engine ISUZU AXIOM 2002 Service Repair Manual

6A±47
ENGINE MECHANICAL (6VE1 3.5L)
Installation
CAUTION: W h e n assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side.
NOTE: Take care that dowel positions are different
between the manual transmission and the automatic
transmission.
If the engine is assembled in the condition that the dowels
have not been mounted in the specified positions, the
transmission may be damaged.
012RS009
1. Install engine assembly. Tighten engine mount fixing
bolts to frame to the specified torque.
Torque: 41 N´m (30 lb ft)
2. Reconnect fuel hose to fuel pipe on engine.
3. Install transmission assembly. Refer to Transmission
section in this manual.
4. Reconnect two heater hoses to engine.
5. Install flywheel dust covers.
6. Install exhaust pipe and temporally tighten two (each
bank) rear exhaust flange nuts then tighten three stud
nuts (each bank) between exhaust manifold and
exhaust pipe, finally tighten rear side nuts to the
specified torque.
Torque:
Nuts: 43 N´m (32 lb ft)
Stud nuts: 67 N´m (49 lb ft)
150R200002
Legend
(1) Exhaust Front Pipe RH
(2) O
2 Sensor
150R200003
Legend
(1) O
2 Sensor
(2) Exhaust Front Pipe LH
7. Reconnect O2 sensor connector.
8. 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.

6A±48
ENGINE MECHANICAL (6VE1 3.5L)
9. Install air conditioner compressor to engine and
tighten to the specified torque.
Torque :
M8 bolts : 22 N´m (16 lb ft)
M10 bolts : 43 N´m (32 lb ft)
10. Install power steering pump, tighten fixing bolt to the
specified torque.
Torque :
M8 bolts : 22N´m (16 lb ft)
M10 bolts : 46 N´m (34 lb ft)
11. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Drive Belt
12. Install upper fan shroud.
13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back of right
dash panel.
19. Reconnect ground cable between engine and
chassis.
20. Reconnect harness connector to transmission and
install transmission harness bracket on engine left
side.
21. Reconnect three engine harness connectors.
22. Reconnect vacuum booster hose.
23. Reconnect canister vacuum hose.24. Install air cleaner assembly.
25. Reconnect air duct.
26. Reconnect throttle position sensor harness
connector.
025RY001
Legend
(1) Throttle Position Sensor Connector
(2) Throttle Valve Assembly
27. Reconnect manifold absolute pressure sensor
harness connectors.
28. Reconnect ion sensing module connectors as shown
in the illustration.
060RY00111
Legend
(1) Green Connector
(2) Blue Connector
(3) Identification Mark (6VE1 Engine Only)
29. Install engine hood to the original position.

Refer to installation procedure for Body section in
this manual.

6A±49
ENGINE MECHANICAL (6VE1 3.5L)
Cylinder Head
Cylinder Head and Associated Parts
011RW008
Legend
(1) Spark Plug
(2) Cylinder Head Bolt
(3) Camshaft Drive Gear Pulley Fixing Bolt
(4) Camshaft Drive Gear Pulley
(5) Camshaft Bearing Cap Fixing Bolt
(6) Camshaft Bearing Cap
(7) Camshaft Exhaust(8) Camshaft Intake
(9) Retainer Fixing Bolt
(10) Retainer Assembly
(11) Tappet with Shim
(12) Split Collar
(13) Valve Spring and Spring Upper Seat
(14) Valve

6A±50
ENGINE MECHANICAL (6VE1 3.5L)
Disassembly
NOTE:

During disassembly, be sure that the valve train
components are kept together and identified so that
they can be reinstalled in their original locations.

Before removing the cylinder head from the engine
and before disassembling the valve mechanism,
perform a compression test and note the results.
1. Remove camshaft drive gear pulley fixing bolt (3),
then pulley (4).
2. Remove camshaft bearing cap fixing bolt (5),
camshaft bearing cap (6), then camshaft exhaust (7),
and intake side (8).
3. Remove tappet with shim (11).
4. Use the J±8062 valve spring compressor and
J±42898 valve spring compressor adapter to remove
the split collar (12), valve spring with upper seat (13)
and valve (14).
014RW042
5. Remove spark plug (1).
CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use surface conditioning disc on any
gasket sealing surface.
Inspection and Repair
1. Inspect cylinder head gasket and mating surfaces for
leaks, corrosion and blow±by. If the gasket has failed,
determine the cause.
± Insufficient torque on head bolts
± Improper installation
± Loose or warped cylinder head
± Missing dowel pins
± Warped case surface
2. Inspect cylinder head for cracks, especially between
valve seats and in the exhaust ports.
3. Inspect cylinder head deck for corrosion, sand
particles in head and porosity.
CAUTION:

Do not attempt to weld the cylinder head. Replace
it.

Do not reuse cylinder head bolts.
4. Inspect cylinder head deck, common chamber and
exhaust manifold mating surfaces for flatness. These
surfaces may be reconditioned by milling. If the
surfaces are ªout of flatº with ªroundº by more than
specification, the surface should be ground to within
specifications. Replace the head if it requires
machining beyond the repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362 in)
011RW019
5. Water jacket sealing plugs seating surfaces.

6A±51
ENGINE MECHANICAL (6VE1 3.5L)
Reassembly
1. Install Spark plug and tighten all the spark plugs to
specified torque.
Torque: 18 N´m (13 lb ft)
2. Tighten sub gear setting bolt.
1. Use J±42686 gear spring lever to turn sub gear to
right direction until the M5 bolt aligns with the hole
between camshaft driven gear and sub gear.
2. Tighten the M5 bolt to a suitable torque to prevent
the sub gear from moving.
014RW025
3. Install camshaft drive gear assembly and tighten
three bolts to the specified torque.
Torque: 10 N´m (87 lb in)
4. Install camshaft assembly and camshaft bearing cap,
tighten twenty bolts on one side bank to the specified
torque.
1. Apply engine oil to camshaft journal and bearing
surface of camshaft bearing cap.
2. Align timing mark on intake camshaft (one dot for
right bank, two dots for left bank) and exhaust
camshaft (one dot for right bank, two dots for left
bank) to timing mark on camshaft drive gear (one
dot).
014RW020
Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discrimination Mark
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust
014RW023
Legend
(1) Right Bank Camshaft Drive Gear
(2) Left Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin

6A±52
ENGINE MECHANICAL (6VE1 3.5L)
014RW024
Legend
(1) Right Bank
(2) Left Bank(3) Alignment Mark on Camshaft Drive Gear
(4) Alignment Mark on Camshaft
(5) Alignment Mark on Retainer
3. Tighten twenty bolts in numerical order on each
bank as shown in the illustration.
Torque: 10 N´m (87 lb in)
014RW031
5. Tighten bolt for camshaft drive gear assembly pulley
to the specified torque.
Torque: 98 N´m (72 lb ft)

6A±53
ENGINE MECHANICAL (6VE1 3.5L)
Valve Spring, Oil Controller, Valve, Valve Guide
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts
014RW039
Legend
(1) Camshaft Bearing Cap Fixing Bolts
(2) Camshaft Assembly Inlet
(3) Camshaft Assembly Exhaust
(4) Shim
(5) Tappet
(6) Split Collar(7) Spring Upper Seat
(8) Valve Spring
(9) Oil Controller
(10) Spring Lower Seat
(11) Valve Guide
(12) Valve
Disassembly
1. Remove camshaft bearing cap fixing bolts (1).
2. Remove camshaft assembly (intake).3. Remove camshaft assembly (Exhaust side).
4. Remove shim (4) and tappet (5).

6A±54
ENGINE MECHANICAL (6VE1 3.5L)
5. Use the J±8062 valve spring compressor and
J±42898 valve spring compressor adapter to remove
split collar.
014RW042
6. Remove valve spring.
7. Remove valve.
8. Remove oil controller and spring lower seat.
9. Remove the valve guide using the J±42899 valve
guide replacer.
Inspection and Repair
Valve Spring
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is evident.
1. Measure the free height of the springs. The springs
must be replaced if the free height is below the
specified limit.
Standard : 44.6 mm (1.756 in)
Limit : 43.6 mm (1.717 in)
014RS004
2. Measure the valve spring squareness with a steel
square and replace the valve springs if the measured
value exceeds the specified limit.
Limit : 2 mm (0.079 in)
014RS005
3. Using a spring tester to compress the springs to the
installed height, measure the compressed spring
tension, and replace the springs if the measured
tension is below the specified limit.
At installed height: 35.0 mm (1.38 in)
Standard: 196 N (44 lb)
Limit: Less than 181 N (41 lb)
014RS006
Valve Guide
CAUTION: Take care not to damage the valve seat
contact surface, when removing carbon adhering to
the valve head. Carefully inspect the valve stem for
scratches or abnormal wear. If these conditions are
present, the valve and the valve guide must be
replaced as a set.

6A±55
ENGINE MECHANICAL (6VE1 3.5L)
1. Measure the valve stem diameter with a micrometer.
If the valve stem diameter is less than the specified
limit, the valve and the valve guide must be replaced
as a set.
Diameter of Valve Stem
Intake
Standard : 5.977 mm±5.959 mm
(0.2353 in±0.2346 in)
Limit : 5.90 mm (0.2323 in)
Exhaust
Standard : 5.952 mm±5.970 mm
(0.2343 in±0.2350 in)
Limit : 5.90 mm (0.2323 in)
014RS007
2. Measure the inside diameter of the valve guide with a
micrometer. Subtract the measured outer diameter of
the valve stem from the measured inner diameter of
the valve guide. If the value exceeds the specified
limit, the valve and the valve guide must be replaced
as a set.
Inside Diameter of the Vale Guide
Inlet clearance
Standard : 0.023 mm±0.056 mm
(0.0009 in±0.0002 in)
Limit : 0.20 mm (0.00787 in)
Exhaust clearance
Standard : 0.030 mm±0.063 mm
(0.0012 in±0.0025 in)
Limit : 0.20 mm (0.00787 in)
Valve Guide Replacement
1. Using Valve guide replacer: J±42899, drive out the
valve guide from the combustion chamber side.
014RS008
2. Apply engine oil to the outside of the valve guide.
Using valve guide replacer J±42899, drive in a new
valve guide from the camshaft side, and check the
valve guide height.
Valve guide upper end height: 13.0 mm (0.5118
in)
(Measured from the cylinder head upper face)
014RW046
3. Check the clearance. If the clearance is less than the
specified value, ream the inside diameter of valve
guide. Using a sharp 6 mm reamer, ream the valve
guide to obtain the specified clearance.

6A±56
ENGINE MECHANICAL (6VE1 3.5L)
Valve Seat
1. Measure the protrusion of the valve stem when a new
valve is installed in the cylinder head. If the protrusion
of the valve stem exceeds the limit, replace the valve
seat insert or the cylinder head assembly.
Protrusion of valve stem
Intake
Standard: 39.32 mm (1.5480 in)
Limit: 39.47 mm (1.5539 in)
Exhaust
Standard: 39.3 mm (1.5472 in)
Limit: 39.45 mm (1.5531 in)
014RW047
2. Measure the valve seat contact width. Make the
necessary corrections if the seat contact surface is
damaged or rough or if the contact width wear
exceeds the limit.
Valve seat contact width
Standard: 1.1 mm (0.0433 in)
Limit: 1.7 mm (0.0669 in)
014RS011
Contact Surface Angle on Valve Seat on
Valve
1. Measure contact surface angle on valve seat.
2. If the measured value exceeds the limit, replace
valve, valve guide and valve seat as a set.
Valve contact surface angle: 45

014RS012
Valve Seat Insert Correction
1. Remove the carbon from the valve seat insert
surface.
2. Use a valve cutter to minimize scratches and other
rough areas. This will bring the contact width back to
the standard value. Remove only the scratches and
rough areas. Do not cut away too much. Take care not
to cut away unblemished areas of the valve seat
surface.
Valve seat angle degree: 90

014RW059