ISUZU AXIOM 2002 Service Repair Manual

6E±544
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Manifold Absolute Pressure
(MAP) Sensor
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector from the MAP
sensor.
055RY00001
3. Remove the bolt securing the MAP sensor to the
mounting bracket on the common chamber.
4. Remove the MAP sensor from the mounting bracket.
055RW002
Installation Procedure
1. Install the MAP sensor in the mounting bracket.
055RW002
2. Install the mounting bracket retaining bolt on the
common chamber.
Tighten

Tighten the bolt to 20 N´m (12 lb ft.).
3. Connect the MAP electrical connector.
055RY00001
4. Connect the negative battery cable.

6E±545
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Malfunction Indicator Lamp
(MIL)
Removal and Installation Procedure
Refer to Warning light bulb, indicator light valve,
illumination light bulb, A/T indicator light bulb in Meter and
Gauge.
Reduced Power Lamp
The reduced power lamp (RPL) turns on when the ignition
key is moved to the ON position. It should turn off in
approximately 3 seconds or immediately after the engine
starts.
If the RPL turns on during vehicle operation, a vehicle
system failure resulting in reduced engine output is
indicated.
If both the reduced RPL and the check engine light turn
on, a serious problem affecting vehicle performance is
indicated.
Refer to the
OBD system check NO and RPL ªONº steady
in this manual.
Powertrain Control Module
(PCM)
Service Precaution
NOTE: To p r e ve n t p ossible electrostatic discharge
damage to the PCM, do not touch the connector pins or
soldered components on the circuit board.
Electrostatic Discharge (ESD)
Damage
Electronic components used in the control systems are
often designed to carry very low voltage. Electronic
components are susceptible to damage caused by
electrostatic discharge. Less than 100 volts of static
electricity can cause damage to some electronic
components. By comparison, it takes as much as 4,000
volts for a person to even feel the zap of a static
discharge.
There are several ways for a person to become statically
charged. The most common methods of charging are by
friction and by induction. An example of charging by
friction is a person sliding across a car seat.
Charging by induction occurs when a person with well
insulated shoes stands near a highly charged object and
momentarily touches ground. Charges of the same
polarity are drained off leaving the person highly charged
with the opposite polarity. Static charges can cause
damage, therefore, it is important to use care when
handling and testing electronic components.
NOTE: To prevent possible Electrostatic Discharge
damage, follow these guidelines:

Do not touch the control module connector pins or
soldered components on the control module circuit
board.
Do not open the replacement part package until the
part is ready to be installed.

Before removing the part from the package, ground
the package to a known good ground on the vehicle.

If the part has been handled while sliding across the
seat, or while sitting down from a standing position, or
while walking a distance, touch a known good ground
before installing the part.
NOTE: To prevent internal PCM damage, the ignition
must be in the ªOFFº position in order to disconnect or
reconnect power to the PCM (for example: battery cable,
PCM pigtail, PCM fuse, jumper cables, etc.).
IMPORTANT:When replacing the production PCM
with a service PCM, it is important to transfer the
broadcast code and production PCM number to the
service PCM label. This will allow positive identification of
PCM parts throughout the service life of the vehicle. Do
not record this information on the metal PCM cover.
IMPORTANT:The ignition should always be in the
ªOFFº position in order to install or remove the PCM
connectors.
Service of the PCM should normally consist of either re-
placement of the PCM or EEPROM programming. If the
diagnostic procedures call for the PCM to be replaced,
the PCM should be checked first to ensure it is the correct
part. If it is, remove the faulty PCM and install the new
service PCM.
The service PCM EEPROM will not be programmed.
DTC P0601 indicates the check sum error.
Removal Procedure
1. Disconnect the negative battery cable.
2. Block the wheels.
3. Remove the two screws from the PCM electrical
connectors.
4. Disconnect the PCM electrical connectors.
060RY00065

6E±546
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
5. After removing the clip which fixes the PCM to the
bracket, remove PCM.
060RY00067
Installation Procedure
1. Install the PCM to bracket and fix with the clip.
060RY00066
2. Connect the PCM electrical connectors.
3. Install the two screws to PCM electrical connectors.
060RY00065

6E±547
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
EEPROM
General Description
The Electronically Erasable Programmable Read Only
Memory (EEPROM) is a permanent memory that is
physically soldered within the PCM. The EEPROM
contains program and calibration information that the
PCM needs to control powertrain operation.
EEPROM Programming
1. Set-up ± Ensure that the following conditions have
been met:

The battery is fully charged.

The ignition is ªON.º

The Vehicle Interface Module cable connection at
the DLC is secure.
2. Program the PCM using the latest software matching
the vehicle. Refer to up-to-date Techline equipment
user's instructions.
3. If the PCM fails to program, proceed as follows:

Ensure that all PCM connections are OK.

Check the Techline equipment for the latest
software version.

Attempt to program the PCM. If the PCM still
cannot be programmed properly, replace the PCM.
The replacement PCM must be programmed.
Functional Check
1. Perform the On-Board Diagnostic System Check.
2. Start the engine and run for one minute.
3. Scan for DTCs using the Tech 2.
Throttle Position (TP) Sensor
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the TPS electrical connector.3. Remove the bolts and the TP sensor from the throttle
body.
060RY00159
NOTE: Do not clean the TP sensor by soaking it in
solvent. The sensor will be damaged as a result.
Function Check
Use a Tech 2 to check the TP sensor output voltage at
closed throttle.

The voltage should be TP1 about 0.4V, TP2 about
4.6V and TP3 about 4.6V.

If the reading is abnormal value, check the throttle
shaft to see if it is binding.
Installation Procedure
1. Install the TP sensor on the throttle body with the
bolts.
060RY00159
2. Connect the TP electrical connector.
3. Install the negative battery cable.

6E±548
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Vehicle Speed Sensor (VSS)
Removal Procedure
CAUTION: The VSS is located on the right side of
the transfer case just ahead of the rear propeller
shaft and very close to the exhaust pipes for 4WD
and on the extension cover for 2WD. Be sure that the
exhaust pipes are cool enough to touch before trying
to remove the VSS. If the pipes are hot, you could be
burned.
1. Disconnect the negative battery cable.
2. Disconnect the VSS electrical connector.
TS23748
3. Remove the bolt and the clamp securing the VSS in
place.
IMPORTANT:Have a container ready to catch any fluid
that leaks out when the VSS is removed from the transfer
case for 4WD and on the extension cover for 2WD.
TS23780
4. Remove the VSS from the transfer case by wiggling it
slightly and pulling it straight out.
Inspection Procedure
1. Inspect the electrical connector for signs of corrosion
or warping. Replace the VSS if the electrical
connector is corroded or warped.
2. Inspect the VSS driven gear for chips, breaks, or worn
condition. Replace the VSS if the driven gear is
chipped, broken or worn.
3. Inspect the O-ring for wear, nicks, tears, or
looseness. Replace the O-ring if necessary.
Installation Procedure
1. Install the VSS in the transfer case with the notch for
the connector facing the rear.
2. Secure the VSS in place with the clamp and the bolt.
Tighten

Tighten the bolt to 16 N´m (12 lb ft.).
TS23780
3. Connect the VSS electrical connector.
TS23748
4. Check the transfer case oil level. Add fluid if
necessary.
5. Connect the negative battery cable.

6E±549
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Air Cleaner/Air Filter
Removal Procedure
1. Loosen the clamp between the air cleaner lid and the
mass air flow sensor.
025RY00001
2. Release the four latches securing the lid to the air
cleaner housing.
3. Remove the air cleaner lid.
4. Remove the air filter element.
5. Remove the retaining bolts and the air cleaner
housing from the vehicle.
025RY00002
Legend
(1) Air Cleaner Housing
(2) Air Filter Element
(3) Air Cleaner Lid
Installation Procedure
1. Install the air cleaner housing in the vehicle with the
retaining bolts.
2. Install the air filter element in the air cleaner housing.
3. Install the air cleaner lid on the MAF sensor and the air
cleaner housing.
025RY00003
Legend
(1) Air Cleaner Housing
(2) Air Filter Element
(3) Air Cleaner Lid
(4) Mass Air Flow Sensor
4. Tighten the clamp and secure the four latches
between the lid and the air cleaner housing.
Common Chamber
Removal and Installation Procedure
Refer to Common Chamber in Engine Mechanical
section.

6E±550
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Accelerator Pedal Replacement
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical harness from the
accelerator position sensor.
101RY00006
Legend
(1) Accelerator Position Sensor
(2) Accelerator Pedal Assembly
3. Remove the two screws from the accelerator pedal
assembly.
101RY00007
4. Remove the accelerator pedal assembly from the
bulkhead.
Installation Procedure
1. Install the accelerator pedal assembly on the
bulkhead.
2. Install the two screws to the accelerator pedal
assembly.
Tighten

Tighten the screws to 22 N´m (16 lb ft.).
101RY00007
3. Connect the electrical harness to the accelerator
position sensor.
101RY00006
Legend
(1) Accelerator Position Sensor
(2) Accelerator Pedal Assembly
4. Install the negative battery cable.

6E±551
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Accelerator Position Sensor
Replacement
CAUTION: R e m o v e t h e Accelerator (A) pedal
assembly as a unit to have it serviced. Do not remove
the Accelerator Position (AP) sensor on the A pedal.
If the AP sensor is removed for emergency cause,
refer to following items as necessary.
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical harness from the AP sensor.
101RY00006
Legend
(1) AP Sensor
(2) A Pedal Assembly
3. Remove the AP sensor.
101RY00009
Legend
(1) AP Sensor
(2) AP Screw
Installation Procedure
1. Install the accelerator position (AP) sensor to bolts
with accelerator (A) pedal.
2. Connect the connector to AP sensor.
3. Install the negative battery cable.
Accelerator Position Sensor
Adjustment
AP sensor is controled three maltiple control system, and
adjust the idle position and WOT position are between A
and B for AP sensor 1, AP sensor 2, and AP sensor 3.
Refer to
ªHow to adjust for AP sensorº.
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical harness from the AP sensor.
How To Adjust For AP Sensor
1. Connect the Tech 2 to DLC on vehicle.
2. Ignition ªON,º engine ªOFF.º.
3. Display the APS date list. Check the following item for
AP position (%).
AP position (%)
Idle position AWOT position B
APS113%87 + 2%
APS287 + 2%13 + 2%
APS387 + 1%34 + 2%
060RY00305

6E±552
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
4. If the problem was found, adjust as necessary.
101RY00011
Fuel Filler Cap
General Description
The fuel filler cap includes a vacuum valve and a pressure
valve.
If high vacuum or high pressure occurs in the fuel tank,
each valve works to adjust the pressure in order to
prevent damage to the tank.
TS23767
Inspection Procedure
NOTE: Replace the fuel filler cap with the same type of
filler cap that was originally installed on the vehicle.

Check the seal ring in the filler cap for any abnormality
and for seal condition.

Replace the filler cap if any abnormality is found.
Fuel Filter
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the fuel filler cap.
041RY00001
3. Disconnect the fuel hose from the fuel filter on the
engine side.
4. Disconnect the fuel hose from the fuel filter on the fuel
tank side.
5. Remove the bolt on the fuel filter holder.
041RW003
Legend
(1) Fuel Hose
(2) Fuel Filter Fixing Bolt
(3) Fuel Filter
6. Remove the fuel filter.

6E±553
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Inspection Procedure
1. Replace the fuel filter when the following occur:

Fuel leaks from the fuel filter body.

The fuel filter body is damaged.

The fuel filter is clogged with dirt or sediment.
2. If the drain hole is clogged, clean the drain.
041RY00002
Installation Procedure
1. Install the fuel filter in the correct direction.
2. Install the bolt on the fuel filter holder.
Tighten

Tighten the screws to 20 N´m (14 lb ft.).
3. Connect the fuel hose on the engine side.
4. Connect the fuel hose on the fuel tank side.
041RW003
Legend
(1) Fuel Hose
(2) Fuel Filter Fixing Bolt
(3) Fuel Filter
5. Install the fuel filler cap.
041RY00001
6. Connect the negative battery cable.
Fuel Gauge Unit
Removal Procedure
Refer to Fuel Gauge Unit Engine Fuel section.
014RW133