2002 ISUZU AXIOM Cylinder head

6A±49
ENGINE MECHANICAL (6VE1 3.5L)
Cylinder Head
Cylinder Head and Associated Parts
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Legend
(1) Spark Plug
(2) Cylinder Head Bolt
(3) Camshaft Drive Gear Pulley Fixing Bolt
(4) Camshaft Drive Gear Pulley
(5) Camshaft Bearing Cap Fixing Bolt
(6) Camshaft Bearing Cap
(7) Camshaft Exhaust(8) Camshaft Intake
(9) Retainer Fixing Bolt
(10) Retainer Assembly
(11) Tappet with Shim
(12) Split Collar
(13) Valve Spring and Spring Upper Seat
(14) Valve

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).
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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)
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5. Water jacket sealing plugs seating surfaces.

6A±55
ENGINE MECHANICAL (6VE1 3.5L)
1. Measure the valve stem diameter with a micrometer.
If the valve stem diameter is less than the specified
limit, the valve and the valve guide must be replaced
as a set.
Diameter of Valve Stem
Intake
Standard : 5.977 mm±5.959 mm
(0.2353 in±0.2346 in)
Limit : 5.90 mm (0.2323 in)
Exhaust
Standard : 5.952 mm±5.970 mm
(0.2343 in±0.2350 in)
Limit : 5.90 mm (0.2323 in)
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2. Measure the inside diameter of the valve guide with a
micrometer. Subtract the measured outer diameter of
the valve stem from the measured inner diameter of
the valve guide. If the value exceeds the specified
limit, the valve and the valve guide must be replaced
as a set.
Inside Diameter of the Vale Guide
Inlet clearance
Standard : 0.023 mm±0.056 mm
(0.0009 in±0.0002 in)
Limit : 0.20 mm (0.00787 in)
Exhaust clearance
Standard : 0.030 mm±0.063 mm
(0.0012 in±0.0025 in)
Limit : 0.20 mm (0.00787 in)
Valve Guide Replacement
1. Using Valve guide replacer: J±42899, drive out the
valve guide from the combustion chamber side.
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2. Apply engine oil to the outside of the valve guide.
Using valve guide replacer J±42899, drive in a new
valve guide from the camshaft side, and check the
valve guide height.
Valve guide upper end height: 13.0 mm (0.5118
in)
(Measured from the cylinder head upper face)
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3. Check the clearance. If the clearance is less than the
specified value, ream the inside diameter of valve
guide. Using a sharp 6 mm reamer, ream the valve
guide to obtain the specified clearance.

6A±56
ENGINE MECHANICAL (6VE1 3.5L)
Valve Seat
1. Measure the protrusion of the valve stem when a new
valve is installed in the cylinder head. If the protrusion
of the valve stem exceeds the limit, replace the valve
seat insert or the cylinder head assembly.
Protrusion of valve stem
Intake
Standard: 39.32 mm (1.5480 in)
Limit: 39.47 mm (1.5539 in)
Exhaust
Standard: 39.3 mm (1.5472 in)
Limit: 39.45 mm (1.5531 in)
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2. Measure the valve seat contact width. Make the
necessary corrections if the seat contact surface is
damaged or rough or if the contact width wear
exceeds the limit.
Valve seat contact width
Standard: 1.1 mm (0.0433 in)
Limit: 1.7 mm (0.0669 in)
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Contact Surface Angle on Valve Seat on
Valve
1. Measure contact surface angle on valve seat.
2. If the measured value exceeds the limit, replace
valve, valve guide and valve seat as a set.
Valve contact surface angle: 45

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Valve Seat Insert Correction
1. Remove the carbon from the valve seat insert
surface.
2. Use a valve cutter to minimize scratches and other
rough areas. This will bring the contact width back to
the standard value. Remove only the scratches and
rough areas. Do not cut away too much. Take care not
to cut away unblemished areas of the valve seat
surface.
Valve seat angle degree: 90

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6A±57
ENGINE MECHANICAL (6VE1 3.5L)
3. Apply abrasive compound to the valve seat insert
surface.
4. Insert the valve into the valve guide.
5. Turn the valve while lapping it to fit the valve seat
insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact
with the entire circumference of the valve.
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Valve Seat Insert Replacement
1. Arc weld the rod at several points. Be careful not to
damage the aluminum section.
2. Allow the rod to cool for a few minutes. This will cause
the valve seat to shrink.
3. Strike the rod and pull it out.
014RS015
4. Carefully clean the valve seat press±fit section on the
cylinder head side.
5. Heat the press±fit section with steam or some other
means to cause expansion. Cool the valve seat with
dry ice or some other means.
6. Insert the press±fit section into the valve seat
horizontally.
Standard fitting interference: 0.14 mm±0.09 mm
(0.0055 in±0.0035 in)
7. After insertion, use a seat grinder to grind finish the
seating face. Carefully note the seating angle, the
contact width, and the depression.
8. Lap the valve and the seat.
Reassembly
1. Install valve guide (1) to cylinder head. Apply engine
oil to the outside of the valve guide. Using valve guide
replacer J±42899, drive in a new valve guide from the
camshaft side.
2. Install oil controller (3) and spring lower seat (2).
Using oil controller replacer J±37281, drive in a new
oil controller.
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6A±58
ENGINE MECHANICAL (6VE1 3.5L)
3. Install valve to valve guide. Before installing valve
guide apply engine oil to the outside of the valve stem.
4. Install valve spring to cylinder head. Attach the valve
spring to the lower spring seat. The painted area of
the valve spring should be facing downward.
014RS020
5. Install lower valve spring seat, valve spring and upper
valve spring seat then put split collars on the upper
spring seat, using the J±8062 valve spring
compressor and J±42898 valve spring compressor
adapter to install the split collars.
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6. Install tappet with shim.
7. Install camshaft assembly.

Refer to installation procedure for Camshaft in this
manual.
Valve Clearance Adjustments
NOTE: To adjust valve clearance, apply engine oil to the
cam as well as to the adjusting shim (2) with the cylinder
head built on the cylinder block, give a few turns to the
camshaft by means of timing pulley tightening bolt, and
measure valve clearance when the nose of cam is just
opposite of maximum cam lift (1) as shown in illustration
below.
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Legend
(1) Cam
(2) Shim
(3) Tappet
Valve Clearance Standard Value (cold)
Intake: 0.23 mm±0.33 mm
(0.0091 in±0.0130 in)
Exhaust: 0.25 mm±0.35 mm
(0.0098 in±0.0138 in)
Selection of Adjusting Shim
Shim to be selected = (Thickness of removed shim) +
(Valve clearance measurement ± Standard value)
Based on the above formula, the best suited shim should
be selected from 41 types of shim (differently thick at
0.02mm (0.0008 in) intervals from 2.40mm (0.0945 in)
through 3.2mm (0.1260 in) thick). Install the shim and
check valve clearance.

6A±62
ENGINE MECHANICAL (6VE1 3.5L)
3. Place the camshaft on V±blocks.
Slowly rotate the camshaft and measure the runout
with a dial indicator.
Replace the camshaft if the runout exceeds the
specified limit.
Runout
Limit : 0.1 mm (0.0039 in)
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4. Measure the camshaft journal oil clearance.
1. Measure the camshaft bracket housing inside
diameter.
NOTE: Tighten camshaft bracket (2) to specified torque
before measuring the camshaft bracket inside diameter.
Torque : 10 N´m (89 lb in)
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2. Subtract the camshaft outside diameter from the
camshaft bracket housing inside diameter.
Oil Clearance
Standard : 0.027 mm±0.078 mm
(0.0011 in±0.0031 in)
Limit : 0.11 mm (0.0043 in)
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5. Replace the cylinder head and/or camshaft if the
measured oil clearance exceeds the specified limit.
1. Carefully clean the camshaft journal, the
camshaft bracket, and the cylinder head.
2. Install camshaft assembly and camshaft brackets
(2), tighten twenty bolts (1) on one side bank to
the specified torque.
Torque: 10 N´m (89 lb in)
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6A±63
ENGINE MECHANICAL (6VE1 3.5L)
3. Measure the camshaft thrust clearance with a dial
indicator. Replace the camshaft and/or the
cylinder head if the camshaft thrust clearance
exceeds the specified limit.
Camshaft thrust Clearance
Standard : 0.03 mm±0.08 mm
(0.0012 in.±0.0031 in.)
Limit : 0.12 mm (0.0047 mm)
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Reassembly
1. Install camshaft drive gear assembly and tighten
three bolts to specified torque.
Torque: 10 N´m (89 lb in)
2. Install the spring ; camshaft gear(1) into the camshaft
assembly.
Ensure the clearance is between the right side of the
spring; camshaft gear (1) and the dowel pin (2).
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3. Align the dowel pin on the sub gear to the clearance of
the spring ; camshaft gear made in step 2 and install
the sub gear (3).
4. Install the wave washer (2). Use snap ring pliers to
install the snap ring (1).
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5. Tighten sub gear setting bolt.
a. Use J±42686 gear spring lever to pre-load the sub
gear. Turn the sub gear in a clockwise direction
until the M5 bolt hole aligns with the hole in the
camshaft driven gear.
b. Install the M5 bolt and tighten to a suitable torque to
prevent the sub gear from moving.
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6. Align the timing mark on the retainer and dowel pin of
the camshaft drive gear.
7. Install camshaft assembly and camshaft brackets,
tighten twenty bolts on one side bank to the specified
torque.