stop start ISUZU AXIOM 2002 Service Owner's Guide

5C±66
POWER±ASSISTED BRAKE SYSTEM
Diagnosis
Road Testing The Brakes
Brake Test
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake
performance cannot be made if the roadway is wet,
greasy or covered with loose dirt where all tires do not grip
the road equally. Testing will also be adversely affected if
the roadway is crowned so as to throw the weight of the
vehicle toward wheels on one side or if the roadway is so
rough that wheels tend to bounce. Test the brakes at
different vehicle speeds with both light and heavy pedal
pressure; however, avoid locking the wheels and sliding
the tires. Braking without locking the tires will stop the
vehicle in less distance than braking to a skid (which has
no brake efficiency). More tire to road friction is present
while braking without locking the tires than braking to a
skid.
The standard brake system is designed and balanced to
avoid locking the wheels except at very high deceleration
levels.
It is designed this way because the shortest stopping
distance and best control is achieved without brake
lock±up.
Because of high deceleration capability, a firmer pedal
may be felt at higher deceleration levels.
External Conditions That Affect Brake Performance
1. Tires: Tires having unequal contact and grip on the
road will cause unequal braking. Tires must be
equally inflated, identical in size, and the thread
pattern of right and left tires must be approximately
equal.
2. Vehicle Loading: A heavily loaded vehicle requires
more braking effort.
3. Wheel Alignment: Misalignment of the wheels,
particularly in regard to excessive camber and caster,
will cause the brakes to pull to one side.
Brake Fluid Leaks
With engine running at idle and the transmission in
ªNeutralº, depress the brake pedal and hold a constant
foot pressure on the pedal. If pedal gradually falls away
with the constant pressure, the hydraulic system may be
leaking.
Check the master cylinder fluid level. While a slight drop in
the reservoir level will result from normal lining wear, an
abnormally low level in reservoir indicates a leak in the
system. The hydraulic system may be leaking internally
as well as externally. Refer to
Master Cylinder Inspection.
Also, the system may appear to pass this test but still
have slight leakage. If fluid level is normal, check the
vacuum booster push rod length. If an incorrect length
push rod is found, adjust or replace the push rod. Check
the brake pedal travel and the parking brake adjustment.
When checking the fluid level, the master cylinder fluid
level may be lower than the ªMAXº mark if the front and
rear linings are worn. This is normal.
Warning Light Operation
When the ignition switch is in the START position, the
ªBRAKEº warning light should turn on and go off when the
ignition switch returns to the ON position.
The following conditions will activate the ªBRAKEº light:
1. Parking brake applied. The light should be on
whenever the parking brake is applied and the ignition
switch is on.
2. Low fluid level. A low fluid level in the master cylinder
will turn the ªBRAKEº light on.
3. During engine cranking the ªBRAKEº light should
remain on. This notifies the driver that the warning
circuit is operating properly.

5C±77 POWER±ASSISTED BRAKE SYSTEM
Brake Pedal
Checking Pedal Height
The push rod serves as the brake pedal stopper when the
pedal is fully released. Brake pedal height adjustment
should be performed as follows:
Adjust Brake Pedal
310R200002
1. Measure the brake pedal height after making sure the
pedal is fully returned by the pedal return spring.
Pedal height must be measured after starting the
engine and stepping on it several times.
Pedal Free Play: 6-10 mm (0.23-0.39 in)
Pedal Height: 173-185 mm (6.81-7.28 in)
NOTE: Pedal free play must be measured after turning
off the engine and stepping on the brake pedal firmly five
times or more.
2. If the measured value is not within the above range,
adjust the brake pedal as follows:
a. Disconnect the stoplight switch connector.
b. Loosen the stoplight switch lock nut.
c. Rotate the stoplight switch so that it moves away
from the brake pedal.
d. Loosen the lock nut (1) on the push rod.
e. Adjust the brake pedal to the specified height by
rotating the push rod in the appropriate direction.
f. Tighten the lock nut to the specified torque.
Torque: 20 N´m (15 lb ft)
g. Adjust the stoplight switch (2) to the specified
clearance (between the switch housing and the
brake pedal) by rotating the switch housing.
Clearance: 0.5±1.0 mm (0.02±0.04 in)
310RY00005
NOTE: While adjusting the stoplight switch, make sure
that the threaded part of the stoplight switch does not
push the brake pedal.
h. Tighten the stoplight switch lock nut.
i. Connect the stoplight switch connector.
Checking Pedal Travel
310R200002
1. Pedal height must be measured after starting the
engine and revving it several times to apply vacuum
to the vacuum booster fully.
NOTE: Pedal height must be 95 mm (3.7 in) or more
when about 50 kg (110.25 lb) of stepping force is applied.
2. If the measured value is lower than the above range,
air may still be present in the hydraulic system
Perform the bleeding procedure.

6A±17
ENGINE MECHANICAL (6VE1 3.5L)
Fuel Consumption Excessive
ConditionPossible causeCorrection
Trouble in fuel systemMixture too rich or too lean due to
trouble in fuel injection systemRefer to ªAbnormal Combustionº
Fuel cut function does not workRefer to ªAbnormal Combustionº
Trouble in ignition systemMisfiring or abnormal combustion
due to trouble in ignition systemRefer to ªHard Startº or ªAbnormal
Combustionº
OthersEngine idle speed too highReset Idle Air Control Valve
Fuel system leakageCorrect or replace
Clutch slippingCorrect
Brake dragCorrect
Selection of transmission gear
incorrectCaution operator of incorrect gear
selection
Excessive Exhaust Gas
Recirculation flow due to trouble in
Exhaust Gas Recirculation systemRefer to ªAbnormal Combustionº
Lubrication Problems
ConditionPossible causeCorrection
Oil pressure too lowWrong oil in useReplace with correct engine oil
Relief valve stickingReplace
Oil pump not operating properlyCorrect or replace
Oil pump strainer cloggedClean or replace strainer
Oil pump wornReplace
Oil pressure gauge defectiveCorrect or replace
Crankshaft bearing or connecting
rod bearing wornReplace
Oil contaminationWrong oil in useReplace with correct engine oil
Oil filter cloggedReplace oil filter
Cylinder head gasket damageReplace gasket
Burned gases leakingReplace piston and piston rings or
cylinder body assembly
Oil not reaching valve systemOil passage in cylinder head or
cylinder body cloggedClean or correct
Engine Oil Pressure Check
1. Check for dirt, gasoline or water in the engine oil.
a. Check the viscosity of the oil.
b. Check the viscosity of the oil.
c. Change the oil if the viscosity is outside the
specified standard.
d. Refer to the ªMaintenance and Lubricationº section
of this manual.
2. Check the engine oil level.
The level should fall somewhere between the ªADDº
and the ªFULLº marks on the oil level dipstick.
If the oil level does not reach the ªADDº mark on the
oil level dipstick, engine oil must be added.3. Remove the oil pressure unit.
4. Install an oil pressure gauge.
5. Start the engine and allow the engine to reach normal
operating temperature (About 80
C).
6. Measure the oil pressure.
Oil pressure should be:
392±550 kPa (56.9±80.4 psi) at 3000 rpm.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure unit.
10. Start the engine and check for leaks.

ENGINE COOLING (6VE1 3.5L)6B±5
Draining and Refilling Cooling
System
Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order. The
engine coolant (EC) level should be between the ªMINº
and ªMAXº lines of reserve tank when the engine is cold.
If low, check for leakage and add EC up to the ªMAXº line.
There should not be any excessive deposit of rust or
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening the
drain plug (2) at the bottom of the radiator.
110RW002
2. Remove the radiator cap.
WARNING: T O AV O I D T H E D A N G E R O F B E I N G
BURNED, DO NOT REMOVE THE CAP WHILE THE
ENGINE AND RADIATOR ARE STILL HOT.
SCALDING FLUID AND STEAM CAN BE BLOWN OUT
UNDER PRESSURE.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water, then
drain it. Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a solution
that is at least 50 percent antifreeze but no more than
70 percent antifreeze.
5. Fill the radiator to the base of the filler neck.
Fill the EC reserve tank to ªMAXº line when the engine
is cold.
6. Block the drive wheels and firmly apply the parking
brake. Shift an automatic transmission to ªPº (Park)
or a manual transmission to neutral.
7. Remove the radiator cap. Start the engine and warm
it up at 2,500 ~ 3,000 rpm for about 30 minutes.
8. When the air comes out from the radiator filler neck
and the EC level has gone down, replenish with the
EC. Repeat this procedure until the EC level does not
go down. Then stop the engine and install the radiator
cap. Let the engine cool down.9. After the engine has cooled, replenish with EC up to
the ªMAXº line of the reserve tank.
10. Start the engine. With the engine running at 3,000
rpm, make sure there is no running water sound from
the heater core (behind the center console).
11. If the running water sound is heard, repeat steps 8 to
10.

6B±10
ENGINE COOLING (6VE1 3.5L)
Cap tester: J±24460±01
Adapter: J±33984±A
110RX002
Installation
1. Install rubber cushions on both sides of radiator
bottom.
2. Install radiator assembly with hose, taking care not to
damage the radiator core with a fan blade.
3. Connect reserve tank hose (4).
4. Install lower fan guide (3).
5. Connect radiator inlet hose and outlet hose to the
engine.
6. Connect oil cooler hose (1) to automatic
transmission.
110RX001
7. Connect battery ground cable.
8. Pour engine coolant up to filler neck of radiator, and
up to MAX mark of reserve tank.
110RW012Important operation (in case of 100% engine coolant
change) procedure for filling with engine coolant.
Engine Coolant Filling Up Procedure
1. Make sure that the engine is cool.
WARNING: WHEN THE COOLANT IS HEATED TO A
HIGH TEMPERATURE, BE SURE NOT TO LOOSEN
OR REMOVE THE RADIATOR CAP. OTHERWISE YOU
MIGHT GET SCALDED BY HOT VAPOR OR BOILING
WATER. TO OPEN THE RADIATOR CAP, PUT A
PIECE OF THICK CLOTH ON THE CAP AND LOOSEN
THE CAP SLOWLY TO REDUCE THE PRESSURE
WHEN THE COOLANT HAS BECOME COOLER.
2. Open radiator cap pour coolant up to filler neck.
3. Pour coolant into reservoir tank up to ªMAXº line.
4. Tighten radiator cap and start the engine. After idling
for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
5. After replenishing with coolant tighten radiator cap,
warm up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and
let the coolant circulate also into heater water system.
6. Check to see the thermometer, continuously idle for 5
minutes and stop the engine.
7. When the engine has been cooled, check filler neck
for water level and replenish if required. Should
extreme shortage of coolant is found, check the
coolant system and reservoir tank hose for leakage.
8. Pour coolant into the reservoir tank up to ªMAXº line.

6D3±2
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Starting System
General Description
Cranking Circuit
The cranking system consists of a battery, starter, starter
switch, starter relay, etc. These main components are
connected.
Starter
The cranking system employs a magnetic type reduction
starter in which the motor shaft is also used as a pinion
shaft. When the starter switch is turned on, the contacts of
magnetic switch are closed, and the armature rotates. At
the same time, the plunger is attracted, and the pinion is
pushed forward by the shift lever to mesh with the ring
gear.
Then, the ring gear runs to start the engine. When the
engine starts and the starter switch is turned off, the
plunger returns, the pinion is disengaged from the ring
gear, and the armature stops rotation. When the engine
speed is higher than the pinion, the pinion idles, so that
the armature is not driven.

6D3±17
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Charging System
General Description
The IC integral regulator charging system and its main
components are connected as shown in illustration.
The regulator is a solid state type and it is mounted along
with the brush holder assembly inside the generator
installed on the rear end cover.
The generator does not require particular maintenance
such as voltage adjustment.The rectifier connected to the stator coil has diodes to
transform AC voltage into DC voltage.
This DC voltage is connected to the output terminal of
generator.
F06RX002
General On±Vehicle Inspection
A basic wiring diagram is shown in the illustration. When
operating normally, the indicator bulb will come on when
the switch is turned on, and will then go out when the
engine starts. If the indicator operates abnormally, or if an
undercharged or overcharged battery condition occurs,
the following procedure may be used to diagnose the
charging system. Remember that an undercharged
battery is often caused by accessories being left on
overnight, or by a defective switch which allows a bulb,
such as a trunk or glove box light, to stay on.
Observe the following procedure:
1. Visually check belt and wiring.
2. Go to step 5. for vehicles without charge indicator
light.
3. Switch on, engine stopped, light should be on. If not,
detach harness at generator, ground ªLº terminal
lead.a. Lamp lights, replace or repair generator.
b. Lamp dose not light, locate open circuit between
grounding lead and ignition switch. Bulb may be
open.
4. Switch on, engine running at moderate speed. Light
should be off. If not, detach wiring harness at
generator.
a. If light goes off, replace or repair generator.
b. If light stays on, check for grounded ªLº terminal
wire in harness.
5. Battery undercharged or overcharged.
a. Detach wiring harness connector from generator.
b. With switch on, engine not running connect
voltmeter from ground to ªLº terminal in wiring
harness, and to ªIGº terminal. If used. Wiring
harness may connect to either ªLº or ªIGº or both.
c. Zero reading indicates open circuit between
terminal and battery. Connect as required.

6D3±18
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
d. Re-connect harness connector to generator, run
engine at moderate speed, with electrical
accessories turned off.
e. Measure voltage across battery. If above 16.0V,
replace or repair generator.
f. Connect ammeter at generator output terminal.
Turn on accessories, load battery with carbon pile
to obtain maximum amperes output.
Maintain voltage at 13.0V or above.
1. If within 15 amperes of rated output, generator is
OK.2. If not within 15 amperes of rated output, replace or
repair generator.
Generator
Removal
1. Disconnect battery ground cable.
2. Move drive belt tensioner to loose side using wrench
then remove drive belt (1).
3. Disconnect the wire from terminal ªBº and disconnect
the connector (4).
4. Remove generator fixing bolt (3).
5. Remove generator assembly (2).
060RW002
Inspection
1. Disconnect the wiring connector from generator.
2. With the engine stopped, turn starter switch to ªonº
and connect a voltmeter between connector terminal
L (1) and ground or between terminal S (2) and
ground.
066RX002If there is no voltage present, then perform
appropriate repair.
3. Reconnect the wiring connector to the generator, run
the engine at must indicate idle speed, and turn off all
electrical devices other than engine.
4. Measure battery voltage. If it exceeds 16V, repair or
replace the generator.
5. Connect an ammeter to output terminal of generator,
and measure output current under load by turning on
the other electrical devices (eg., headlights). At this
time the amperes must not be less than 15A and the
voltage must not be less than 13V.

6E±37
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
The Diagnostic Executive records DTCs and turns on the
MIL when emission-related faults occur. It can also turn
off the MIL if the conditions cease which caused the DTC
to set.
Diagnostic Information
The diagnostic charts and functional checks are designed
to locate a faulty circuit or component through a process
of logical decisions. The charts are prepared with the
requirement that the vehicle functioned correctly at the
time of assembly and that there are no multiple faults
present.
There is a continuous self-diagnosis on certain control
functions. This diagnostic capability is complemented by
the diagnostic procedures contained in this manual. The
language of communicating the source of the malfunction
is a system of diagnostic trouble codes. When a
malfunction is detected by the control module, a
diagnostic trouble code is set and the Malfunction
Indicator Lamp (MIL) (ªCheck Engineº lamp) is
illuminated.
Malfunction Indicator Lamp (MIL)
The Malfunction Indicator Lamp (MIL) looks the same as
the MIL you are already familiar with (ªCheck Engineº
lamp). However, OBD II requires that it illuminate under a
strict set of guide lines.
Basically, the MIL is turned on when the PCM detects a
DTC that will impact vehicle emissions.
The MIL is under the control of the Diagnostic Executive.
The MIL will be turned on if an emissions-related
diagnostic test indicates a malfunction has occurred. It
will stay on until the system or component passes the
same test, for three consecutive trips, with no emissions
related faults.
If the vehicle is experiencing a misfire malfunction which
may cause damage to the Three-Way Catalytic
Converter (TWC), the MIL will flash once per second.
This will continue until the vehicle is outside of speed and
load conditions which could cause possible catalyst
damage, and the MIL will stop flashing and remain on
steady.
Extinguishing the MIL
When the MIL is on, the Diagnostic Executive will turn off
the MIL after
three(3) consecutive trips that a ªtest
passedº has been reported for the diagnostic test that
originally caused the MIL to illuminate.
Although the MIL has been turned off, the DTC will remain
in the PCM memory (both Freeze Frame and Failure
Records) until
forty(40) warm-up cycles after no faults
have been completed.
If the MIL was set by either a fuel trim or misfire-related
DTC, additional requirements must be met. In addition to
the requirements stated in the previous paragraph, these
requirements are as follows:

The diagnostic tests that are passed must occur
within 375 RPM of the RPM data stored at the time the
last test failed.

Plus or minus ten (10) percent of the engine load that
was stored at the time the last failed.
Similar engine temperature conditions (warmed up or
warming up ) as those stored at the time the last test
failed.
Meeting these requirements ensures that the fault which
turned on the MIL has been corrected.
The MIL (ªCheck Engineº lamp) is on the instrument
panel and has the following function:

It informs the driver that a fault affects vehicle
emission levels has occurred and that the vehicle
should be taken for service as soon as possible.

As a bulb and system check, the MIL will come ªONº
with the key ªONº and the engine not running. When
the engine is started, the MIL will turn ªOFF.º

When the MIL remains ªONº while the engine is
running, or when a malfunction is suspected due to a
driveability or emissions problem, a Powertrain
On-Board Diagnostic (OBD ll) System Check must be
performed. The procedures for these checks are
given in On-Board Diagnostic (OBD) System Check.
These checks will expose faults which may not be
detected if other diagnostics are performed first.
DTC Types
Each DTC is directly related to a diagnostic test. The
Diagnostic Management System sets DTC based on the
failure of the tests during a trip or trips. Certain tests must
fail two (2) consecutive trips before the DTC is set. The
following are the four (4) types of DTCs and the
characteristics of those codes:

Type A

Emissions related

Requests illumination of the MIL of the first trip with a
fail

Stores a History DTC on the first trip with a fail

Stores a Freeze Frame (if empty)

Stores a Fail Record

Updates the Fail Record each time the diagnostic
test fails

Type B

Emissions related

ªArmedº after one (1) trip with a fail

ªDisarmedº after one (1) trip with a pass

Requests illumination of the MIL on the
second
consecutive trip
with a fail

Stores a History DTC on the second consecutive trip
with a fail (The DTC will be armed after the first fail)

Stores a Freeze Frame on the second consecutive
trip with a fail (if empty)

Stores a Fail Record when the first test fails (not
dependent on
consecutive trip fails)

Updates the Fail Record each time the diagnostic
test fails
(Some special conditions apply to misfire and fuel trim
DTCs)

Type C (if the vehicle is so equipped)

Non-Emissions related

Requests illumination of the Service

Stores a History DTC on the
first trip with a fail

6E±72
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure
(Steps 7-11)

 
StepNo Ye s Value(s) Action
91. Connect the J 39021-5V Fuel Injector Tester and J
39021-90 Injector Switch Box the fuel injector
harness connector.
2. Set the amperage supply selector switch on the fuel
injector tester to the ªBalance Testº 0.5±2.5 amp
position.
3. Using the Tech 2 turn the fuel pump ªONº then
ªOFFº in order to pressurize the fuel system.
4. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure stabilizes.
This is the first pressure reading.
5. Energize the fuel injector by depressing the ªPush
to Start Testº button on the fuel injector tester.
6. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure gauge
needle has stopped moving. This is the second
pressure reading.
7. Repeat steps 1 through 6 for each fuel injector.
8. Subtract the second pressure reading from the first
pressure reading for one fuel injector. The result is
the pressure drop value.
9. Obtain a pressure drop value for each fuel injector.
10.Add all of the individual pressure drop values. This
is the total pressure drop.
11. Divide the total pressure drop by the number of fuel
injectors. This is the average pressure drop.
Does any fuel injector have a pressure drop value that
is either higher than the average pressure drop or lower
than the average pressure drop by the specified value?
10 kPa
(1.5 psi)
Go to Step 10
Go to OBD
System
Check
10Re-test any fuel injector that does not meet the
specification. Refer to the procedure in step 9.
NOTE: Do not repeat any portion of this test before
running the engine in order to prevent the engine from
flooding.
Does any fuel injector still have a pressure drop value
that is either higher than the average pressure drop or
lower than the average pressure drop by the specified
value?
10 kPa
(1.5 psi)
Go to Step 11
Go to
Symptoms
11Replace the faulty fuel injector(s). Refer to Fuel
Injector.
Is the action complete?ÐVerify repairÐ