2002 ISUZU AXIOM fuel pump

0A±12
GENERAL INFORMATION
Abbreviations Charts
List of automotive abbreviations which may be used
in this manual
A Ð Ampere(s)
ABS Ð Antilock Brake System
AC Ð Alternating Current
A/C Ð Air Conditioning
ACCEL Ð Accelerator
ACC Ð Accessory
ACL Ð Air Cleaner
Adj Ð Adjust
A/F Ð Air Fuel Ratio
AIR Ð Secondary Air Injection System
Alt Ð Altitude
AMP Ð Ampere(s)
ANT Ð Antenna
ASM Ð Assembly
A/T Ð Automatic Transmission/Transaxle
ATDC Ð After Top Dead Center
ATF Ð Automatic Transmission Fluid
Auth Ð Authority
Auto Ð Automatic
BARO Ð Barometric Pressure
Bat Ð Battery
B+ Ð Battery Positive Voltage
Bbl Ð Barrel
BHP Ð Brake Horsepower
BPT Ð Backpressure Transducer
BTDC Ð Before Top Dead Center

C Ð Degrees Celsius
CAC Ð Charge Air Cooler
Calif Ð California
cc Ð Cubic Centimeter
CID Ð Cubic Inch Displacement
CKP Ð Crankshaft Position
CL Ð Closed Loop
CLCC Ð Closed Loop Carburetor Control
CMP Ð Camshaft Position
CO Ð Carbon Monoxide
Coax Ð Coaxial
Conn Ð Connector
Conv Ð Converter
Crank Ð Crankshaft
Cu. In. Ð Cubic Inch
CV Ð Constant Velocity
Cyl Ð Cylinder(s)
DI Ð Distributor Ignition
Diff Ð Differential
Dist Ð Distributor
DLC Ð Data Link Connector
DOHC Ð Double Overhead Camshaft
DTC Ð Diagnostic Trouble Code
DTM Ð Diagnostic Test Mode
DTT Ð Diagnostic Test Terminal
DVM Ð Digital Voltmeter (10 meg.)
DVOM Ð Digital Volt Ohmmeter
EBCM Ð Electronic Brake Control Module
ECM Ð Engine Control Module
ECT Ð Engine Coolant Temperature
EEPROM Ð Electronically Erasable Programmable
Read Only Memory
EGR Ð Exhaust Gas Recirculation
EI Ð Electronic Ignition
ETR Ð Electronically Tuned Receiver
EVAP Ð Evaporation EmissionExh Ð Exhaust

F Ð Degrees Fahrenheit
Fed Ð Federal (All States Except Calif.)
FF Ð Front Drive Front Engine
FL Ð Fusible Link
FLW Ð Fusible Link Wire
FP Ð Fuel Pump
FRT Ð Front
ft Ð Foot
FWD Ð Front Wheel Drive
4WD Ð Four Wheel Drive
4 x 4 Ð Four Wheel Drive
4 A/T Ð Four Speed Automatic Transmission/Transaxle
Gal Ð Gallon
GEN Ð Generator
GND Ð Ground
Gov Ð Governor
g Ð Gram
Harn Ð Harness
HC Ð Hydrocarbons
HD Ð Heavy Duty
Hg Ð Hydrargyrum (Mercury)
HiAlt Ð High Altitude
HO2S Ð Heated Oxygen Sensor
HVAC Ð Heater±Vent±Air±Conditioning
IAC Ð Idle Air Control
IAT Ð Intake Air Temperature
IC Ð Integrated Circuit / Ignition Control
ID Ð Identification / Inside Diameter
IGN Ð Ignition
INJ Ð Injection
IP Ð Instrument Panel
IPC Ð Instrument Panel Cluster
Int Ð Intake
ISC Ð Idle Speed Control
J/B Ð Junction Block
kg Ð Kilograms
km Ð Kilometers
km/h Ð Kilometer per Hour
kPa Ð Kilopascals
kV Ð Kilovolts (thousands of volts)
kW Ð Kilowatts
KS Ð Knock Sensor
L Ð Liter
lb ft Ð Foot Pounds
lb in Ð Inch Pounds
LF Ð Left Front
LH Ð Left Hand
LR ÐLeft Rear
LS Ð Left Side
LWB Ð Long Wheel Base
L±4 Ð In±Line Four Cylinder Engine
MAF Ð Mass Air Flow
MAN Ð Manual
MAP Ð Manifold Absolute Pressure
Max Ð Maximum
MC Ð Mixture Control
MFI Ð Multiport Fuel Injection
MIL Ð Malfunction Indicator Lamp
Min Ð Minimum
mm Ð Millimeter
MPG Ð Miles Per Gallon
MPH Ð Miles Per Hour
M/T Ð Manual Transmission/Transaxle
MV Ð Millivolt

6A±3
ENGINE MECHANICAL (6VE1 3.5L)
General Description
Engine Cleanliness And Care
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, it
should be understood that proper cleaning and protection
of machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.

A liberal coating of engine oil should be applied to all
friction areas during assembly to protect and lubricate
the surfaces on initial operation.

Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.

At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.

Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.

The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.
General Information on Engine Service
The following information on engine service should be
noted carefully, as it is important in preventing damage
and contributing to reliable engine performance.

When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump
strainer, jacking against the oil pan may cause
damage to the oil pick±up unit.

The 12±volt electrical system is capable of damaging
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at the
battery.

Any time the intake air duct or air cleaner is removed,
the intake opening should be covered. This will
protect against accidental entrance of foreign
material into the cylinder which could cause extensive
damage when the engine is started.
Cylinder Block
The cylinder block is made of aluminum die±cast casting
for 75
V±type six cylinders. It has a rear plate integrated
structure and employs a deep skirt. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width is different
between No.2, No.3 and No.1, No.4; the width of No.3
bearing on the body side is different in order to support the
thrust bearing. The bearing cap is made of nodular cast
iron and each bearing cap uses four bolts and two side
bolts.
Cylinder Head
The cylinder head, made of aluminum alloy casting
employs a pent±roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V±type design. The ports are cross±flow
type.
Valve Train
Intake and exhaust camshaft on both banks are driven
with a camshaft drive gear by the timing belt. The valves
are operated by the camshaft and the valve clearance is
adjusted to select suitable thickness shim.
Intake Manifold
The intake manifold system is composed of the aluminum
cast common chamber and intake manifold attached with
six fuel injectors.
Exhaust Manifold
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods
Aluminum pistons are used after selecting the grade that
meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin made
of chromium steel is offset 1mm toward the thrust side,
and the thrust pressure of piston to the cylinder wall varies
gradually as the piston travels. The connecting rods are
made of forged steel. The connecting rod bearings are
graded for correct size selection.
Crankshaft and Bearings
The crankshaft is made of Ductile cast±iron. Pins and
journals are graded for correct size selection for their
bearing.

6A±4
ENGINE MECHANICAL (6VE1 3.5L)
Engine Diagnosis
First of all the engine diagnose to check the fuel quantity,
the engine level and the engine coolant level.
Hard Starting
1. Starting Motor Does Not Turn Over
Troubleshooting Procedure
Turn on headlights and starter switch.
Condition
Possible causeCorrection
Headlights go out or dim
considerably
Battery run down or under chargedRecharge or replace battery
considerablyTerminals poorly connectedClean battery posts and terminals
and connect properly
Starting motor coil circuit shortedOverhaul or replace
Starting motor defectiveOverhaul or replace
2. Ignition Trouble Ð Starting Motor Turns Over But Engine Does Not Start
Spark Test
Disconnect an ignition coil from any spark plug. Connect
the spark plug tester (For example J±26792), start the
engine, and check if a spark is generated in the spark plugtester. Before starting the engine, make sure that the
spark plug tester is properly grounded. To avoid electrical
shock, do not touch the part where insulation of the
ignition coil is broken while the engine is running.
Condition
Possible causeCorrection
Spark jumps across gapSpark plug defectiveClean, adjust spark gap or replace
Ignition timing incorrectRefer to Ignition System
Fuel not reaching fuel injector(s) or
engineRefer to item 3 (Trouble in fuel
system)
Valve timing incorrectAdjust
Engine lacks compressionRefer to item 4 (Engine lacks
compression)
No sparking takes placeIgnition coil disconnected or brokenConnect properly or replace
Electronic Ignition System with
moduleReplace
Poor connections in engine harnessCorrect
Powertrain Control Module cable
disconnected or defectiveCorrect or replace
3. Trouble In Fuel System
Condition
Possible causeCorrection
Starting motor turns over and spark
occurs but engine does not start
Fuel tank emptyFill
occurs but engine does not start.Water in fuel systemClean
Fuel filter cloggedReplace filter
Fuel pipe cloggedClean or replace
Fuel pump defectiveReplace
Fuel pump circuit openCorrect or replace
Evaporative Emission Control
System circuit cloggedCorrect or replace
Multiport Fuel Injection System faultyRefer to ªElectronic Fuel Injectionº
section

6A±5
ENGINE MECHANICAL (6VE1 3.5L)
4. Engine Lacks Compression
Condition
Possible causeCorrection
Engine lacks compressionSpark plug loosely fitted or spark
plug gasket defectiveTighten to specified torque or replace
gasket
Valve timing incorrectAdjust
Cylinder head gasket defectiveReplace gasket
Valve incorrectly seatedLap valve
Valve stem seizedReplace valve and valve guide
Valve spring weakened or brokenReplace
Cylinder or piston rings wornOverhaul engine
Piston ring seizedOverhaul engine.
Engine Compression Test Procedure
1. Start and run the engine until the engine reaches
normal operating temperature.
2. Turn the engine off.
3. Remove all the spark plugs.
4. Remove ignition coil fuse (15A) and disable the
ignition system.
5. Remove the fuel pump relay from the relay and fuse
box.
6. Engage the starter and check that the cranking speed
is approximately 300 rpm.
7. Install cylinder compression gauge into spark plug
hole.
8. With the throttle valve opened fully, keep the starter
engaged until the compression gage needle reaches
the maximum level. Note the reading.
9. Repeat the test with each cylinder.
If the compression pressure obtained falls below the
limit, engine overhaul is necessary.
Limit; 1000 kPa (145 psi)

6A±6
ENGINE MECHANICAL (6VE1 3.5L)
Rough Engine Idling or Engine Stalling
ConditionPossible causeCorrection
Trouble in fuel injection systemThrottle shutting off incompleteCorrect or replace
Throttle position sensor circuit open
or shortedCorrect or replace
Fuel injector circuits open or shortedCorrect or replace
Fuel injectors damagedReplace
Fuel pump relay defectiveReplace
Mass Airflow Sensor circuit open or
poor connectionsCorrect or replace
Mass Airflow Sensor defectiveReplace
Manifold Absolute Pressure Sensor
circuit open or poor connectionsCorrect or replace
Manifold Absolute Pressure Sensor
defectiveReplace
Engine Coolant Temperature Sensor
circuit open or poor connectionsCorrect or replace
Engine Coolant Temperature Sensor
defectiveReplace
Intake Air Temperature sensor circuit
open or poor connectionsCorrect or replace
Intake Air Temperature sensor
defectiveReplace
Ion Sensing Module cable broken or
poor connectionsCorrect or replace
Ion Sensing Module defectiveReplace
Vehicle Speed Sensor circuit open or
shortedCorrect or replace
Vehicle Speed Sensor defectiveReplace
Trouble in emission control systemPowertrain Control Module defectiveReplace
Exhaust Gas Recirculation Valve
circuit open or poor connectionsCorrect or replace
Exhaust Gas Recirculation Valve
faultyReplace
Canister purge valve circuit open or
poor connectionsCorrect or replace
Canister purge valve defectiveReplace
Evaporative Emission Canister
Purge control valve defectiveReplace
Trouble in ignition systemRefer to ªHard Startº
OthersEngine lacks compressionRefer to ªHard Startº
Valve incorrectly seatedLap valve
Air Cleaner Filter cloggedReplace filter element
Valve timing incorrectReadjust
Idle air control valve brokenReplace
Fast idle solenoid defectiveReplace
Positive Crankcase Ventilation valve
defective or cloggedReplace

6A±8
ENGINE MECHANICAL (6VE1 3.5L)
Hesitation
ConditionPossible causeCorrection
Hesitation on accelerationThrottle Position Sensor adjustment
incorrectReplace throttle valve assembly
Throttle Position Sensor circuit open
or shortedCorrect or replace
Mass Airflow Sensor circuit open or
poor connectionsCorrect or replace
Mass Airflow Sensor defectiveReplace
Manifold Absolute Pressure (MAP)
Sensor circuit open or shortedCorrect or replace
MAP Sensor defectiveReplace
Intake Air Temperature (IAT) Sensor
circuit open or poor connectionsCorrect or replace
Ion Sensing Module circuit open or
poor connectionsCorrect or replace
Ion Sensing Module defectiveReplace
IAT Sensor defectiveReplace
Hesitation at high speedsFuel tank strainer cloggedClean or replace
(Fuel pressure too low)Fuel pipe cloggedClean or replace
Fuel filter cloggedReplace
Defective fuel pump systemCheck and replace
Fuel Pressure Control Valve leakingReplace
Hesitation at high speeds
(Fuel injector not working normally)Power supply or ground circuit for
Multiport Fuel Injection System
shorted or openCheck and correct or replace
Fuel Injector defectiveReplace
Cable of Multiport Fuel Injection
System circuit open or poor
connectionsCorrect or replace

6A±10
ENGINE MECHANICAL (6VE1 3.5L)
Engine Lacks Power
ConditionPossible causeCorrection
Trouble in fuel systemFuel Pressure Control Valve not
working normallyReplace
Fuel injector cloggedClean or replace
Fuel pipe cloggedClean
Fuel filter clogged or fouledReplace
Fuel pump drive circuit not working
normallyCorrect or replace
Fuel tank not sufficiently breathing
due to clogged Evaporative
Emission Control System circuitClean or replace
Water in fuel systemClean
Inferior quality fuel in fuel systemUse fuel of specified octane rating
Powertrain Control Module supplied
poor voltageCorrect circuit
Throttle Position Sensor cable
broken or poor connectionsCorrect or replace
Throttle Position Sensor defectiveReplace
Mass Airflow Sensor not working
normallyReplace
Manifold Absolute Pressure Sensor
not working normallyReplace
Intake Air Temperature Sensor not
working normallyReplace
Engine Coolant Temperature Sensor
circuit open or shortedCorrect or replace
Engine Coolant Temperature Sensor
defectiveReplace
Powertrain Control Module defectiveReplace
Trouble in intake or exhaust systemAir Cleaner Filter cloggedReplace filter element
Air duct kinked or flattenedCorrect or replace
TWC defectiveRepair
Ignition failureÐÐÐÐRefer to Hard Start Troubleshooting
Guide
Heat range of spark plug inadequateInstall spark plugs of adequate heat
range
Ignition coil defectiveReplace

6A±13
ENGINE MECHANICAL (6VE1 3.5L)
Troubleshooting Procedure for Slapping or Hitting etc Noise
The slapping sound stops when spark plug on bad
cylinder is shorted out.
Condition
Possible causeCorrection
Timing belt noiseTiming belt tension is incorrectReplace pusher or adjust the tension
pulley or replace timing belt
Tensioner bearing defectiveReplace
Timing belt defectiveReplace
Timing pulley defectiveReplace
Timing belt comes in contact with
timing coverReplace timing belt and timing cover
Valve noiseValve clearance incorrectReplace adjusting shim
Valve and valve guide seizedReplace valve and valve guide
Valve spring broken or weakenedReplace
Valve seat off±positionedCorrect
Camshaft worn outReplace
Crankshaft noiseCrankshaft end play excessive
(noise occurs when clutch is
engaged)Replace thrust bearing
Engine knockingPreignition due to use of spark plugs
of inadequate heat rangeInstall Spark Plugs of adequate heat
range
Carbon deposits in combustion
chambersClean
Fuel too low in octane ratingReplace fuel
Wide Open Throttle enrichment
system failureRefer to Section 6E
Selection of transmission gear
incorrectCaution operator of incorrect gear
selection
Engine overheatingRefer to ªEngine Lacks Powerº
OthersWater pump defectiveReplace
Drive belt slippingReplace auto tensioner or drive belt