engine ISUZU AXIOM 2002 Service Repair Manual

6G±3
ENGINE LUBRICATION (6VE1 3.5L)
Oil Pump
Oil Pump and Associated Parts
051RW005
Legend
(1) Crankshaft Timing Pulley
(2) Crankcase with Oil Pan
(3) Oil Pipe
(4) Oil Strainer
(5) Oil Pump Assembly
(6) Plug
(7) Spring(8) Relief Valve
(9) Oil Pump Cover
(10) Driven Gear
(11) Drive Gear
(12) Oil Seal
(13) O-ring
(14) Oil Pump Body

6G±4
ENGINE LUBRICATION (6VE1 3.5L)
Disassembly
1. Remove crankshaft timing pulley.
2. Remove crankcase with oil pan.
3. Remove oil pipe.
4. Remove oil strainer.
5. Remove oil pump assembly.
6. Remove plug.
7. Remove spring.
8. Remove relief valve.
9. Remove oil pump cover.
10. Remove driven gear.
11. Remove drive gear.
12. Remove oil seal.
13. Remove O-ring.
Inspection and Repair
CAUTION: M a k e necessary correction or parts
replacement if wear, damage or any other abnormal
conditions are found during inspection.
Relief Valve

Check to see that the relief valve slides freely.

The oil pump must be replaced if the relief valve does
not slide freely.

Replace the spring and/or the oil pump assembly (5) if
the spring is damaged or badly worn.
051RS002
Body and Gears
The pump assembly must be replaced if one or more of
the conditions below is discovered during inspection.

Badly worn or damaged driven gear (10).

Badly worn drive gear (11) driving face.

Badly scratched or scored body sliding face (14) or
driven gear (10).

Badly worn or damaged gear teeth.
Measure the clearance between the body and the driven
gear with a feeler gauge.
Standard : 0.10 mm±0.18 mm
(0.0039 in.±0.0070 in)
Limit : 0.20mm (0.0079 in)
051RS004

Measure the clearance between the drive gear and
driven gear with a feeler gauge.
Standard : 0.11 mm±0.24 mm
(0.0043 in±0.0094 in)
Limit : 0.35mm (0.0138 in)
051RS003

6G±5
ENGINE LUBRICATION (6VE1 3.5L)

Measure the side clearance with a precision straight
edge and a feeler gauge.
Clearance
Standard : 0.03 mm±0.09 mm
(0.0011 in±0.0035 in)
Limit : 0.15mm (0.0059 in)
051RS005
Oil Strainer
Check the oil strainer for cracking and scoring. If cracking
and scoring are found, the oil strainer must be replaced.
051RS006
Reassembly
1. Install drive gear (11).
2. Install driven gear (10).
3. Install oil pump cover (9) and first, loosely tighten all of
the attaching screws. Next, tighten the attaching
screws to the specified torque.
Torque : 10 N´m (87 lb in)
After installation, check that the gear rotates
smoothly.4. Install relief valve (8) and apply engine oil to the relief
valve and spring (7).
5. Install spring (7).
6. Install the plug (6).
Torque : 8 N´m (69 lb in)
051RS007
7. Install oil pump assembly (5).

Carefully remove any oil from the cylinder body and
the pump. Apply sealant (TB±1207B or equivalent)
to the pump fitting face as shown in illustration. Take
care that sealant is not applied to oil port surfaces.
The oil pump assembly must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.
CAUTION: Do not apply an excessive amount of
sealant to the contact surface. Applying too much
sealant will overflow the contact surfaces. This
could cause serious damage to the engine.

Attach oil pump assembly to cylinder body.

Tighten the oil pump fixing bolts.
Torque : 25 N´m (18 lb´ft)
051RW002

6G±6
ENGINE LUBRICATION (6VE1 3.5L)
051RW001
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin
8. Install the new oil seal (12). Apply engine oil to the oil
seal lip before installation then use J±39202 oil seal
Installer, install oil seal.
015RS001
9. Install oil strainer (4) with O-ring (13).
Torque: 25 N´m (18 lb ft)
10. Install oil pipe (3) with O-ring (13).
Torque: 25 N´m (18 lb ft)
11. Install crankcase with oil pan (2).

Remove oil on crankcase mounting surface and dry
the surface.

Apply a proper 4.5 mm (0.7 in) wide bead of sealant
(TB1207C or equivalent) to the crankcase
mounting surface. The bead must be continuous.

The crankcase must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.

Tighten fixing bolts to the specified torque.
Torque : 10 N´m (87 lb in)
013RW010
12. Install crankshaft timing pulley.

6G±7
ENGINE LUBRICATION (6VE1 3.5L)
Oil Pan and Crankcase
Removal
1. Disconnect battery ground cable.
2. Lift vehicle by supporting the frame.
3. Remove under cover.
4. Drain engine oil.
5. Remove front wheels.
6. Remove oil level dipstick from level gauge tube.
7. Remove radiator under fan shroud.
8. Remove shift on the fly from axle housing.
9. Remove suspension cross member fixing bolts, 2 pcs
each per side and remove suspension cross member.
10. Remove axle housing assembly four fixing bolts from
housing isolator side and mounting bolts from wheel
side. At this time support the axle with a garage jack
and remove axle housing assembly. (for 4y4)
11. Remove the steering unit assembly.
12. Remove starter fixing bolts.
13. Remove oil pan fixing bolts.
14. Remove oil pan, using J-37228 sealer cutter, remove
oil pan.
013RS003
15. Remove crankcase fixing bolts.
16. Remove crankcase, using J-37228 sealer cutter,
remove crankcase.
NOTE: Do not deform or damage the flange of oil pan and
crankcase.
Replace the oil pan and/or crankcase if deformed or dam-
aged.
013RS003
Installation
1. Install crankcase.
A. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
B. Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB-1207C or equivalent) to mounting
surface of crankcase.
Sealant bead must be continuous.

The crankcase must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.
013RW010

6G±8
ENGINE LUBRICATION (6VE1 3.5L)
C. Install crankcase, tighten crankcase fixing bolts to
the specified torque.
Torque : 10 N´m (87 lb in)
013RW004
2. Install oil pan
A. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
B. Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB-1207C or equivalent) to mounting
surface of oil pan.
Sealant beat must be continuous.

The crankcase must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.
013RW003
C. Install oil pan, tighten oil pan fixing bolts to the
specified torque.
Torque : 10 N´m (87 lb in)
3. Install starter and tighten fixing bolts.
Torque: 40 N´m (30 lb ft)4. Install axle housing assembly and tighten fixing bolts
to the specified torque. (for 4y4)
Axle case bolts
Torque : 82 N´m (61 lb ft)
Mounting bolts
Torque : 152 N´m (112 lb ft)
013RW005
5. Install the shift on the fly.
6. Install relay lever assembly and tighten fixing bolts.
Torque: 44 N´m (33 lb ft)
7. Install suspension cross member and tighten fixing
bolts to the specified torque.
Torque : 78 N´m (58 lb ft)
013RW007
8. Install radiator under fan shroud.
9. Install under cover.
10. Install engine oil level dipstick.
11. Fill engine oil until full level on engine oil gauge
dipstick.

6G±9
ENGINE LUBRICATION (6VE1 3.5L)
Oil Pump
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove crankcase assembly.

Refer to removal procedure for Oil Pan and
Crankcase in this manual.
4. Remove crankshaft pulley.

Refer to removal procedure for Crankshaft Pulley in
this manual.
5. Remove timing belt.

Refer to removal procedure for Timing Belt in this
manual.
6. Remove timing pulley from crankshaft.
7. Remove four fixing bolts from oil filter assembly.
8. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.
9. Remove three bolts from oil pipe and O-ring.
10. Remove eight oil pump fixing bolts, then oil pump
assembly.
11. Remove sealant from mounting surface of oil pump
assembly, cylinder block and take care not to damage
mounting surfaces of oil pump and cylinder block.
Installation
1. Install oil pump assembly

Apply sealant (TB-1207B or equivalent) to the oil
pump mounting surfaces as shown in the
illustration.

The oil pump assembly must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.
NOTE: Do not apply sealant to the oil ports.
051RW002

Use J-39202 installer when installing new oil seal.

Apply engine oil to oil seal lip.

Install oil pump assembly to the cylinder block.
NOTE: Do not damage oil seal during installation of oil
pump assembly.
015RS001

Tighten fixing bolts to the specified torque.
Torque : 25 N´m (18 lb ft)
051RW001
2. Install oil pipe with O-ring, tighten fixing bolt to the
specified torque.
Torque : 10 N´m (87 lb in)
3. Install oil strainer with O-ring, tighten fixing bolt to the
specified torque.
Torque : 25 N´m (18 lb ft)

6G±10
ENGINE LUBRICATION (6VE1 3.5L)
4. Install oil filter assembly and tighten bolts to the
specified torque.
Torque : 25 N´m (18 lb ft)
050RW001
Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter
5. Install timing pulley on crankshaft.
Install timing belt.

Refer to installation procedure for Timing Belt in this
manual.
6. Install crankshaft pulley.

Refer to install procedure for Crankshaft Pulley in
this manual.
7. Install crankcase assembly.

Refer to installation procedure for Oil Pan and
Crankcase in this manual.
8. Refill engine oil until full level on engine oil dipstick.

6G±11
ENGINE LUBRICATION (6VE1 3.5L)
Oil Pump Oil Seal
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove crankshaft pulley.

Refer to removal procedure for Crankshaft Pulley in
this manual.
4. Remove timing belt.

Refer to removal procedure for Timing Belt in this
manual.
5. Remove timing pulley from crankshaft.
6. Remove oil pump oil seal using a sealer puller.
NOTE: Take care not to damage sealing surfaces of oil
pump and crankshaft when removing oil seal.
Installation
1. Install oil pump oil seal, apply engine oil to oil seal lip,
then install oil seal using J-39202 installer.
015RS001
2. Install timing pulley to crankshaft.
3. Install timing belt.

Refer to installation procedure for Timing Belt in this
manual.
4. Install crankshaft pulley.

Refer to installation procedure for CRANKSHAFT
PULLEY in this manual.
5. Refill engine oil until full level.

6G±12
ENGINE LUBRICATION (6VE1 3.5L)
Oil Filter
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove oil filter using J-36390 filter wrench.
Installation
1. Apply a light coat of engine oil to the oil filter gasket.
2. Hand tighten the filter until the gasket contacts the
sealing face.
3. Using J±36390 filter wrench, tighten the filter an
additional 7/8 turn or by torque 22 N´m (16 lb ft).
050RW001
Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Filter
(5) To Filter
4. Fill the oil to the proper lever by following the oil level
check procedures.
5. Reconnect battery ground cable.
6. Run the engine and inspect for leaks.