2002 ISUZU AXIOM battery

6D3±12
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Brush Spring
Use spring balancer to measure the spring setting force
when remove the spring from the brush.
Standard: 17.65±23.54 N (38.9±51.9 lb)
Limit: 11.77 N (25.9 lb)
Magnetic Switch
Temporarilly connect the magnetic switch between the
overrunning clutch and housing.
Perform the steps described below in 3 to 5 seconds.
1. Pull in test
Connect the ground (±) to terminal C and magnetic
switch body.
Verify that the pinion pulls out when the battery (+)
pole is connected to terminal 50.
065R100017
2. Hold in test
Observe that the pinion stays when the lead wire is
disconnected from terminal C.
065R100018
3. Return test
Connect the ground (±) to terminal 50 and magnetic
switch body.
Verify that the pinion pulls out when the battery (+)
pole is connected to terminal C and the pinion pulls
away when the lead wire is disconnected from
terminal 50.
065R100019
Field Coil
1. Check for continuity between the end of the field coil
and yoke body.
Replace the field coil, if there is continuity.
065RY00065

6D3±17
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Charging System
General Description
The IC integral regulator charging system and its main
components are connected as shown in illustration.
The regulator is a solid state type and it is mounted along
with the brush holder assembly inside the generator
installed on the rear end cover.
The generator does not require particular maintenance
such as voltage adjustment.The rectifier connected to the stator coil has diodes to
transform AC voltage into DC voltage.
This DC voltage is connected to the output terminal of
generator.
F06RX002
General On±Vehicle Inspection
A basic wiring diagram is shown in the illustration. When
operating normally, the indicator bulb will come on when
the switch is turned on, and will then go out when the
engine starts. If the indicator operates abnormally, or if an
undercharged or overcharged battery condition occurs,
the following procedure may be used to diagnose the
charging system. Remember that an undercharged
battery is often caused by accessories being left on
overnight, or by a defective switch which allows a bulb,
such as a trunk or glove box light, to stay on.
Observe the following procedure:
1. Visually check belt and wiring.
2. Go to step 5. for vehicles without charge indicator
light.
3. Switch on, engine stopped, light should be on. If not,
detach harness at generator, ground ªLº terminal
lead.a. Lamp lights, replace or repair generator.
b. Lamp dose not light, locate open circuit between
grounding lead and ignition switch. Bulb may be
open.
4. Switch on, engine running at moderate speed. Light
should be off. If not, detach wiring harness at
generator.
a. If light goes off, replace or repair generator.
b. If light stays on, check for grounded ªLº terminal
wire in harness.
5. Battery undercharged or overcharged.
a. Detach wiring harness connector from generator.
b. With switch on, engine not running connect
voltmeter from ground to ªLº terminal in wiring
harness, and to ªIGº terminal. If used. Wiring
harness may connect to either ªLº or ªIGº or both.
c. Zero reading indicates open circuit between
terminal and battery. Connect as required.

6D3±18
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
d. Re-connect harness connector to generator, run
engine at moderate speed, with electrical
accessories turned off.
e. Measure voltage across battery. If above 16.0V,
replace or repair generator.
f. Connect ammeter at generator output terminal.
Turn on accessories, load battery with carbon pile
to obtain maximum amperes output.
Maintain voltage at 13.0V or above.
1. If within 15 amperes of rated output, generator is
OK.2. If not within 15 amperes of rated output, replace or
repair generator.
Generator
Removal
1. Disconnect battery ground cable.
2. Move drive belt tensioner to loose side using wrench
then remove drive belt (1).
3. Disconnect the wire from terminal ªBº and disconnect
the connector (4).
4. Remove generator fixing bolt (3).
5. Remove generator assembly (2).
060RW002
Inspection
1. Disconnect the wiring connector from generator.
2. With the engine stopped, turn starter switch to ªonº
and connect a voltmeter between connector terminal
L (1) and ground or between terminal S (2) and
ground.
066RX002If there is no voltage present, then perform
appropriate repair.
3. Reconnect the wiring connector to the generator, run
the engine at must indicate idle speed, and turn off all
electrical devices other than engine.
4. Measure battery voltage. If it exceeds 16V, repair or
replace the generator.
5. Connect an ammeter to output terminal of generator,
and measure output current under load by turning on
the other electrical devices (eg., headlights). At this
time the amperes must not be less than 15A and the
voltage must not be less than 13V.

6D3±19
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Installation
1. Install generator assembly to the position.
2. Install generator assembly and tighten the fixing bolts
to the specified torque.
Torque:
M10 bolt: 41 N´m (30 Ib ft)
M8 bolt: 21 N´m (15 Ib ft)
3. Connect wiring harness connector and direct terminal
ªBº.4. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
5. Reconnect battery ground cable.
Disassembled View
066RW022
Legend
(1) Pulley Nut
(2) Pulley
(3) Front Cover Assembly
(4) Rotor Assembly
(5) Stator Assembly
(6) Through Bolt(7) Nut
(8) Terminal Insulator
(9) Rear Cover Assembly
(10) Rectifier
(11) Brush Holder Assembly
(12) Regulator Assembly

6D3±23
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Rectifier Assembly
1. Measure the resistance between each diode terminal
and aluminum diode fin in forward and reverse
directions with the connection of the tester leads
switched. The diodes are normal if resistance is
nearly zero ohms in one direction and is infinitely high
in the other direction.
2. If a diode has no resistance or equal resistance in
both directions, it is defective and should be replaced
together with the holder.
066RS036
IC Regulator Assembly
Connect a variable resistor, two 12V batteries, a fixed
resistor, and a voltmeter to the IC regulator as shown in
illustration.
a. Measuring equipment specifications
1. Fixed resistor (R1) : 10 Ohms /3W
2. Variable resistor (Rv) : 0-300 Ohms/12W
3. Batteries (BAT1, BAT2) : 12V (2 Batteries)
4. DC voltmeter : 0-50V/0.5 steps (4 Check points)
b. Measuring procedure
1. Measure the voltage ªV1º across the first battery
(BAT1). If the reading is between 10 and 13 volts,
the battery is normal.
2. Measure the voltage ªV3º across both the batteries
(BAT1, BAT2). If the reading is between 20 and 26
bolts, the batteries are normal.
3. Gradually increase the resistance of the variable
resistor from zero. Measure the voltage ªV2º (the
voltage across the F and E terminals).
Check to see that the voltage across ªV1º changes at
this time. If there is no change, the voltage regulator
is faulty and must be replaced.4. Measure the voltage at ªV4º (the voltage across the
variable resistor center tap and terminal E with the
variable resistor resistance held constant). The
measured voltage should be within the specified
(14.4+0.3 volts) limits. If it is not, the regulator must
be replaced.
066RX003
Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:
NOTE:

Never make battery connections with polarities
reversed, or battery will be shorted via the diodes.
This will cause damage to the diodes.

Do not connect generator B terminal to ground; it is
connected directly to the battery.
This cable will burn if it is connected to ground.

Make sure to disconnect the positive (+) terminal of
the battery when quick-charging battery .
Diodes may be damaged due to abnormal pulse
voltage generated by the quick charger.

When reassembling the front section to rear section,
insert a stiff wire into hole in the rear face of the rear
cover from the outboard side to support the brush in
raised position, then insert the front section to which
rotor is assembled.

Reassemble parts carefully to be sure they fit into
their original position, paying attention to the
insulated portions.

Wipe insulating tubes, washers and plates clean and
install them in position carefully to avoid getting oil or
grease on them.

6D3±25
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Main Data and Specifications
General Specifications
Battery voltageV12
Rated outputA90
Direction of rotation
(as viewed from pulley side)Clockwise
Rated rotation speedrpm 5000
Maximum speedrpm18000

6E±39
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Identifying stored Diagnostic Trouble Codes (DTCs).

Clearing DTCs.

Performing output control tests.

Reading serial data.
TS24064
Decimal/Binary/Hexadecimal Conversions
Beginning in 1996, Federal Regulations require that all
auto manufacturers selling vehicles in the United States
provide Scan Tool manufacturers with software
information to display vehicle operating parameters. All
Scan Tool manufacturers will display a variety of vehicle
information which will aid in repairing the vehicle. Some
Scan Tools will display encoded messages which will aid
in determining the nature of the concern. The method of
encoding involves the use of a two additional numbering
systems: Binary and Hexadecimal.
The binary number system has a base of two numbers.
Each digit is either a 0 or a 1. A binary number is an eight
digit number and is read from right to left. Each digit has a
position number with the farthest right being the 0 position
and the farthest left being the 7 position. The 0 position,
when displayed by a 1, indicates 1 in decimal. Each
position to the left is double the previous position and
added to any other position values marked as a 1.
A hexadecimal system is composed of 16 different alpha
numeric characters. The alpha numeric characters used
are numbers 0 through 9 and letters A through F. The
hexadecimal system is the most natural and common
approach for Scan Tool manufacturers to display data
represented by binary numbers and digital code.
Verifying Vehicle Repair
Verification of vehicle repair will be more comprehensive
for vehicles with OBD II system diagnostic. Following a
repair, the technician should perform the following steps:
1. Review and record the Fail Records and/or Freeze
Frame data for the DTC which has been diagnosed
(Freeze Frame data will only be stored for an A or B
type diagnostic and only if the MIL has been
requested).
2. Clear DTC(s).
3. Operate the vehicle within conditions noted in the Fail
Records and/or Freeze Frame data.
4. Monitor the DTC status information for the DTC which
has been diagnosed until the diagnostic test
associated with that DTC runs.
Following these steps are very important in verifying
repairs on OBD ll systems. Failure to follow these steps
could result in unnecessary repairs.
Reading Diagnostic Trouble Codes Using
The Tech 2 Scan Tool
The procedure for reading diagnostic trouble code(s) is to
use a diagnostic Scan Tool. When reading DTC(s), follow
instructions supplied by tool manufacturer.
Clearing Diagnostic Trouble Codes
IMPORTANT:Do not clear DTCs unless directed to do
so by the service information provided for each diagnostic
procedure. When DTCs are cleared, the Freeze Frame
and Failure Record data which may help diagnose an
intermittent fault will also be erased from memory.
If the fault that caused the DTC to be stored into memory
has been corrected, the Diagnostic Executive will begin to
count the ªwarm-upº cycles with no further faults
detected, the DTC will automatically be cleared from the
PCM memory.
To clear Diagnostic Trouble Codes (DTCs), use the
diagnostic Scan Tool ªclear DTCsº or ªclear informationº
function. When clearing DTCs follow instructions
supplied by the tool manufacturer.
When a Scan Tool is not available, DTCs can also be
cleared by disconnecting
one of the following sources for
at least thirty (30) seconds.
NOTE: To prevent system damage, the ignition key must
be ªOFFº when disconnecting or reconnecting battery
power.

The power source to the control module. Examples:
fuse, pigtail at battery PCM connectors, etc.

The negative battery cable. (Disconnecting the
negative battery cable will result in the loss of other
on-board memory data, such as preset radio tuning).

6E±66
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
A/C Clutch Control Circuit Diagnosis

 
StepNo Ye s Value(s) Action
21Use an ohmmeter to check continuity between the
pressure switch and the A/C thermostat relay.
Was the circuit open?
ÐGo to Step 22Go to Step 23
22Repair the open circuit between the pressure switch
and the A/C thermostat relay.
Is the action complete?
ÐVerify repairÐ
23Check for damaged pin or terminal at F45 of the PCM.
Was a damaged pin or terminal found?
ÐGo to Step 24Go to Step 25
24Repair the damaged pin or terminal.
Is the action complete?
ÐVerify repairÐ
25Replace the PCM.
IMPORTANT:The replacement PCM must be
programmed. Refer to
On-Vehicle Service in
Powertrain Control Module Sensors for procedures.
And also refer to latest Service Bulletin.
Check to see if the Latest software is released or not.
And then Down Load the LATEST PROGRAMMED
SOFTWARE to the replacement PCM.
Is the action complete?
ÐVerify repairÐ
261. Remove the A/C compressor relay.
2. Ignition ªONº.
3. Use a DVM to check voltage at both of the wires at
the A/C compressor relay socket.
Is the voltage equal to the specified value?
B+Go to Step 28Go to Step 27
27Repair the faulty wire between the A/C fuse and the
A/C compressor relay .
Is the action complete?
ÐVerify repairÐ
281. A/C compressor relay removed.
2. Engine idling.
3. A/C ªONº.
4. Blower ªONº.
5. Use a DVM to measure voltage between the wire at
the A/C compressor relay socket and battery+.
Did the DVM indicate the specified value?
B+Go to Step 32Go to Step 29
29Check for an open wire between PCM terminal F4 and
the A/C compressor relay.
Was the wire open?
ÐGo to Step 30Go to Step 31
30Repair the open wire between the PCM and the A/C
compressor relay.
Is the action complete?
ÐVerify repairÐ
31Check for a damaged pin or terminal at F4 of the PCM.
Was a damaged pin or a terminal found?
ÐGo to Step 24Go to Step 25