2002 ISUZU AXIOM ad blue

0B±11 MAINTENANCE AND LUBRICATION
Recommended Liquid Gasket
TypeBrand NameManufacturerRemarks
RTV*
Silicon Base
Three Bond 1207B
Three Bond 1207C
Three Bond 1215
Three Bond 1280
Three Bond 1281Three Bond
Three Bond
Three Bond
Three Bond
Three BondFor Engine Repairs
For Axle Case
Repairs T/M
Repairs T/M
Water BaseThree Bond 1141EThree BondFor Engine Repairs
Solvent
Three Bond 1104
Belco Bond 4
Belco Bond 401
Belco Bond 402Three Bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anaerobic
LOCTITE 515
LOCTITE 518
LOCTITE 17430Loctite
Loctite
Loctite
All
* RTV: Room Temperature Vulcanizer
NOTE:
1. It is very important that the liquid gaskets listed above
or their exact equivalent be used on the vehicle.
2. Be careful to use the specified amount of liquid
gasket.
Follow the manufacturer's instructions at all times.
3. Be absolutely sure to remove all lubricants and
moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. Do not apply LOCTITE 17430, LOCTITE 515 and
LOCTITE 518 between two metal surfaces having a
clearance of greater than 0.25 mm (0.01 in). Poor
adhesion will result.
Recommended Thread Locking
Agents
LOCTITE TypeLOCTITE Color
LOCTITE 242Blue
LOCTITE 262Red
LOCTITE 271Red
Application Steps
1. Completely remove all lubricant and moisture from
the bolts and the female-threaded surfaces of the
parts to be joined.
The surfaces must be perfectly dry.
2. Apply LOCTITE to the bolts.
F00RW014
3. Tighten the bolts to the specified torque.
After tightening, be sure to keep the bolts free from
vibration and torque for at least an hour until
LOCTITE hardens.
NOTE: When the application procedures are specified in
this manual, follow them.

DIFFERENTIAL (FRONT) 4A1±18
16. Tighten the cap bolt to the specified torque.
Torque: 97 N´m (72 lb ft)
425RS036
Gear Tooth Contact Pattern Check and
Adjustment
1. Apply a thin coat of prussian blue or equivalent to
at least 7±8 ring gear teeth. Rotate the ring gear
and inspect the contact point of the impressions
and make the necessary adjustments as
described in the next page.
425RS038
Legend
(1) Heel
(2) Toe
(3) Concave Side(Coast)
(4) Convex Side(Drive)
425RS039

6A±23
ENGINE MECHANICAL (6VE1 3.5L)
7. Connect each connector.
8. Connect vacuum booster hose.
9. Connect the Ion sensing module connectors as
shown in the illustration.
060RY00111
Legend
(1) Green Connector
(2) Blue Connector
(3) Identification Mark (6VE1 Engine Only)
10. Install air cleaner duct assembly.
013RY00001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Mass Air Flow Sensor

6A±48
ENGINE MECHANICAL (6VE1 3.5L)
9. Install air conditioner compressor to engine and
tighten to the specified torque.
Torque :
M8 bolts : 22 N´m (16 lb ft)
M10 bolts : 43 N´m (32 lb ft)
10. Install power steering pump, tighten fixing bolt to the
specified torque.
Torque :
M8 bolts : 22N´m (16 lb ft)
M10 bolts : 46 N´m (34 lb ft)
11. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Drive Belt
12. Install upper fan shroud.
13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back of right
dash panel.
19. Reconnect ground cable between engine and
chassis.
20. Reconnect harness connector to transmission and
install transmission harness bracket on engine left
side.
21. Reconnect three engine harness connectors.
22. Reconnect vacuum booster hose.
23. Reconnect canister vacuum hose.24. Install air cleaner assembly.
25. Reconnect air duct.
26. Reconnect throttle position sensor harness
connector.
025RY001
Legend
(1) Throttle Position Sensor Connector
(2) Throttle Valve Assembly
27. Reconnect manifold absolute pressure sensor
harness connectors.
28. Reconnect ion sensing module connectors as shown
in the illustration.
060RY00111
Legend
(1) Green Connector
(2) Blue Connector
(3) Identification Mark (6VE1 Engine Only)
29. Install engine hood to the original position.

Refer to installation procedure for Body section in
this manual.

6A±71
ENGINE MECHANICAL (6VE1 3.5L)
015RS012
Legend
(1) Number 1 and 4 main bearing upper and lower
(2) Number 2 and 3 main bearing upper
(3) Number 2 and 3 main bearing lower
mm ( in)
1 Size
MarkMain Bearing
Bore DiameterCrank Shaft Main
Journal Diameter2 Size
Mark
Crank
Shaft
Bearing
Size Mark
(Upper
Side)Crank
Shaft
Bearing
Size Mark
(Lower
Side)
Oil Clearance
(Reference)
168.994-69.000
63.918-63.925
(2.5165-2.5167)2BlueBlue0.030-0.049
(0.0012-0.0019)
1(2.7163-2.7165)63.926-63.933
(2.5168-2.5170)1
BrownBrown
0.028-0.047
(0.0011-0.0019)
268.987-68.993
63.918-63.925
(2.5165-2.5167)2
BrownBrown0.029-0.048
(0.0011-0.0019)
2(2.7160-2.7163)63.926-63.933
(2.5168-2.5170)1
GreenGreen
0.027-0.046
(0.0011-0.0018)
368.980-68.986
63.918-63.925
(2.5165-2.5167)2
GreenGreen0.028-0.047
(0.0011-0.0019)
3(2.7157-2.7160)63.926-63.933
(2.5168-2.5170)1YellowYellow0.026-0.045
(0.0010-0.0018)
Reassembly
1. Crankshaft (12)

Install the main bearings to the cylinder block and
the main bearing caps.

Be sure that they are positioned correctly.

Apply new engine oil to the upper and lower main
bearing faces.
NOTE: Do not apply engine oil to the main bearing back
faces.
015RS012

6D1±2
ENGINE ELECTRICAL (6VE1 3.5L)
Battery
General Description
The battery is completely sealed except for the two small
vent holes (2) on the side. These vent holes (2) permit the
escape of small amounts of gas generated by the battery.
This type of battery has the following advantages over
conventional batteries:
1. There is no need to add water during the entire
service life of the battery.
2. The battery is much less vulnerable to self discharge
than a conventional type battery.
Diagnosis
1. Visual Inspection
Inspect the battery for obvious physical damage, such as
a cracked or broken case, which would permit electrolyte
loss.
Replace the battery if obvious physical damage is
discovered during inspection.
Check for any other physical damage and correct it as
necessary.
2. Hydrometer Check
There is a built±in hydrometer (Charge test indicator(1))
at the top of the battery. It is designed to be used during
diagnostic procedures.
Before trying to read the hydrometer, carefully clean the
upper battery surface.
If your work area is poorly lit, additional light may be
necessary to read the hydrometer.
a. BLUE RING OR DOT VISIBLE(4) ± Go to Step 3.
b. BLUE RING OR DOT NOT VISIBLE(3) ± Replace
the battery.
061R200001
3. Voltage Check
1. Put voltmeter test leads to battery terminals.
a. VOLTAGE IS 12.4V OR ABOVE ± Go to Step 4
Load Test.
b. VOLTAGE IS UNDER 12.4V ± Go to procedure (2)
below.
2. Determine fast charge amperage from specification.
(See Main Data and Specifications in this section).
Fast charge battery for 30 minutes at amperage rate
no higher than specified value.
Take voltage and amperage readings after charge.
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
AMPERAGE RATE ± Replace battery.
b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF
AMPERAGE RATE ± Drop charging voltage to 15V
and charge for 10 ± 15 hours. Then go to Step 4
Load Test.
c. VOLTAGE IS BETWEEN 12V AND 16V ±
Continue charging at the same rate for an
additional 3±1/2 hours. Then go to Step 4 Load
Test.
d. VOLTAGE BELOW 12V ± Replace the Battery.
4. Load Test
1. Connect a voltmeter and a battery load tester across
the battery terminals.
2. Apply 300 ampere load for 15 seconds to remove
surface charge from the battery. Remove load.
3. Wait 15 seconds to let battery recover. Then apply
specified load from specifications (See Main Data
and Specifications in this section).
Read voltage after 15 seconds, then remove load.
a. VOLTAGE DOES NOT DROP BELOW THE
MINIMUM LISTED IN THE TABLE ± The battery is
good and should be returned to service.
b. VOLTAGE IS LESS THAN MINIMUM LISTED ±
Replace the battery.
ESTIMATED TEMPERATURE
MINIMUM
VOLTAGE

F
CV
70219.6
60169.5
50109.4
4049.3
30±19.1
20±78.9
10±128.7
0±188.5
The battery temperature must be estimated by feel
and by the temperature the battery has been
exposed to for the preceding few hours.

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±1
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
AXIOM
ENGINE
6VE1 3.5L ENGINE
DRIVEABILITY AND EMISSIONS
CONTENTS
Specifications 6E±6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening Specifications 6E±6. . . . . . . . . . . . . . .
Diagrams and Schematics 6E±7. . . . . . . . . . . . . . . .
PCM Wiring Diagram (1 of 7) 6E±7. . . . . . . . . . . .
PCM Wiring Diagram (2 of 7) 6E±8. . . . . . . . . . . .
PCM Wiring Diagram (3 of 7) 6E±9. . . . . . . . . . . .
PCM Wiring Diagram (4 of 7) 6E±10. . . . . . . . . . . .
PCM Wiring Diagram (5 of 7) 6E±11. . . . . . . . . . . .
PCM Wiring Diagram (6 of 7) 6E±12. . . . . . . . . . . .
PCM Wiring Diagram (7 of 7) 6E±13. . . . . . . . . . . .
PCM Pinouts 6E±14. . . . . . . . . . . . . . . . . . . . . . . . . . .
PCM Pinout Table, 80-Way Blue Connector
± Row ªF1 ~ 20º 6E±14. . . . . . . . . . . . . . . . . . . . . .
PCM Pinout Table, 80-Way Blue Connector
± Row ªF20 ~ 40º 6E±15. . . . . . . . . . . . . . . . . . . . .
PCM Pinout Table, 80-Way Blue Connector
± Row ªF41 ~ 60º 6E±16. . . . . . . . . . . . . . . . . . . . .
PCM Pinout Table, 80-Way Blue Connector
± Row ªF61 ~ 80º 6E±17. . . . . . . . . . . . . . . . . . . . .
PCM Pinout Table, 80-Way Red Connector
± Row ªS1 ~ 20º 6E±19. . . . . . . . . . . . . . . . . . . . . .
PCM Pinout Table, 80-Way Red Connector
± Row ªS21 ~ 40º 6E±21. . . . . . . . . . . . . . . . . . . . .
PCM Pinout Table, 80-Way Red Connector
± Row ªS41 ~ 60º 6E±23. . . . . . . . . . . . . . . . . . . . .
PCM Pinout Table, 80-Way Red Connector
± Row ªS61 ~ 80º 6E±25. . . . . . . . . . . . . . . . . . . . .
Component Locators 6E±27. . . . . . . . . . . . . . . . . . .
Undercarriage Component Locator 6E±29. . . . . .
Fuse and Relay Panel (Underhood
Electrical Center) 6E±30. . . . . . . . . . . . . . . . . . . . .
Sensors and Miscellaneous Component
Locators 6E±31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis 6E±33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strategy-Based Diagnostics 6E±33. . . . . . . . . . . . .
DTC Stored 6E±33. . . . . . . . . . . . . . . . . . . . . . . . . . .
No DTC 6E±33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No Matching Symptom 6E±33. . . . . . . . . . . . . . . . .
Intermittents 6E±33. . . . . . . . . . . . . . . . . . . . . . . . . .
No Trouble Found 6E±33. . . . . . . . . . . . . . . . . . . . .
Verifying Vehicle Repair 6E±33. . . . . . . . . . . . . . . .
General Service Information 6E±33. . . . . . . . . . . . . .
OBD II Serviceablity Issues 6E±33. . . . . . . . . . . . .
Emissions Control Information Label 6E±34. . . . .
Visual / Physical Engine Compartment
Inspection 6E±34. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic Knowledge of Tools Required 6E±35. . . . . .
Serial Data Communications 6E±35. . . . . . . . . . . . . . Class 2 Serial Data Communications 6E±35. . . . .
On-Board Diagnostic (OBD II) 6E±35. . . . . . . . . . . . .
On-Board Diagnostic Tests 6E±35. . . . . . . . . . . . .
Comprehensive Component Monitor
Diagnostic Operation 6E±35. . . . . . . . . . . . . . . . . .
System Status and Drive Cycle for
Satisfying Federal Inspection/Maintenance
(I/M 240) Regulations 6E±36. . . . . . . . . . . . . . . . . .
Common OBD II Terms 6E±36. . . . . . . . . . . . . . . . .
The Diagnostic Executive 6E±36. . . . . . . . . . . . . . .
DTC Types 6E±37. . . . . . . . . . . . . . . . . . . . . . . . . . .
Decimal/Binary/Hexadecimal Conversions 6E±39
Verifying Vehicle Repair 6E±39. . . . . . . . . . . . . . . .
Reading Diagnostic Trouble Codes Using
The Tech 2 Scan Tool 6E±39. . . . . . . . . . . . . . . . .
Tech 2 6E±40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tech 2 Features 6E±41. . . . . . . . . . . . . . . . . . . . . . .
Getting Started 6E±41. . . . . . . . . . . . . . . . . . . . . . . .
Operating Procedure (For Example) 6E±42. . . . .
DTC Modes 6E±43. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC Information Mode 6E±43. . . . . . . . . . . . . . . . .
Miscellaneous Test 6E±44. . . . . . . . . . . . . . . . . . . .
Lamps Test 6E±44. . . . . . . . . . . . . . . . . . . . . . . . . . .
Relays Test 6E±46. . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAP Test 6E±47. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System Test 6E±48. . . . . . . . . . . . . . . . . . . . . .
Instruments Test 6E±50. . . . . . . . . . . . . . . . . . . . . . .
EGR Control Test 6E±52. . . . . . . . . . . . . . . . . . . . . .
Variable Intake Manifold Solenoid Test 6E±52. . .
Injector Balance Test 6E±54. . . . . . . . . . . . . . . . . . .
Plotting Snapshot Graph 6E±54. . . . . . . . . . . . . . . . .
Plotting Graph Flow Chart (Plotting graph
after obtaining vehicle information) 6E±55. . . . . .
Flow Chart for Snapshot Replay (Plotting
Graph) 6E±56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary System-Based Diagnostic 6E±57. . . . . . . . .
Primary System-Based Diagnostic 6E±57. . . . . . .
Fuel Control Heated Oxygen Sensor 6E±57. . . . .
HO2S Heater 6E±57. . . . . . . . . . . . . . . . . . . . . . . . .
Catalyst Monitor Heated Oxygen Sensors
and Diagnostic Operation 6E±57. . . . . . . . . . . . . .
Misfire Monitor Diagnostic Operation 6E±58. . . . . . .
Misfire Monitor Diagnostic Operation 6E±58. . . . .
Misfire Counters 6E±58. . . . . . . . . . . . . . . . . . . . . . .