ISUZU AXIOM 2002 Service Repair Manual

6F±2ENGINE EXHAUST (6VE1 3.5L)
General Description
150RW023
When inspecting or replacing exhaust system
components, make sure there is adequate clearance
from all points on the underbody to prevent overheating
the floor pan and possible damage to the passenger
compartment insulation and trim materials.
Check complete exhaust system and nearby body areas
and rear compartment lid for broken, damaged, missing
or mispositioned parts, open seams, holes, loose
connections or other deterioration which could permit
exhaust fumes to seep into the rear compartment or
passenger compartment. Dust or water in the rear
compartment may be an indication of a problem in one of
these areas. Any faulty areas should be corrected
immediately.
Hangers
Various types of hangers are used to support exhaust
system(s). These include conventional rubber straps,
rubber rings, and rubber blocks.
The installation of exhaust system supports is very
important, as improperly installed supports can cause
annoying vibrations which can be difficult to diagnose.
Three Way Catalytic Converter
The three way catalytic converter is an emission control
device added to the exhaust system to reduce pollutants
from the exhaust gas stream.
CAUTION: The catalytic converter requires the use
of unleaded fuel only.
Periodic maintenance of the exhaust system is not
required. If the vehicle is raised for other service, it is
advisable to check the condition of the complete exhaust
system.
A dual bed monolith catalytic converter is used in
combination with three way catalytic converter.
Catalytic Converter Types:
Three way (Reduction/Oxidation) catalyst
The catalyst coating on the three way (reduction)
converter contains platinum and rhodium which lowers
the levels of nitrous oxide (NOx) as well as hydrocarbons
(HC) and carbon monoxide (Co).
Gasket
The gasket must be replaced whenever a new exhaust
pipe, muffler or catalytic converter is installed.

6F±3
ENGINE EXHAUST (6VE1 3.5L)
Three Way Catalytic Converter RH and Forked Exhaust Pipe
Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated
Parts
150RY00003
Legend
(1) Front Exhaust Pipe Assembly Fixing Nuts
(2) O
2 Sensor Terminal Connector
(3) Three Way Catalytic Converter RH
(4) Mounting Rubber
(5) Forked Exhaust Pipe Fixing Bolts(6) O
2 Sensor Terminal Connector
(7) Forked Exhaust Pipe
(8) Forked Exhaust Pipe Fixing Nuts
(9) Exhaust Silencer Fixing Nuts
(10) Forked Exhaust Pipe Fixing Bolts
Removal
1. Disconnect battery ground cable.
2. Lift up the vehicle and support with suitable safety
stands.
3. Disconnect O
2 sensor harness connectors (2) (6).
4. Remove the forked exhaust pipe fixing bolts and nuts
(5) (8) (10) and the exhaust silencer fixing nuts (9),
then remove the forked exhaust pipe (7) and the
mass damper.
5. Remove the front exhaust pipe assembly fixing nuts
(1) and the mounting rubber (4), then remove the
three way catalytic converter (3).
Installation
1. Install the three way catalytic converter (3) and the
mounting rubber (4), and tighten the fixing nuts (1) to
the specified torque.
Torque
Nuts : 67 N´m (49 lb ft)
2. Install the forked exhaust pipe (7), and tighten the
fixing bolts (5) & nuts (8) (9) to the specified torque.
Torque
Bolts&Nuts : 43 N´m (32 lb ft)
Nuts : 43 N´m (32 lb ft)
3. Connect the O
2 sensor connectors (2) (6).

6F±4ENGINE EXHAUST (6VE1 3.5L)
Three Way Catalytic Converter LH and Forked Exhaust Pipe
Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated
Parts
150RY00004
Legend
(1) Forked Exhaust Pipe Fixing Bolts
(2) Forked Exhaust Pipe
(3) Forked Exhaust Pipe Fixing Nuts
(4) Exhaust Silencer Fixing Nuts
(5) Forked Exhaust Pipe Fixing Bolts(6) Mounting Rubber
(7) O
2 Sensor Terminal Connector
(8) Three Way Catalytic Converter LH
(9) O
2 Sensor Terminal Connector
(10) Front Exhaust Pipe Assembly Fixing Nuts
Removal
1. Disconnect battery ground cable.
2. Lift up the vehicle and support with suitable safety
stands.
3. Disconnect O
2 sensor harness connectors (7) (9).
4. Remove the forked exhaust pipe fixing bolts and nuts
(1) (3) (5) and the exhaust silencer fixing nuts (4), then
remove the forked exhaust pipe (2).
5. Remove the front exhaust pipe assembly fixing nuts
(10) and the mounting rubber (6), then remove the
three way catalytic converter (8).
Installation
1. Install the three way catalytic converter (8) and the
mounting rubber (6), and tighten the fixing nuts (10) to
the specific torque.
Torque
Nuts: 67 N´m (49 lb ft)
2. Install the forked exhaust pipe (2) and tighten the
fixing bolts (1) (5) and nuts (3) (4) to the specified
torque.
Torque
Bolts&Nuts: 43 N´m (32 lb ft)
Nuts: 43 N´m (32 lb ft)
3. Connect the O
2 sensor connectors (7) (9).

6F±5
ENGINE EXHAUST (6VE1 3.5L)
Forked Exhaust Pipe
Forked Exhaust Pipe and Associated Parts
150RY00005
Legend
(1) Forked Exhaust Pipe Fixing Bolts
(2) Forked Exhaust Pipe(3) Forked Exhaust Pipe Fixing Nuts
(4) Exhaust Silencer Fixing Nuts
(5) Forked Exhaust Pipe Fixing Bolts
Removal
1. Disconnect battery ground cable.
2. Lift up the vehicle and support with suitable safety
stands.
3. Remove the forked exhaust pipe fixing bolts & nuts
(1) (3) (5) and the exhaust silencer fixing nuts (4), then
remove the forked exhaust pipe (2).
Installation
1. Install the forked exhaust pipe (2), and tighten the
fixing bolts (1) (5) and the nuts (3) (4) to the specified
torque.
Torque
Bolts&nuts : 43 N´m (32 lb ft)
Nuts : 43 N´m (32 lb ft)

6F±6ENGINE EXHAUST (6VE1 3.5L)
Exhaust Silencer
Exhaust Silencer and Associated Parts
150RY00006
Legend
(1) Forked Exhaust Pipe
(2) Support Rubber Fixing Nuts(3) Exhaust Silencer
(4) Exhaust Silencer Fixing Nuts
(5) Rear Exhaust Pipe Fixing Nuts
Removal
1. Disconnect battery ground cable.
2. Lift up the vehicle and support with suitable safety
stands.
3. Remove the support rubber fixing nuts (2), the
exhaust silencer fixing nuts (4) and rear exhaust pipe
fixing nuts (5), then remove the exhaust silencer (3).
Installation
1. Install the exhaust silencer (3) and tighten the fixing
nuts (4) (5) to the specified torque.
Torque
Nuts: 43 N´m (32 lb ft)
2. Tighten the support rubber fixing nuts (2) to the
specified torque.
Torque
Bolts: 15 N´m (11 lb ft)

6F±7
ENGINE EXHAUST (6VE1 3.5L)
Rear Exhaust pipe
Rear Exhaust pipe and Associated
Parts
150RW028
Legend
(1) Mounting Rubber
(2) Rear Exhaust Pipe Fixing Nuts
(3) Mounting Rubber
(4) Rear Exhaust Pipe
Removal
1. Disconnect battery ground cable.
2. Lift up the vehicle and support with suitable safety
stands.
3. Remove the rear exhaust fixing nuts (2) and the
mounting rubbers (1) (3), then remove the rear
exhaust pipe (4).
Installation
1. Install the rear exhaust pipe (4) and the mounting
rubbers (1) (3), then tighten the fixing nuts (2) to the
specified torque.
Torque
Nuts: 43 N´m (32 lb ft)

6F±8ENGINE EXHAUST (6VE1 3.5L)
Main Data and Specifications
Torque Specifications
150RY00007

6G±1
ENGINE LUBRICATION (6VE1 3.5L)
AXIOM
ENGINE
ENGINE LUBRICATION (6VE1 3.5L)
CONTENTS
Service Precaution 6G±1. . . . . . . . . . . . . . . . . . . . . .
General Description 6G±2. . . . . . . . . . . . . . . . . . . . .
Oil Pump 6G±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump and Associated Parts 6G±3. . . . . . . . . .
Disassembly 6G±4. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6G±4. . . . . . . . . . . . . . . . . .
Reassembly 6G±5. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan and Crankcase 6G±7. . . . . . . . . . . . . . . . . .
Removal 6G±7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6G±7. . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump 6G±9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6G±9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6G±9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Oil Seal 6G±11. . . . . . . . . . . . . . . . . . . . . . .
Removal 6G±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6G±11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter 6G±12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6G±12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6G±12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specification 6G±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.

6G±2
ENGINE LUBRICATION (6VE1 3.5L)
General Description
C06RW003
Legend
(1) Oil Strainer
(2) Oil Pump
(3) Relief Valve
(4) Oil Pressure Switch
(5) Oil Filter
(6) Safety Valve
(7) Oil Gallery
(8) Crankshaft Bearing
(9) Crankshaft(10) Connecting Rod Bearing
(11) Connecting Rod
(12) Piston
(13) Oil Gallery; Cylinder Head
(14) Camshaft
(15) Camshaft Journal
(16) Front Journal; Camshaft Drive Gear
(17) Rear Journal; Camshaft Drive Gear
(18) Oil Pan

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