2002 ISUZU AXIOM interference

0A±13
GENERAL INFORMATION
N Ð Newtons
NA Ð Natural Aspirated
NC Ð Normally Closed
N´M Ð Newton Meters
NO Ð Normally Open
NOX Ð Nitrogen, Oxides of
OBD Ð On-Board Diagnostic
OD Ð Outside Diameter
O/D Ð Over Drive
OHC Ð Overhead Camshaft
OL Ð Open Loop
O2 Ð Oxygen
O2S Ð Oxygen Sensor
PAIR Ð Pulsed Secondary Air Injection System
P/B Ð Power Brakes
PCM Ð Powertrain Control Module
PCV Ð Positive Crankcase Ventilation
PRESS Ð Pressure
PROM Ð Programmable Read Only Memory
PNP Ð Park/Neutral Position
P/S Ð Power Steering
PSI Ð Pounds per Square Inch
PSP Ð Power Steering Pressure
Pt. Ð Pint
Pri Ð Primary
PWM Ð Pulse Width Modulate
Qt. Ð Quart
REF Ð Reference
RF Ð Right Front
RFI Ð Radio Frequency Interference
RH Ð Right Hand
RPM Ð Revolutions Per Minute
RPM Sensor Ð Engine Speed Sensor
RPO Ð Regular Production Option
RR Ð Right Rear
RS Ð Right Side
RTV Ð Room Temperature Vulcanizing
RWAL Ð Rear Wheel Antilock Brake
RWD Ð Rear Wheel Drive
SAE Ð Society of Automotive Engineers
Sec Ð Secondary
SFI Ð Sequential Multiport Fuel Injection
SI Ð System International
SIR Ð Supplemental Inflatable Restraint System
SOHC Ð Single Overhead Camshaft
Sol Ð Solenoid
SPEC Ð Specification
Speedo Ð Speedometer
SRS Ð Supplemental Restraint System
ST Ð Start / Scan Tool
Sw Ð Switch
SWB Ð Short Wheel Base
SYN Ð Synchronize
Tach Ð Tachometer
TB Ð Throttle Body
TBI Ð Throttle Body Fuel Injection
TCC Ð Torque Converter Clutch
TCM Ð Transmission Control Module
TDC Ð Top Dead Center
Term Ð Terminal
TEMP Ð Temperature
TODÐ Torque On Demand
TP Ð Throttle Position
TRANS Ð Transmission/Transaxle
TURBO Ð TurbochargerTVRS Ð Television & Radio Suppression
TVV Ð Thermal Vacuum Valve
TWC Ð Three Way Catalytic Converter
3 A/T Ð Three Speed Automatic Transmission/Transaxle
2WD Ð Two Wheel Drive
4 x 2 Ð Two Wheel Drive
U±joint Ð Universal Joint
V Ð Volt(s)
VAC Ð Vacuum
VIN Ð Vehicle Identification Number
VRRRE Ð Vehicle Refrigerant Recovery and Recycling
Equipment
V±ref Ð ECM Reference Voltage
VSS Ð Vehicle Speed Sensor
VSV Ð Vacuum Switch Valve
V±6 Ð Six Cylinder ªVº Engine
V±8 Ð Eight Cylinder ºVº Engine
W Ð Watt(s)
w/ Ð With
w/b Ð Wheel Base
w/o Ð Without
WOT Ð Wide Open Throttle
Service Parts Identification Plate
The Vehicle Information Plate (Service Parts ID plate) is
provided on all vehicle models.
It is located on the center dash wall inside the engine
compartment. The plate lists the VIN (Vehicle
Identification Number), paint information and all
production options and special equipment on the vehicle
when it was shipped from the factory.
905R200002

0B±7 MAINTENANCE AND LUBRICATION
Automatic Transmission Fluid
Replacement
Under harsh operating conditions, such as constant
driving in heavy city traffic during hot weather, or in hilly or
mountainous terrain, change the transmission fluid and
service the sump filter after every 20,000 miles (32,000
km) of operation.
More over, the remaining life percentage of ATF can be
estimated by using TECH±II as an auxiliary tool to judge
the right time for ATF replacement.
The remaining life percentage is calculated from ATF'S
heat history. When it is close to 0%, ATF replacement is
recommended.
Auto Cruise Control Inspection
Check to see if the clearance between cruise link and
accelerator link is normal. Also check that the connected
properly.
Accelerator Linkage Inspection
Inspect for interference, binding, and damaged or
missing parts. Check accelerator pedal for smooth
operation and even pedal effort. Replace parts as
needed.

3F±8INTELLIGENT SUSPENSION
INTERMITTENT CONDITIONS
If the Warning Lamp flashes a diagnostic trouble code as
intermittent, or if after a test drive a DTC does not
reappear though the detection conditions for this DTC are
present: the problem is most likely a faulty electrical
connection or loose wiring. Terminals and grounds should
always be the prime suspect. Intermittents rarely occur
inside sophisticated electronic components such as the
Control Unit.
Use the DTC information to understand which wires and
sensors are involved.
When an intermittent problem is encountered, check
suspect circuits for:
1. Poor terminal to wire connection.
2. Terminals not fully seated in the connector body
(backed out).
3. Improperly formed or damaged terminals.
4. Loose, dirty, or corroded ground connections:
HINT: Any time you have an intermittent in more than
one circuit, check whether the circuits share a
common ground connection.
5. Pinched or damaged wires.
6. Electro-Magnetic Interference (EMI):
HINT: Check that all wires are properly routed away
from spark plug wires, distributor wires, coil, and
generator. Also check for improperly installed
electrical options, such as lights, 2-way radios, etc.
BULB CHECK
When the starter switch is turned on in the normal state,
the Control Unit turns on the Warning Lamp to check the
bulb. After the engine starts, the Warning Lamp turns off.
F03RY00003
DTC CHECK
1. Diagnosis Trouble Codes (DTC) have been identified
by FLASHING CODES.
2. You have written the list of the DTC. The order of the
malfunctions has no meanings for this Control Unit.
Usually only one or two malfunctions should be set for
a given problem.
3. Check directly the DTCs you identified. The DTC are
sorted by number:
DIAGNOSTIC TROUBLE CODES.

4D2±28
TRANSFER CASE (TOD)
13. Install the snap ring of the input shaft bearing to the
transfer case.
265RY00003
14. Using snap ring pliers, open the snap ring from the
gap on the carrier assembly.
While opening the snap ring, securely attach the input
shaft and carrier assembly to the transfer case.
265RY00002
Inspection and Repair (Transfer Case
Assembly)
When wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired or
replaced. Wash all the parts with clean detergent, and
check that old oil, metallic particles, dirt, or foreign
materials are completely removed. Blow the air into oil
holes and grooves to remove foreign materials or residual
detergent.
Chain

Check whether the face that contacts the sprocket is
free from excessive wear or damage. If defects are
observed, replace the part.

If the chain interference mark is found on the inside
wall of the transfer cover or the chain is so slack that a
skipped engagement occurs between the chain and
sprocket, replace the chain.
Sprocket

Check whether the sprocket tooth surface is
excessively worn or damaged, and there is evidence
of burrs, chipping, wear, or damage on the gear
spline. Remove minor flaws or scratches with oil
stone. If excessive wear or damage is observed,
replace the part.

If excessive wear or damage is observed on the
sprocket inside sliding surface, replace the part.
Gear

Check whether the gear tooth surface is excessively
worn or damaged, and there is evidence of burrs,
chipping, wear, or damage on the gear spline.
Remove minor flaws or scratches with oil stone. If
excessive wear or damage is observed, replace the
part.
Thickness of Reduction Hub

Measure the thickness with a micrometer.

If the measurement exceeds the limit, replace the
reduction hub.
Standard : 3.05±3.30 mm (0.120±0.130 in)
Allowable limit : 2.5 mm (0.098 in)
265RW005

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.
014RS014
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.
014RW058

6A±78
ENGINE MECHANICAL (6VE1 3.5L)
015RS026

Positioning mark (1) is painted as shown in the
illustration.
Marked T : No.1 Compression ring
Marked T2 : No.2 Compression ring
015RS027
2. Measure the clearance between the piston ring
groove and the piston ring with a feeler gauge. If the
piston ring groove / piston ring clearance exceeds the
specified limit, the piston must be replaced.
Compression Ring Clearance
Standard : 0.025 mm±0.065 mm
(0.0006 in.±0.0015 in)
Limit : 0.1mm (0.0059 in)
015RS028
Piston Pin
NOTE: Do not reuse the old piston pin.
1. Use a micrometer to measure the new piston pin
outside diameter in both directions at three different
positions.
2. Measure the inside diameter of the connecting rod
small end. If the fitting interference between the small
end and pin does not conform to the specified value,
the connecting rod must be replaced.
Standard : 0.023 mm±0.038 mm (0.0009
in±0.0015 in)
015RS029

6E±138
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
4. A frequency reading with the MAF sensor connector
disconnected indicates an electromagnetic
interference (EMI) related fault.
8. This vehicle is equipped with a PCM which utilizes
an electrically erasable programmable read only
memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.
Refer to
PCM Replacement and Programming
Procedures
in Powertrain Control Module (PCM)
and Sensors
.

TRANSMISSION CONTROL SYSTEM (4L30±E)7A1±23
Intermittent Conditions
If the Tech 2 displays a diagnostic trouble code as
intermittent, or if after a test drive a DTC does not
reappear though the detection conditions for this DTC are
present, the problem is most likely a faulty electrical
connection or loose wiring. Terminals and grounds should
always be the prime suspect. Intermittents rarely occur
inside sophisticated electronic components such as the
PCM.
Use the DTC information to understand which wires and
sensors are involved.
When an intermittent problem is encountered, check
suspect circuits for:
1. Poor terminal to wire connection.
2. Terminals not fully seated in the connector body
(backed out).
3. Improperly formed or damaged terminals.
4. Loose, dirty, or corroded ground connections:
HINT: Any time you have an intermittent in more than
one circuit, check whether the circuits share a
common ground connection.5. Pinched or damaged wires.
6. Electro±Magnetic Interference (EMI):
HINT: Check that all wires are properly routed away
from coil, and generator. Also check for improperly
installed electrical options, such as lights, 2±way
radios, etc.
Use the F2: SNAPSHOT mode of the Tech 2 to help
isolate the cause of an intermittent fault. The snapshot
mode will record information before and after the problem
occurs. Set the snapshot to ªtriggerº on the suspect DTC.
If you notice the reported symptom during the test drive,
trigger the snapshot manually.
After the snapshot has been triggered, command the
Tech 2 to play back the flow of data recorded from each of
the various sensors. Signs of an intermittent fault in a
sensor circuit are sudden unexplainable jump in data
values out of the normal range.
Transmission And PCM Identification
The chart below contains a list of all important information
concerning rear axle ratio, Powertrain Control Module
(PCM), and transmission identification.
VEHICLE
Rr axlePCMTRANSMISSION
TypeEngine
Rr axle
RatioISUZU Parts No.Calibration
CodeIsuzu Part No.Model Code
Isuzu /35LV64 3008±97287±830±0G268±96023±779±0YB (4y4)
Axiom3.5L V64.3008±09389±969±0G268±96024±169±0YE (4y2)
240R200001