disc on any
gasket sealing surface.
Inspection and Repair
1. Inspect cylinder head gasket and mating surfaces for
leaks, corrosion and blow±by. If the gasket has failed,
determine the cause.
± Insufficient torque on head bolts
± Improper installation
± Loose or warped cylinder head
± Missing dowel pins
± Warped case surface
2. Inspect cylinder head for cracks, especially between
valve seats and in the exhaust ports.
3. Inspect cylinder head deck for corrosion, sand
particles in head and porosity.
CAUTION:

Do not attempt to weld the cylinder head. Replace
it.

Do not reuse cylinder head bolts.
4. Inspect cylinder head deck, common chamber and
exhaust manifold mating surfaces for flatness. These
surfaces may be reconditioned by milling. If the
surfaces are ªout of flatº with ªroundº by more than
specification, the surface should be ground to within
specifications. Replace the head if it requires
machining beyond the repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362 in)
011RW019
5. Water jacket sealing plugs seating surfaces.

ENGINE ELECTRICAL (6VE1 3.5L)6D1±3
Battery Charging
Observe the following safety precautions when charging
the battery:
1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during charging
procedure.
Battery charging should be discontinued or the rate of
charge reduced if the battery feels hot to the touch.
Battery charging should be discontinued or the rate of
charge reduced if the battery begins to gas or spew
electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue dot
or ring, it may be necessary to jiggle or tilt the battery.
4. Battery temperature can have a great effect on
battery charging capacity.
5. The sealed battery used on this vehicle may be either
quick charged or slow charged in the same manner as
other batteries.
Whichever method you decide to use, be sure that
you completely charge the battery. Never partially
charge the battery.
Jump Starting
Jump Starting with an Auxiliary (Booster)
Battery
CAUTION: Never push or tow the vehicle in an
attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.
Treat both the discharged battery and the booster
battery with great care when using jumper cables.
Carefully follow the jump starting procedure, being
careful at all times to avoid sparking.
WARNING: FAILURE TO CAREFULLY FOLLOW THE
JUMP STARTING PROCEDURE COULD RESULT IN
THE FOLLOWING:
1. Serous personal injury, particularly to your eyes.
2. Property damage from a battery explosion, battery
acid, or an electrical fire.
3. Damage to the electronic components of one or both
vehicles particularly.
Never expose the battery to an open flame or electrical
spark. Gas generated by the battery may catch fire or
explode.
Remove any rings, watches, or other jewelry before
working around the battery. Protect your eyes by wearing
an approved set of goggles.
Never allow battery fluid to come in contact with your eyes
or skin.Never allow battery fluid to come in contact with fabrics or
painted surfaces.
Battery fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes, skin,
fabric, or a painted surface, immediately and thoroughly
rinse the affected area with clean tap water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any other
metal surface of the vehicle. This will protect against a
short circuit.
Always keep batteries out of reach of young children.
Jump Starting Procedure
1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission, place the selector level in the ªPARKº
position.
If the vehicle is equipped with a manual transmission,
place the shift lever in the ªNEUTRALº position.
Turn ªOFFº the ignition.
Turn ªOFFº all lights and any other accessory
requiring electrical power.
2. Look at the built±in hydrometer.
If the indication area of the built±in hydrometer is
completely clear, do not try to jump start.
3. Attach the end of one jumper cable to the positive
terminal of the booster battery.
Attach the other end of the same cable to the positive
terminal of the discharged battery.
Do not allow the vehicles to touch each other. This will
cause a ground connection, effectively neutralizing
the charging procedure.
Be sure that the booster battery has a 12 volt rating.
4. Attach one end of the remaining cable to the negative
terminal of the booster battery.
Attach the other end of the same cable to a solid
engine ground (such as the air conditioning
compressor bracket or the generator mounting
bracket) of the vehicle with the discharged battery.
The ground connection must be at least 450 mm (18
in.) from the battery of the vehicle whose battery is
being charged.
WARNING: NEVER ATTACH THE END OF THE
JUMPER CABLE DIRECTLY TO THE NEGATIVE
TERMINAL OF THE DEAD BATTERY.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical accessories
have been turned ªOFFº.
6. Start the engine of the vehicle with the dead battery.

6E±4
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
DTC P1107 MAP Circuit Intermittent Low
Voltage 6E±386. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D T C P 1111 I AT Sensor Circuit Intermittent
High Voltage 6E±388. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1112 IAT Sensor Circuit Intermittent
Low Voltage 6E±391. . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1114 ECT Sensor Circuit Intermittent
Low Voltage 6E±393. . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1115 ECT Sensor Circuit Intermittent
High Voltage 6E±395. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code(DTC)P1120-TPS 1
Throttle Position Sensor (TPS1) Output
Abnormal 6E±398. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1125 ETC (Electric Throttle Control)
Limit Performance Mode 6E±401. . . . . . . . . . . . . . . . .
DTC P1133 HO2S Insufficient Switching
Bank 1 Sensor 1 6E±404. . . . . . . . . . . . . . . . . . . . . . . .
DTC P1134 HO2S Transition Time Ratio
Bank 1 Sensor 1 6E±408. . . . . . . . . . . . . . . . . . . . . . . .
DTC P1153 HO2S Insufficient Switching
Bank 2 Sensor 1 6E±412. . . . . . . . . . . . . . . . . . . . . . . .
DTC P1154 HO2S Circuit Transition Time
Ratio Bank 2 Sensor 1 6E±416. . . . . . . . . . . . . . . . . .
DTC P1167 Fuel System Rich During Decel
Fuel Cut Off (Bank 1) 6E±420. . . . . . . . . . . . . . . . . . . .
DTC P1169 Fuel System Rich During Decel
Fuel Cut Off (Bank 2) 6E±422. . . . . . . . . . . . . . . . . . . .
DTC P1171 Fuel System Lean During
Acceleration 6E±424. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1220 Throttle Position Senser2
(TPS2) Circuit Fault 6E±427. . . . . . . . . . . . . . . . . . . . .
DTC P1221 TPS1 ± TPS2 Correlation
(Circuit Performance) 6E±430. . . . . . . . . . . . . . . . . . .
DTC P1271 APS 1± 2 Correlation Error 6E±433. . .
DTC P1272 APS 2 ± 3 Correlation Error 6E±436. . .
DTC P1273 APS 1 ± 3 Correlation Error 6E±439. . . .
DTC P1275 APS 1 Output Fault 6E±442. . . . . . . . . . .
DTC P1280 APS 2 Output Fault 6E±444. . . . . . . . . . .
DTC P1285 APS 3 Output Fault 6E±446. . . . . . . . . . .
DTC P1290 ETC Forced Idle Mode 6E±448. . . . . . . .
DTC P1295 ETC Power Management Mode 6E±451
DTC P1299 ETC Forced Engine Shutdown
Mode 6E±455. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1310 ION Sensing Module Diagnosis 6E±459
DTC P1311 ION Sensing Module SEC
Line 1 Circuit Fault 6E±462. . . . . . . . . . . . . . . . . . . . . .
DTC P1312 ION Sensing Module SEC
Line 2 Circuit Fault 6E±465. . . . . . . . . . . . . . . . . . . . . .
DTC P1326 ION Sensing Module Combustion
Quality Input Circuit Fault 6E±468. . . . . . . . . . . . . . . .
DTC P1340 ION Sensing Module Cylinder ID
Fault (Cylinder Synchronization Fail) 6E±471. . . . . .
DTC P1404 EGR Stuck Closed 6E±474. . . . . . . . . . .
DTC P1441 EVAP System Flow During
Non-Purge 6E±477. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1514 TPS - MAF Correlation Error 6E±480. . . DTC P1515 Command - Actual TPS
Correlation Error 6E±484. . . . . . . . . . . . . . . . . . . . . . . .
DTC P1516 Command - Actual TPS
Correlation Error 6E±487. . . . . . . . . . . . . . . . . . . . . . . .
DTC P1523 Actuator Control Return
Performance 6E±490. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1571 Brake Switch No Operation 6E±493. . . .
DTC P1625 PCM Unexpected Reset 6E±495. . . . . . .
DTC P1635 Reference Voltage # 1 Circuit
Fault 6E±496. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1639 Reference Voltage # 2 Circuit
Fault 6E±498. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1640 Driver-1-Output Circuit Fault
(ODM) 6E±500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P1650 Quad Driver Module ªAº Fault 6E±503. .
Symptom Diagnosis 6E±506. . . . . . . . . . . . . . . . . . . . .
Default Matrix Table 6E±535. . . . . . . . . . . . . . . . . . . . .
On Vehicle Service
Crankshaft Position (CKP) Sensor 6E±538. . . . . . . . .
Engine Coolant Temperature (ECT) Sensor 6E±538.
Heated Oxygen Sensor (HO2S) 6E±539. . . . . . . . . . .
Intake Air Temperature (IAT) Sensor 6E±542. . . . . . .
ION Sensing Module 6E±542. . . . . . . . . . . . . . . . . . . . .
Mass Air Flow (MAF) Sensor 6E±543. . . . . . . . . . . . .
Manifold Absolute Pressure (MAP) Sensor 6E±544.
Malfunction Indicator Lamp (MIL) 6E±545. . . . . . . . . .
Reduced Power Lamp 6E±545. . . . . . . . . . . . . . . . . . .
Powertrain Control Module (PCM) 6E±545. . . . . . . . .
Service Precaution 6E±545. . . . . . . . . . . . . . . . . . . .
EEPROM 6E±547. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Position (TP) Sensor 6E±547. . . . . . . . . . . . .
Vehicle Speed Sensor (VSS) 6E±548. . . . . . . . . . . . .
Air Cleaner/Air Filter 6E±549. . . . . . . . . . . . . . . . . . . . .
Common Chamber 6E±549. . . . . . . . . . . . . . . . . . . . . .
Accelerator Pedal Replacement 6E±550. . . . . . . . . . .
Accelerator Position Sensor Replacement 6E±551. .
Accelerator Position Sensor Adjustment 6E±551. . . .
Fuel Filler Cap 6E±552. . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter 6E±552. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge Unit 6E±553. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Injectors 6E±554. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Metering System 6E±555. . . . . . . . . . . . . . . . . . . .
Fuel Pump Assembly 6E±555. . . . . . . . . . . . . . . . . . . .
Fuel Pump Relay 6E±556. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Rail Assembly 6E±557. . . . . . . . . . . . . . . . . . . . . .
Fuel Tank 6E±558. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Body (TB) 6E±558. . . . . . . . . . . . . . . . . . . . . . .
Electronic Ignition System 6E±560. . . . . . . . . . . . . . . .
Catalytic Converter 6E±561. . . . . . . . . . . . . . . . . . . . . .
Air Conditioning Thermo Relay 6E±561. . . . . . . . . . .
EVAP Canister Hoses 6E±561. . . . . . . . . . . . . . . . . . . .
EVAP Canister 6E±562. . . . . . . . . . . . . . . . . . . . . . . . . .
EVAP Canister Vent Solenoid 6E±562. . . . . . . . . . . . .

6E±47
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
11. Turn on Air Conditioning.
060RY00094
12. Turn ªOnº and ªOffº A/C Switch.
13. Contol A/C Clutch Relay and check data list.
14. If the data list changes, the Fuel Pump Relay is
normal.
EVAP Test
This test is conducted to check EVAP system for its power
operation.
Tech 2 must be used for this test.
Test Procedure:
1. Connect Tech 2 to the vehicle DLC.
2. Run the Engine at idle.
3. Select F3: Miscellaneous Test in the Application
Menu.
060R100078
4. Select F2: EVAP Test in the Miscellaneous Test.
060RY00082
5. Select F0: Purge Solenoid.
060RX025