engine ISUZU AXIOM 2002 Service Repair Manual

6A±57
ENGINE MECHANICAL (6VE1 3.5L)
3. Apply abrasive compound to the valve seat insert
surface.
4. Insert the valve into the valve guide.
5. Turn the valve while lapping it to fit the valve seat
insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact
with the entire circumference of the valve.
014RS014
Valve Seat Insert Replacement
1. Arc weld the rod at several points. Be careful not to
damage the aluminum section.
2. Allow the rod to cool for a few minutes. This will cause
the valve seat to shrink.
3. Strike the rod and pull it out.
014RS015
4. Carefully clean the valve seat press±fit section on the
cylinder head side.
5. Heat the press±fit section with steam or some other
means to cause expansion. Cool the valve seat with
dry ice or some other means.
6. Insert the press±fit section into the valve seat
horizontally.
Standard fitting interference: 0.14 mm±0.09 mm
(0.0055 in±0.0035 in)
7. After insertion, use a seat grinder to grind finish the
seating face. Carefully note the seating angle, the
contact width, and the depression.
8. Lap the valve and the seat.
Reassembly
1. Install valve guide (1) to cylinder head. 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.
2. Install oil controller (3) and spring lower seat (2).
Using oil controller replacer J±37281, drive in a new
oil controller.
014RW058

6A±58
ENGINE MECHANICAL (6VE1 3.5L)
3. Install valve to valve guide. Before installing valve
guide apply engine oil to the outside of the valve stem.
4. Install valve spring to cylinder head. Attach the valve
spring to the lower spring seat. The painted area of
the valve spring should be facing downward.
014RS020
5. Install lower valve spring seat, valve spring and upper
valve spring seat then put split collars on the upper
spring seat, using the J±8062 valve spring
compressor and J±42898 valve spring compressor
adapter to install the split collars.
014RW042
6. Install tappet with shim.
7. Install camshaft assembly.

Refer to installation procedure for Camshaft in this
manual.
Valve Clearance Adjustments
NOTE: To adjust valve clearance, apply engine oil to the
cam as well as to the adjusting shim (2) with the cylinder
head built on the cylinder block, give a few turns to the
camshaft by means of timing pulley tightening bolt, and
measure valve clearance when the nose of cam is just
opposite of maximum cam lift (1) as shown in illustration
below.
014RW081
Legend
(1) Cam
(2) Shim
(3) Tappet
Valve Clearance Standard Value (cold)
Intake: 0.23 mm±0.33 mm
(0.0091 in±0.0130 in)
Exhaust: 0.25 mm±0.35 mm
(0.0098 in±0.0138 in)
Selection of Adjusting Shim
Shim to be selected = (Thickness of removed shim) +
(Valve clearance measurement ± Standard value)
Based on the above formula, the best suited shim should
be selected from 41 types of shim (differently thick at
0.02mm (0.0008 in) intervals from 2.40mm (0.0945 in)
through 3.2mm (0.1260 in) thick). Install the shim and
check valve clearance.

6A±59
ENGINE MECHANICAL (6VE1 3.5L)
Replacement of Shim
Let the cam push down the edge of tappet by using
J±42689 valve clearance adjusting tool and push out the
shim with a flat blade screw driver as shown in illustrations
below.
014RW082
014RW083
014RW084

6A±60
ENGINE MECHANICAL (6VE1 3.5L)
Camshaft
Camshaft and Associated Parts
014R100028
Legend
(1) Camshaft Bracket Fixing Bolt
(2) Camshaft Bracket
(3) Camshaft Assembly Intake
(4) Camshaft Assembly Exhaust
(5) Pulley Fixing Bolt(6) Camshaft Drive Gear Pulley
(7) Retainer Fixing Bolt
(8) Retainer
(9) Camshaft Drive Gear
(10) Oil Seal
(11) O±ring
Disassembly
1. Remove fixing bolt (5) for camshaft drive gear pulley
using the J±43041 universal holder.
014RW060

6A±61
ENGINE MECHANICAL (6VE1 3.5L)
2. Remove twenty fixing bolts from intake and exhaust
camshaft bracket on one side bank, then camshaft
brackets (2).
014RW027
3. Remove camshaft assembly (3), (4) with camshaft
end plug.
4. Remove three fixing bolts (7) from camshaft drive
gear retainer (8), then camshaft drive gear assembly.
5. Use the snap ring pliers to remove the snap ring(1).
6. Remove the wave washer(2), sub gear(3) and spring
camshaft gear(4) from the camshaft assembly(5).
014R100018
Legend
(1) Snap Ring
(2) Wave Washer
(3) Sub Gear
(4) Spring; Camshaft Gear
(5) Camshaft Assembly
Inspection and Repair
1. Use a micrometer to measure the cam lobe height
and uneven wear. Replace the camshaft if either the
lobe height or the uneven wear exceeds the specified
limit.
Lobe height : 44.709 mm (1.7602 in)
Uneven wear : 0.05 mm (0.0020 in)
014RW043
2. Use a micrometer to measure the diameter and the
uneven wear of the camshaft journals.
Replace the camshaft if the diameter or the uneven
wear exceeds the specified limit.
Journal Diameter
Standard : 25.972 mm±25.993 mm
(1.0225 in±1.0233 in)
Limit : 25.8 mm (1.0157 in)
Uneven wear : 0.05 mm (0.0020 in)
014RS023

6A±62
ENGINE MECHANICAL (6VE1 3.5L)
3. Place the camshaft on V±blocks.
Slowly rotate the camshaft and measure the runout
with a dial indicator.
Replace the camshaft if the runout exceeds the
specified limit.
Runout
Limit : 0.1 mm (0.0039 in)
014RW044
4. Measure the camshaft journal oil clearance.
1. Measure the camshaft bracket housing inside
diameter.
NOTE: Tighten camshaft bracket (2) to specified torque
before measuring the camshaft bracket inside diameter.
Torque : 10 N´m (89 lb in)
014RW031
2. Subtract the camshaft outside diameter from the
camshaft bracket housing inside diameter.
Oil Clearance
Standard : 0.027 mm±0.078 mm
(0.0011 in±0.0031 in)
Limit : 0.11 mm (0.0043 in)
014RW037
5. Replace the cylinder head and/or camshaft if the
measured oil clearance exceeds the specified limit.
1. Carefully clean the camshaft journal, the
camshaft bracket, and the cylinder head.
2. Install camshaft assembly and camshaft brackets
(2), tighten twenty bolts (1) on one side bank to
the specified torque.
Torque: 10 N´m (89 lb in)
014RW031

6A±63
ENGINE MECHANICAL (6VE1 3.5L)
3. Measure the camshaft thrust clearance with a dial
indicator. Replace the camshaft and/or the
cylinder head if the camshaft thrust clearance
exceeds the specified limit.
Camshaft thrust Clearance
Standard : 0.03 mm±0.08 mm
(0.0012 in.±0.0031 in.)
Limit : 0.12 mm (0.0047 mm)
014RW035
Reassembly
1. Install camshaft drive gear assembly and tighten
three bolts to specified torque.
Torque: 10 N´m (89 lb in)
2. Install the spring ; camshaft gear(1) into the camshaft
assembly.
Ensure the clearance is between the right side of the
spring; camshaft gear (1) and the dowel pin (2).
014R100017
3. Align the dowel pin on the sub gear to the clearance of
the spring ; camshaft gear made in step 2 and install
the sub gear (3).
4. Install the wave washer (2). Use snap ring pliers to
install the snap ring (1).
014R100018
5. Tighten sub gear setting bolt.
a. Use J±42686 gear spring lever to pre-load the sub
gear. Turn the sub gear in a clockwise direction
until the M5 bolt hole aligns with the hole in the
camshaft driven gear.
b. Install the M5 bolt and tighten to a suitable torque to
prevent the sub gear from moving.
014RW041
6. Align the timing mark on the retainer and dowel pin of
the camshaft drive gear.
7. Install camshaft assembly and camshaft brackets,
tighten twenty bolts on one side bank to the specified
torque.

6A±64
ENGINE MECHANICAL (6VE1 3.5L)
a. Apply engine oil to camshaft journal and bearing
surface of camshaft bracket.
b. 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).
014R100016
Legend
(1) Alignment Mark on the Camshaft Gear
(2) Alignment Mark on the Camshaft Drive Gear
014R100025
Legend
(1) Discrimination Mark for Right Bank Intake
Camshaft Gear
(2) Alignment Mark for Right Bank (One Dot)
(3) Camshaft Timing Gear for Right Bank Intake
014R100026
Legend
(1) Alignment Mark for Left Bank (Two Dots)
(2) Discrimination Mark for Left Bank Intake
Camshaft Gear
(3) Camshaft Timing Gear for Left Bank Intake
014R100027
Legend
(1) Discrimination Mark
LE : Left Bank Exhaust
RE : Right Bank Exhaust
(2) Alignment Mark
One Dot for Right Bank
Two Dots for Left Bank
(3) Camshaft Timing Gear for Exhaust

6A±65
ENGINE MECHANICAL (6VE1 3.5L)
014R100023
Legend
(1) Timing Mark on the Camshaft Drive Gear for
Right Bank Exhaust Camshaft
(2) Timing Mark on the Camshaft Drive Gear for
Right Bank Intake Camshaft
(3) Dowel Pin
014R100024
Legend
(1) Timing Mark on the Camshaft Drive Gear for
Left Bank Intake Camshaft
(2) Timing Mark on the Camshaft Drive Gear for
Left Bank Exhaust Camshaft
(3) Dowel Pin
c. Tighten twenty bolts in numerical order on one side
bank as shown in the illustration.
Torque: 10 N´m (89 lb in)
014RW031
8. If the oil seal requires replacement, use the J±42985
to install the oil seal.
014RW034

6A±66
ENGINE MECHANICAL (6VE1 3.5L)
9. If the camshaft end plug requires replacement, use
the J±42985 to install the camshaft end plug.
014R100031
10. Tighten bolt for camshaft drive gear pulley to the
specified torque using the J±43041 universal holder.
Torque: 98 N´m (72 lb ft)
014RW060