engine ISUZU AXIOM 2002 Service Repair Manual

6A±67
ENGINE MECHANICAL (6VE1 3.5L)
Crankshaft
Crankshaft and Associated Parts
013RW009
Legend
(1) Cylinder Head Assembly
(2) Crankcase with Oil Pan
(3) Oil Pipe and O-ring
(4) Oil Strainer and O-ring
(5) Oil Pump Assembly
(6) Cylinder Block Side Bolts
(7) Oil Gallery(8) Piston and Connecting Rod Assembly
(9) Flywheel
(10) Rear Oil Seal Retainer and Oil Seal
(11) Main Bearing Cap
(12) Crankshaft
(13) Main Bearing Cap Fixing Bolts
(14) Oil Gallery Fixing Bolts
Disassembly
1. Remove cylinder head assembly (1). Refer to
ªCylinder Headº in this manual.
2. Remove crankcase with oil pan (2). Refer to ªOil Pan
and Crankcaseº in this manual.CAUTION: Take care not to damage or deform the
sealing flange surface of crankcase.
3. Remove oil pipe and O-ring (3).
4. Remove oil strainer and O-ring (4).
5. Remove oil pump assembly (5).
6. Remove crankcase side bolts (6).

6A±68
ENGINE MECHANICAL (6VE1 3.5L)
7. Remove oil gallery (7).
8. Remove piston and connecting rod assembly (8).
Refer to ªPiston, Piston Ring and Connecting Rodº in
this manual.
9. Remove flywheel (9).
10. Remove rear oil seal retainer (10).
11. Remove main bearing cap (11).
12. Remove crankshaft (12).
Inspection and Repair for Bearings
1. Inspect Crankshaft
Set the dial indicator as shown in the illustration and
measure the crankshaft thrust clearance. If the thrust
clearance exceeds the specified limit, replace the
thrust bearings as a set.
Thrust Clearance
Standard : 0.06 mm±0.24 mm
(0.0024 in±0.0094 in)
Limit : 0.30 mm (0.0118 in)
015RS003
Main Bearing Clearance
1. Remove the bearing caps and measure the oil
clearance.
2. Remove the main bearing cap fixing bolts in the
sequence shown in the illustration.
Arrange the removed main bearing caps in the
cylinder number order.
Remove the main bearings.
015RS004
3. Remove the crankshaft.
Remove the main bearings.
4. Clean the upper and lower bearings as well as the
crankshaft main journal.
5. Check the bearings for damage or excessive wear.
The bearings must be replaced as a set if damage or
excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to their
original positions.
Carefully install the crankshaft.
7. Set the lower bearings to the bearing cap original
position.
8. Apply plastigage to the crankshaft journal unit as
shown in the illustration.
NOTE: Do not set the plastigage on the oil hole.
015RS005

6A±69
ENGINE MECHANICAL (6VE1 3.5L)
9. Install main bearing caps, oil gallery and crank case
bolts in the order shown, and tighten each bolt to the
specified torque.
NOTE: Do not apply engine oil to the crank case side
bolts.
Main bearing cap bolts.
Torque: 39 N´m (29lb ft)
Oil gallery fixing bolts.
Torque:
1st step: 29 N´m (22 lb ft)
2nd step 55
~ 65

Crank case side bolts
Torque : 39 N´m (29lb ft)
NOTE: Do not allow the crankshaft to rotate.
015RS006
10. Remove the main bearing caps in the sequence
shown in the illustration.
015RS004
11. Measure the plastigage width and determine the oil
clearance. If the oil clearance exceeds the specified
limit, replace the main bearings as a set and/or
replace the crankshaft.
Standard : 0.019 mm±0.043 mm
(0.0007 in±0.0017 in)
Limit : 0.08 mm (0.0031 in)
015RS008
12. Clean the plastigage from the bearings and the
crankshaft.
Remove the crankshaft and the bearings.
Crankshaft Inspection
Inspect the surface of the crankshaft journal and crank
pins for excessive wear and damage. Inspect the oil seal
fitting surfaces for excessive wear and damage. Inspect
the oil ports for obstructions.

6A±70
ENGINE MECHANICAL (6VE1 3.5L)
Inspection and Repair for Crankshaft
1. Carefully set the crankshaft on the V±blocks. Slowly
rotate the crankshaft and measure the runout. If the
crankshaft runout exceeds the specified limit, the
crankshaft must be replaced.
Runout : 0.04 mm (0.0016 in)
015RS007
2. Measure the diameter and the uneven wear of main
journal and crank pin. If the crankshaft wear exceeds
the specified limit, crankshaft must be replaced.
Main journal diameter : 63.918 mm±63.933 mm
(2.5165 in±2.5170 in)
Crank pin diameter : 53.922 mm±53.937 mm
(2.1229 in.±2.1235 in.)
Uneven wear limit : 0.005 mm (0.0002 in)
015RS009
Crankshaft Bearing Selection
When installing new crankshaft bearings or replacing
bearings, refer to the selection table below. Select and
install the new crankshaft bearings, paying close
attention to the cylinder block journal hole.
1. Diameter size mark (1) and the crankshaft journal.
015RS010
2. Diameter size mark (1).
The diameter size marks are stamped on the No.1
crankshaft balancer as shown in the illustration.
015RS011
NOTE: Take care to ensure the bearings are positioned
correctly.

6A±71
ENGINE MECHANICAL (6VE1 3.5L)
015RS012
Legend
(1) Number 1 and 4 main bearing upper and lower
(2) Number 2 and 3 main bearing upper
(3) Number 2 and 3 main bearing lower
mm ( in)
1 Size
MarkMain Bearing
Bore DiameterCrank Shaft Main
Journal Diameter2 Size
Mark
Crank
Shaft
Bearing
Size Mark
(Upper
Side)Crank
Shaft
Bearing
Size Mark
(Lower
Side)
Oil Clearance
(Reference)
168.994-69.000
63.918-63.925
(2.5165-2.5167)2BlueBlue0.030-0.049
(0.0012-0.0019)
1(2.7163-2.7165)63.926-63.933
(2.5168-2.5170)1
BrownBrown
0.028-0.047
(0.0011-0.0019)
268.987-68.993
63.918-63.925
(2.5165-2.5167)2
BrownBrown0.029-0.048
(0.0011-0.0019)
2(2.7160-2.7163)63.926-63.933
(2.5168-2.5170)1
GreenGreen
0.027-0.046
(0.0011-0.0018)
368.980-68.986
63.918-63.925
(2.5165-2.5167)2
GreenGreen0.028-0.047
(0.0011-0.0019)
3(2.7157-2.7160)63.926-63.933
(2.5168-2.5170)1YellowYellow0.026-0.045
(0.0010-0.0018)
Reassembly
1. Crankshaft (12)

Install the main bearings to the cylinder block and
the main bearing caps.

Be sure that they are positioned correctly.

Apply new engine oil to the upper and lower main
bearing faces.
NOTE: Do not apply engine oil to the main bearing back
faces.
015RS012

6A±72
ENGINE MECHANICAL (6VE1 3.5L)

Carefully mount the crankshaft.

Apply engine oil to the thrust washer.

Assemble the thrust washer to the No.3 bearing
journal. The oil grooves must face the crankshaft.
015RS013
2. Rear oil seal (10)

Remove the oil from the cylinder block and the
retainer mounting surface.

Apply sealant (TB±1207B or equivalent) to the
retainer mounting surface, following the pattern
shown in the illustration.
The retainer must be installed within 5 minutes after
sealant application to prevent premature hardening
of sealant.
015RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin

Apply engine oil to the oil seal lip.

Align the cylinder block dowel pin holes with the rear
retainer dowel pins.

Tighten the rear retainer fixing bolts. New bolts
should be used when installing rear retainer.
Torque: 18 N´m (13 lb ft)
NOTE: Be very careful not to disengage the oil seal garter
spring during installation of the rear retainer.
If the seal was removed from retainer for
replacement, apply engine oil to the oil seal lip and
install the oil seal using J±39201 oil seal installer.
015RW001
015RS017
3. Flywheel (9)
1. Thoroughly clean and remove the oil from the
threads of crankshaft.
2. Remove the oil from the crankshaft and flywheel
mounting faces.
3. Mount the flywheel on the crankshaft and then
install the washer.

6A±73
ENGINE MECHANICAL (6VE1 3.5L)
4. Hold the crankshaft to prevent from rotating then
install the bolts in the order shown to the specified
torque.
Torque: 54 N´m (40 lb ft)
NOTE: Do not reuse the bolt and do not apply oil or thread
lock to the bolt.
015RS018
4. Piston and connecting rod assembly (8)

Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft pins.
Check to see that the piston ring end gaps are
correctly positioned.
015RS019
Legend
(1) No.1 Compression Ring
(2) No.2 Compression Ring
(3) Oil Ring Side Rail Upper
(4) Oil Ring Side Rail Lower
(5) Piston Front Mark

Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor. The
front marks must be facing the front of the engine.

Match the numbered caps with the numbers on the
connecting rods. Align the punched marks on the
connecting rods and caps.

Apply engine oil to the threads and seating faces of
the nuts.

Tighten the nuts.
Torque: 54 N´m (40 lb ft)
After tightening the cap nuts, check to see that the
crankshaft rotates smoothly.
NOTE: Do not apply engine oil to the bearing back faces.
015RS020
5. Install oil gallery (7) and tighten the bolts in 2 steps, in
the order shown.
1st step: 29 N´m (22 lb ft)
2nd step: 55
~ 65

051RS009

6A±74
ENGINE MECHANICAL (6VE1 3.5L)
6. Cylinder block side bolts (6)

Tighten all the bolts to the specified torque in the
order shown.
NOTE: Do not apply engine oil to the crank case side
bolts.
Torque: 39 N´m (29 lb ft)
012RS001
7. Install oil pump assembly (5), refer to ªOil pumpº in
this manual.
8. Install oil strainer and O-ring (4).
9. Install oil pipe and O-ring (3) and tighten the bolts.
Torque: 25 N´m (18 lb ft)
10. Install crankcase with oil pan (2).
1. Completely remove all residual sealant, lubricant
and moisture from the sealing surfaces. The
surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TBÐ
1207C or its equivalent) to the contact surfaces of
the oil pan. There must be no gaps in the bead.
3. The crankcase assembly must be installed within
5 minutes after sealant application.
4. Tighten the bolts and nuts to the specified torque.
Torque : 10 N´m (87 lb in)
013RW010
Legend
(1) Portion Between Bolt Holes
(2) Bolt Hole Portion
11. Install cylinder head assembly, refer to ªCylinder
headº in this manual.

6A±75
ENGINE MECHANICAL (6VE1 3.5L)
Piston and Connecting Rod
Piston, Connecting Rod and Associate Parts
015RW019
Legend
(1) Cylinder Head Assembly
(2) Cylinder Head Gasket
(3) Crankcase with Oil Pan
(4) Oil Pipe and O-ring
(5) Oil Strainer and O-ring
(6) Oil Gallery(7) Piston and Connecting Rod Assembly
(8) Piston Ring
(9) Piston Pin
(10) Piston
(11) Connecting Rod
(12) Connecting Rod Cap
Disassembly
1. Remove cylinder head assembly (1). Refer to
ªCylinder Head Removalº in this manual.
2. Remove cylinder head gasket (2).
3. Remove crankcase with oil pan (3). Refer toªOil Pan
and Crankcaseº in this manual.
4. Remove oil pipe and O-ring (4).5. Remove oil strainer and O-ring (5).
6. Remove oil gallery (6).
7. Remove connecting rod cap with connecting rod
lower bearing (12).
8. Remove piston and connecting rod assembly (7).
NOTE: Before removing piston and connecting rod
assembly, measure thrust clearance.

6A±76
ENGINE MECHANICAL (6VE1 3.5L)
015RS031

Remove any ridge or carbon build up from the top
end of the cylinder.
9. Remove the piston rings (8) with a piston ring
expander. Arrange the removed piston rings in the
cylinder number order.
015RS022
10. Remove the piston pin (9) using J±24086±C piston
pin service set and piston support with a press.
NOTE: Keep the parts removed from each cylinder
separate. All parts must be reinstalled in their original
positions. Heating the connecting rod will permit easy
removal of the piston pin.
015RS023
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
11. Piston (10)
12. Connecting rod (11)
Inspection and Repair
Pistons
Carefully clean away all the carbon adhering to the piston
head and the piston ring grooves.
NOTE: Never use a wire brush to clean the pistons.
Damage will result. Visually check each piston for
cracking, scoring, and other signs of excessive wear. If
any of the above conditions are found, the piston must be
replaced.
Piston Diameter
1. Measure the piston outside diameter with micrometer
at the piston grading position and a right angle to the
piston pin.
Piston grading position (from piston head)
Piston grading position : 43.0 mm (1.6929 in)