ISUZU AXIOM 2002 Service Repair Manual

ENGINE COOLING (6VE1 3.5L)6B±7
Thermostat
Thermostat and Associated Parts
031RW001
Legend
(1) Thermostat Housing
(2) Thermostat
(3) Outlet Pipe
Removal
1. Disconnect battery ground cable.
2. Drain engine coolant from the radiator and engine.
3. Disconnect radiator hose from the inlet pipe.
4. Remove thermostat housing.
5. Remove thermostat(2).
Inspection
Suspend the thermostat in a water±filled container using
thin wire. Place a thermometer next to the thermostat.
Do not directly heat the thermostat.
Gradually increase the water temperature. Stir the water
so that the entire water is same temperature.
031RS003Confirm the temperature when the valve first begins to
open.
Valve opening temperature 74.5C ~ 78.5
C
(166.1
F ~ 173.3
F)
Confirm the temperature when the valve is fully opened.
Valve full open temperature and lift More than
8.5mm (0.33 in) at 90
C (194
F)
Make necessary repair and parts replacement if extreme
wear or damage is found during inspection.
Installation
1. Install thermostat into the outlet pipe(4) making sure
that the air hole is in the up position.
2. Install thermostat housing and tighten bolts to the
specified torque.
Torque: 25 N´m (18 lb ft)
3. Installation rubber hose.
4. Replenish engine coolant (EC).
5. Start engine and check for EC leakage.

6B±8
ENGINE COOLING (6VE1 3.5L)
Radiator
Radiator and Associated Parts
110RW010
Legend
(1) Oil Cooler Hose For Automatic Transmission
(2) Radiator Hose
(3) Fan Guide, Lower(4) Reserve Tank Hose
(5) Radiator Assembly
(6) Reserve Tank
Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug(2) to drain EC.
3. Disconnect oil cooler hose(1) on automatic
transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose from
the engine.
110RW002
5. Remove fan guide(1), clips(3) on both sides and the
bottom lock, then remove fan guide lower(3) with fan
shroud(4).
110RW001

ENGINE COOLING (6VE1 3.5L)6B±9
6. Disconnect the reserve tank hose(4) from radiator.
110RX001
7. Lift up and remove the radiator assembly with hose,
taking care not to damage the radiator core with a fan
blade.
8. Remove rubber cushions on both sides at the bottom.
Inspection
Radiator Cap
Measure the valve opening pressure of the pressurizing
valve with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside
the standard range.
Valve opening pressure kPa (psi) 93.3 ~ 122.7
(13.5 ~17.8)
Cap tester: J±24460±01
Adapter: J±33984±A
Check the condition of the vacuum valve in the center of
the valve seat side of the cap. If considerable rust or dirt is
found, or if the valve seat cannot be moved by hand, clean
or replace the cap.
Valve opening vacuum kPa (psi) 0 ~ 6.9 (0 ~ 1.0)
110RS006
Radiator Core
1. A bent fin may result in reduced ventilation and
overheating may occur. All bent fins must be
straightened. Pay close attention to the base of the fin
when it is being straightened.
2. Remove all dust, bugs and other foreign material.
Flushing the Radiator
Thoroughly wash the inside of the radiator and the engine
coolant passages with cold water and mild detergent.
Remove all signs of scale and rust.
Cooling System Leakage Check
Use a radiator cap tester to force air into the radiator
through the filler neck at the specified pressure of 150 kPa
(22 psi) with a cap tester:

Leakage from the radiator

Leakage from the coolant pump

Leakage from the water hoses

Check the rubber hoses for swelling.

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.

ENGINE COOLING (6VE1 3.5L)6B±11
Drive Belt and Cooling Fan
Drive Belt and Associated Parts
015RW005
Legend
(1) Crankshaft Pulley
(2) Generator
(3) Power Steering Pump(4) Water Pump and Cooling Fan Pulley
(5) Idle Pulley
(6) Tension Pulley
(7) Drive Belt
The drive belt adjustment is not required as automatic
drive belt tensioner is equipped.
Removal
Move the tension pulley drive belt loosen side, remove the
drive belt.
Inspection
Check drive belt for wear or damage, and replace with a
new one as necessary.
Installation
Install cooling fan assembly and tighten bolts/nuts to the
specified torque.
Torque : 22 N´m (16 lb ft) for fan pulley and fan
bracket.
Torque : 7.5 N´m (66.4 lb in) for fan and clutch
assembly.

6B±12
ENGINE COOLING (6VE1 3.5L)
Main Data and Specifications
General Specifications
A/T
Cooling systemEngine coolant forced circulation
RadiatorTube type corrugated (2 tube in row)
Heat radiation capacity85,500 kcal/h
Heat radiation area14.02m
(150.9ft
)
Radiator front area0.263m
(2.83ft
)
Radiator dry weight56N (12.6lb)
Radiator cap valve opening pressure93.3 ~ 122.7kpa (13.5 ~ 17.8psi)
Engine coolant capacity2.4lit (0.6 US gal)
Engine coolant pumpCentrifugal impeller type
Delivery300 (317) or more
Pump speed5000 + 50 rpm
ThermostatWax pellet type with air hole
Valve opening temperature74.5 ~ 78.5
C (166.1 ~ 173.3
F)
Engine coolant total capacity10.0lit (2.64 US gal)
Torque Specifications
E06RW004

ENGINE COOLING (6VE1 3.5L)6B±13
Special Tool
ILLUSTRATIONTOOL NO.
TOOL NAME
J±24460±01
Tester; radiator cap
J±33984±A
Adapter; radiator cap

6C±1 ENGINE FUEL (6VE1 3.5L)
AXIOM
ENGINE
ENGINE FUEL
CONTENTS
Service Precaution 6C±1. . . . . . . . . . . . . . . . . . . . . .
General Description 6C±2. . . . . . . . . . . . . . . . . . . . .
Fuel Metering 6C±3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter 6C±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6C±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6C±4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6C±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
In±Tank Fuel Filter 6C±5. . . . . . . . . . . . . . . . . . . . .
Fuel Pump Flow Test 6C±5. . . . . . . . . . . . . . . . . . .
Fuel Pump 6C±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump and Associated Parts 6C±6. . . . . . . .
Removal 6C±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C±7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tube / Quick ± Connector Fittings 6C±8. . . . .
Precautions 6C±8. . . . . . . . . . . . . . . . . . . . . . . . . . .
Cautions During Work 6C±8. . . . . . . . . . . . . . . . . . Removal 6C±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reuse of Quick±Connector 6C±9. . . . . . . . . . . . .
Assembling Advice 6C±9. . . . . . . . . . . . . . . . . . . .
Fuel Pump Relay 6C±10. . . . . . . . . . . . . . . . . . . . . . . .
General Description 6C±10. . . . . . . . . . . . . . . . . . . .
Fuel Tank 6C±10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank and Associated Parts 6C±10. . . . . . . . .
Removal 6C±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C±11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge Unit 6C±12. . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation 6C±12. . . . . . . . . . . . . . .
Fuel Filler Cap 6C±12. . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6C±12. . . . . . . . . . . . . . . . . . . .
Inspection 6C±12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6C±13. . . . . . . . . . . . .
Special Tool 6C±13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

6C±2
ENGINE FUEL (6VE1 3.5L)
General Description
140R200004
Legend
(1) Fuel Filler Cap
(2) Fuel Tank
(3) Rollover Valve
(4) Fuel Pump and Sender Assembly
(5) Fuel Filter
(6) Fuel Rail Right
(7) Right Bank
(8) Fuel Rail Left
(9) Left Bank(10) Fuel Pressure Control Valve
(11) Common Chamber
(12) Duty Solenoid Valve
(13) Throttle Valve
(14) Canister
(15) Vent Hose
(16) Vent Solenoid Valve
(17) Separator
(18) Shut off Valve (With Over Pressure Relief
Valve)

6C±3 ENGINE FUEL (6VE1 3.5L)
When working on the fuel system, there are several
things to keep in mind:

Any time the fuel system is being worked on,
disconnect the battery ground cable except for those
tests where battery voltage is required.

Always keep a dry chemical (Class B) fire
extinguisher near the work area.

Replace all pipes with the same pipe and fittings that
were removed.

Clean and inspect ªOº rings. Replace if required.

Always relieve the line pressure before servicing any
fuel system components.

Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.

Adhere to all Notices and Cautions.
All gasoline engines are designed to use only unleaded
gasoline. Unleaded gasoline must be used for proper
emission control system operation.
Its use will also minimize spark plug fouling and extend
engine oil life. Using leaded gasoline can damage the
emission control system and could result in loss of
emission warranty coverage.
The vapor pressure sensor and vent solenoid valve for
vapor pressure sensor are used to detect abnormalities in
the evaporative emission control system.
The PCM decides whether there is an abnormality in the
evaporative emission control system based on vapor
pressure sensor signal.Fuel Metering
The Powertrain Control Module (PCM) is in complete
control of this fuel delivery system during normal driving
conditions.
The intake manifold function, like that of a diesel, is used
only to let air into the engine. The fuel is injected by
separate injectors that are mounted over the intake
manifold.
The Manifold Absolute Pressure (MAP) sensor measures
the changes in the intake manifold pressure which result
from engine load and speed changes, which the MAP
sensor converts to a voltage output.
This sensor generates the voltage to change
corresponding to the flow of the air drawn into the engine.
The changing voltage is transformed into an electric
signal and provided to the PCM.
With receipt of the signals sent from the MAP sensor,
Intake Air Temperature sensor and others, the PCM
determines an appropriate fuel injection pulse width
feeding such information to the fuel injector valves to
affect an appropriate air/fuel ratio.
The Multiport Fuel Injection system utilizes an injection
system where the injectors turn on at every crankshaft
revolution. The PCM controls the injector on time so that
the correct amount of fuel is metered depending on
driving conditions.
Two interchangeable ªOº rings are used on the injector
that must be replaced when the injectors are removed.
The fuel rail is attached to the top of the intake manifold
and supplies fuel to all the injectors.
Fuel is recirculated through the rail continually while the
engine is running. This removes air and vapors from the
fuel as well as keeping the fuel cool during hot weather
operation.
The fuel pressure control valve that is mounted on the fuel
rail maintains a pressure differential across the injectors
under all operating conditions. It is accomplished by
controlling the amount of fuel that is recirculated back to
the fuel tank based on engine demand.
See Section ªDriveability and Emissionº for more
information and diagnosis.