torque ISUZU AXIOM 2002 Service Repair Manual

6D2±1
IGNITION SYSTEM (6VE1 3.5L)
AXIOM
ENGINE
IGNITION SYSTEM (6VE1 3.5L)
CONTENTS
Service Precaution 6D2±1. . . . . . . . . . . . . . . . . . . . . .
General Description 6D2±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 6D2±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Coil 6D2±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6D2±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D2±3. . . . . . . . . . . . . . . . . .
Installation 6D2±3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug 6D2±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 6D2±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D2±5. . . . . . . . . . . . . . . . . .
Installation 6D2±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Position Sensor 6D2±6. . . . . . . . . . . . . . .
Removal 6D2±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6D2±6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D2±7. . . . . . . . . . . . .
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

6D2±3
IGNITION SYSTEM (6VE1 3.5L)
Ignition Coil
Removal
1. Disconnect battery ground cable.
2. Ignition coil connector and ignition coil.

Disconnect three connector from ignition coil.

Remove harness bracket bolt on cylinder head
cover.

Remove fixing bolts on ignition coil.
060RY023
Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assembly
Inspection and Repair
Check the ignition coil assembly for insulation. Check
terminals for corrosion or damage, and replace as
necessary.
Measuring resistance of ignition coil assembly.
Terminal No.
Limit
1 to 2Without 0 ohm or infinity
maximum ohm.
1 to 3Same as above
2 to 3Same as above
Measure resistance of ignition coil assembly, and replace
the ignition coil assembly if its value exceeds the
standard.
060RW006
Installation
1. Install the ignition coil assembly (3).
Connect ignition coil connector (1) and ignition coil
(3), then tighten bolt (2) to the specified torque.
Torque: 4 N´m (35 lb in)
060RY023

6D2±5
IGNITION SYSTEM (6VE1 3.5L)
Spark Plug
Removal
1. Remove spark plugs.
Inspection and Repair
The spark plug affects entire engine performance and
therefore its inspection is very important.

Check electrode and insulator for presence of cracks,
and replace if any.

Check electrode for wear, and replace if necessary.

Check gasket for damage, and replace if necessary.

Measure insulation resistance with an ohmmeter, and
replace if faulty.

Adjust spark plug gap to 1.0 mm ± 1.1 mm (0.0394 in ±
0.0433 in).
011RS011
NOTE:
± Do not adjust the spark plugs gap without new
spark plugs.
± Do not damage to tip of spark plugs.
± Do not cleaning the spark plugs. If require the
cleaning it due to heavy dirt, it is allowed only 20
seconds to be used spark plug cleaner.

Check fuel and electrical systems if spark plug is
extremely dirty.

Use spark plugs having low heat value (hot type plug)
if fuel and electrical systems are normal.

Use spark plugs having high heat value (cold type
plug) if insulator and electrode are extremely burned.
Sooty Spark Plugs
Much deposit of carbon or oil on the electrode and
insulator of spark plug reduces the engine performance.
Possible causes:

Too rich mixture

Presence of oil in combustion chamber

Incorrectly adjusted spark plug gap
Burning Electrodes
This fault is characterized by scorched or heavily oxidized
electrode or blistered insulator nose.
Possible causes:

Too lean mixture

Improper heat value
Measuring Insulation Resistance

Measure insulation resistance using a 500 volt
megaohm meter.

Replace spark plugs if measured value is out of
standard.
Insulation resistance: 50 M
or more
011RS010
Installation
1. Spark plugs

Tighten spark plugs to the specified torque.
Torque: 18 N´m (13 lb ft)

6D2±6
IGNITION SYSTEM (6VE1 3.5L)
Crankshaft Position Sensor
Removal
1. Disconnect battery ground cable
2. Wiring connector from crankshaft position sensor.
3. Remove crankshaft position sensor from cylinder
block.
012RS008
Installation
1. Install crankshaft position sensor into the cylinder
block.
Before installation,apply small amount of engine oil to
the O±ring.
Torque: 10 N´m (87 lb in)
2. Reconnect wiring connector to crankshaft position
sensor.

6D2±7
IGNITION SYSTEM (6VE1 3.5L)
Main Data and Specifications
General Specifications
Ignition System
Ignition FormElectronic Ignition System (El system) with Crankshaft position Sensor
Spark Plug
TypeK16PR±P11
RC10PYP4
PK16PR11
Plug gap1.0 mm ± 1.1 mm (0.0394 in ± 0.0433 in)
Torque18 N´m (13lb ft)
Torque Specifications
E06R100003

6D3±1
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
AXIOM
ENGINE
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
CONTENTS
Service Precaution 6D3±1. . . . . . . . . . . . . . . . . . . . . .
Starting System 6D3±2. . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6D3±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 6D3±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter 6D3±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6D3±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6D3±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 6D3±7. . . . . . . . . . . . . . . . . . . .
Disassembly 6D3±8. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D3±10. . . . . . . . . . . . . . . . . .
Reassembly 6D3±13. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D3±14. . . . . . . . . . .
Charging System 6D3±17. . . . . . . . . . . . . . . . . . . . . . . . General Description 6D3±17. . . . . . . . . . . . . . . . . . . .
General On±Vehicle Inspection 6D3±17. . . . . . . . . . .
Generator 6D3±18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6D3±18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6D3±18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6D3±19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 6D3±19. . . . . . . . . . . . . . . . . . . .
Disassembly 6D3±20. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D3±21. . . . . . . . . . . . . . . . . .
Reassembly 6D3±23. . . . . . . . . . . . . . . . . . . . . . . . . .
Bench Test 6D3±24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D3±25. . . . . . . . . . . . .
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

6D3±5
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Starter
Removal
1. Battery ground cable.
2. Disconnect Heated O
2 Sensor connector (1).
3. Remove exhaust front left pipe(2).
150R100011
4. Disconnect starter wiring connector from terminals
ª30º (1) and ª50º (2).
5. Remove starter assembly mounting bolts on inside
and outside(3).
6. Remove starter assembly (4) toward the bottom of
engine.
065RY00050
Legend
(1) Terminal ª30º
(2) Terminal ª50º
(3) Fixing Bolts
(4) Starter Assembly
Installation
1. Install starter assembly(4).
2. Install mounting bolts and tighten bolts to specified
torque(3).
Torque: 40 N´m (30 lb ft)
3. Reconnect the connectors to terminals ª50º (2)
tighten terminals ª30º (1) to specified torque.
Torque: 9 N´m (78 lb in)
065RY00050
Legend
(1) Terminal ª30º
(2) Terminal ª50º
(3) Fixing Bolts
(4) Starter Assembly
4. Install exhaust front left pipe (2) and tighten bolts and
nuts to specified torque.
Stud Nuts
Torque: 67 N´m (49 lb ft)
Bolts
Torque: 43 N´m (32 lb ft)

6D3±14
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Main Data and Specifications
General Specifications
ModelSpecification
Rating
Voltage12 V
Output1.4 Kw
Time30 sec
Number of teeth of pinion 9
Rotating direction(as viewed from pinion)Clockwise
Weight(approx.)37 N
No±load characteristics
Condition: Voltage 11.5V
Current 90A or less
Speed 3000rpm or more
Load characteristics
Condition: Voltage/Torque 8.5V/13.2 N´m (113 lb in)
Current Maximum 350A
Speed 1000rpm or more
Locking characteristics
Condition: Voltage 2.4V
Current Maximum 500A
Torque11.8N´m or more

6D3±15
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Torque Specifications
065R100013

6D3±19
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Installation
1. Install generator assembly to the position.
2. Install generator assembly and tighten the fixing bolts
to the specified torque.
Torque:
M10 bolt: 41 N´m (30 Ib ft)
M8 bolt: 21 N´m (15 Ib ft)
3. Connect wiring harness connector and direct terminal
ªBº.4. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
5. Reconnect battery ground cable.
Disassembled View
066RW022
Legend
(1) Pulley Nut
(2) Pulley
(3) Front Cover Assembly
(4) Rotor Assembly
(5) Stator Assembly
(6) Through Bolt(7) Nut
(8) Terminal Insulator
(9) Rear Cover Assembly
(10) Rectifier
(11) Brush Holder Assembly
(12) Regulator Assembly