2002 ISUZU AXIOM engine

6D2±2
IGNITION SYSTEM (6VE1 3.5L)
General Description
Ignition is done by the electronic ignition (El) that directly
fires the spark plugs from ignition coils through spark plug
wires without using a distributor. The firing orders are
selected No.1, No.2, No.3, No.4, No.5, and No6.
Since the cylinder on exhaust stroke requires less energy
to fire its ignition plug, energy from the ignition coils can be
utilized to fire the mating cylinder on compression stroke.
After additional 360
rotation, respective cylinder strokes
are reversed.
The EI consists of six ignition coils,ignition control
module, crank position sensor, powertrain control module
(PCM) and other components.
The ignition coils are connected with the PCM by means
of a 80 pin connector.The ignition control module turns on/off the primary circuit
of ignition coils, and also it controls the ignition timing at
the engine speed below 538 rpm.
A notch in the timing disc on the crankshaft activates the
crank position sensor which then sends information such
as firing order and starting timing of each ignition coil to
the PCM.
Further, the El employs ignition control (IC) to control
similar to a distributor system.
By receiving signals such as crank position,engine
speed, water temperature and Manifold Absolute
Pressure (MAP), the PCM controls the ignition timing.
D06RY00037
Diagnosis
Refer to Section Drivability and Emissions for the
diagnosis to electronic ignition system (El system).

6D2±5
IGNITION SYSTEM (6VE1 3.5L)
Spark Plug
Removal
1. Remove spark plugs.
Inspection and Repair
The spark plug affects entire engine performance and
therefore its inspection is very important.

Check electrode and insulator for presence of cracks,
and replace if any.

Check electrode for wear, and replace if necessary.

Check gasket for damage, and replace if necessary.

Measure insulation resistance with an ohmmeter, and
replace if faulty.

Adjust spark plug gap to 1.0 mm ± 1.1 mm (0.0394 in ±
0.0433 in).
011RS011
NOTE:
± Do not adjust the spark plugs gap without new
spark plugs.
± Do not damage to tip of spark plugs.
± Do not cleaning the spark plugs. If require the
cleaning it due to heavy dirt, it is allowed only 20
seconds to be used spark plug cleaner.

Check fuel and electrical systems if spark plug is
extremely dirty.

Use spark plugs having low heat value (hot type plug)
if fuel and electrical systems are normal.

Use spark plugs having high heat value (cold type
plug) if insulator and electrode are extremely burned.
Sooty Spark Plugs
Much deposit of carbon or oil on the electrode and
insulator of spark plug reduces the engine performance.
Possible causes:

Too rich mixture

Presence of oil in combustion chamber

Incorrectly adjusted spark plug gap
Burning Electrodes
This fault is characterized by scorched or heavily oxidized
electrode or blistered insulator nose.
Possible causes:

Too lean mixture

Improper heat value
Measuring Insulation Resistance

Measure insulation resistance using a 500 volt
megaohm meter.

Replace spark plugs if measured value is out of
standard.
Insulation resistance: 50 M
or more
011RS010
Installation
1. Spark plugs

Tighten spark plugs to the specified torque.
Torque: 18 N´m (13 lb ft)

6D2±6
IGNITION SYSTEM (6VE1 3.5L)
Crankshaft Position Sensor
Removal
1. Disconnect battery ground cable
2. Wiring connector from crankshaft position sensor.
3. Remove crankshaft position sensor from cylinder
block.
012RS008
Installation
1. Install crankshaft position sensor into the cylinder
block.
Before installation,apply small amount of engine oil to
the O±ring.
Torque: 10 N´m (87 lb in)
2. Reconnect wiring connector to crankshaft position
sensor.

6D3±1
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
AXIOM
ENGINE
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
CONTENTS
Service Precaution 6D3±1. . . . . . . . . . . . . . . . . . . . . .
Starting System 6D3±2. . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6D3±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 6D3±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter 6D3±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6D3±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6D3±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 6D3±7. . . . . . . . . . . . . . . . . . . .
Disassembly 6D3±8. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D3±10. . . . . . . . . . . . . . . . . .
Reassembly 6D3±13. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D3±14. . . . . . . . . . .
Charging System 6D3±17. . . . . . . . . . . . . . . . . . . . . . . . General Description 6D3±17. . . . . . . . . . . . . . . . . . . .
General On±Vehicle Inspection 6D3±17. . . . . . . . . . .
Generator 6D3±18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6D3±18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6D3±18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6D3±19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 6D3±19. . . . . . . . . . . . . . . . . . . .
Disassembly 6D3±20. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D3±21. . . . . . . . . . . . . . . . . .
Reassembly 6D3±23. . . . . . . . . . . . . . . . . . . . . . . . . .
Bench Test 6D3±24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D3±25. . . . . . . . . . . . .
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.

6D3±2
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Starting System
General Description
Cranking Circuit
The cranking system consists of a battery, starter, starter
switch, starter relay, etc. These main components are
connected.
Starter
The cranking system employs a magnetic type reduction
starter in which the motor shaft is also used as a pinion
shaft. When the starter switch is turned on, the contacts of
magnetic switch are closed, and the armature rotates. At
the same time, the plunger is attracted, and the pinion is
pushed forward by the shift lever to mesh with the ring
gear.
Then, the ring gear runs to start the engine. When the
engine starts and the starter switch is turned off, the
plunger returns, the pinion is disengaged from the ring
gear, and the armature stops rotation. When the engine
speed is higher than the pinion, the pinion idles, so that
the armature is not driven.

6D3±5
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Starter
Removal
1. Battery ground cable.
2. Disconnect Heated O
2 Sensor connector (1).
3. Remove exhaust front left pipe(2).
150R100011
4. Disconnect starter wiring connector from terminals
ª30º (1) and ª50º (2).
5. Remove starter assembly mounting bolts on inside
and outside(3).
6. Remove starter assembly (4) toward the bottom of
engine.
065RY00050
Legend
(1) Terminal ª30º
(2) Terminal ª50º
(3) Fixing Bolts
(4) Starter Assembly
Installation
1. Install starter assembly(4).
2. Install mounting bolts and tighten bolts to specified
torque(3).
Torque: 40 N´m (30 lb ft)
3. Reconnect the connectors to terminals ª50º (2)
tighten terminals ª30º (1) to specified torque.
Torque: 9 N´m (78 lb in)
065RY00050
Legend
(1) Terminal ª30º
(2) Terminal ª50º
(3) Fixing Bolts
(4) Starter Assembly
4. Install exhaust front left pipe (2) and tighten bolts and
nuts to specified torque.
Stud Nuts
Torque: 67 N´m (49 lb ft)
Bolts
Torque: 43 N´m (32 lb ft)

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.