oil temperature ISUZU AXIOM 2002 Service User Guide

4D2±2
TRANSFER CASE (TOD)
General Description
A04R200003
The Torque-On-Demand (TOD) is an
electronically-controlled torque-split 4-wheel drive
system with the following features.
Shifting Between High and Low Ranges
The shifting mechanism consists of the cam and shaft rail
assembly, the high/low shift motor and the encoder. The
encoder is built-in to the motor.
The encoder senses high/low range shift motor rotation
position and sends this data to the TOD control unit.
Based on this data, the TOD control unit adjusts motor
rotation speed or stops the motor.
The shifting between the high and low ranges using the
TOD switch only is possible. The vehicle must be stopped
or nearly stopped (vehicle speed less than 2 km/h (1.2
mph) and engine speed less than 1,500 rpm), the
automatic transmission selector level must be in the
neutral (N) position, and the brakes must be applied.
Electronically-controlled Wet-type Multiple
Disc Clutch
The clutch automatically provides the optimum drive
power to the front wheels of the vehicle in response to
varying road surface conditions when the vehicle is
operated in the TOD mode. The delivered power ranges
from 0% to 100% of power train output. Superior
operational stability is maintained over a wide range of
operating conditions.
Front Output Drive
Front output drive is provided by a chain. This reduces the
loud noise associated with 4-wheel drive operation.
Oil Pump Lubrication
An oil pump is used to lubricate the transfer. This ensures
stable multiple-disc clutch operation and maintains the
lubricating oil at a constant temperature.

4D2±30
TRANSFER CASE (TOD)
Bearing
Check the profile of the needle, roller, ball, and thrust
bearings. Wash the bearings with clean detergent
completely, and dry with air.
NOTE: If the bearing is rotated excessively, the rollers
may be damaged. So, rotate the bearing slowly with your
hand. Apply grease to the bearing, and check the
smoothness of the bearing while slowly rotating the race
with your hand.
Allowable limit : 0.23 mm (0.009 in)
226RW143
Lockup Fork Spring
Check the lockup fork spring for distortion, cracking, and
wear. If defects are observed, replace the part.
Multi Plate Disk Clutch

If the burned, mirror-surfaced clutch facing, or
scraping is observed on the clutch plates, clutch
housing, armature plate, and insulator washer,
replace the parts.
266R200003
Legend
(1) Clutch Housing
(2) Clutch Plate
(3) Insulator Washer
(4) Armature Plate
Coil Assembly

Check the resistance of the coil with a tester. If
defects are observed, replace the coil assembly.
Standard : 1.7+0.3
(at ordinary temperature)
Allowable limit : 1.0~5.0

261RY00022
Cam Pulley, Cam Ball, and Cam & Coil
Housing

Check the cam balls and cam for excessive wear or
damage. If defective, replace the parts.
266RW016

4D2±31 TRANSFER CASE (TOD)
4H and 4L Switch

Check the continuity of 4H and 4L switch.
If defects are observed, replace the 4H and 4L switch.
261R200006
261RW049
Switch
Stroke4H Switch
Signal4L Switch
SignalThe
correspon-
ding
Terminal 2 to
Switch BodyTerminal
1 to 3
g
position of
TOD
switch
1OpenOpen2H, TOD
2OpenClose4L
3CloseCloseNeutral
Shift Motor Assembly

Check the resistance of the shift motor assembly
(between terminal 4 to 7) with a tester.
If defects are observed, replace the shift motor
assembly.
Standard : 0.63+0.2
(at ordinary temperature)
8±6
261RY00023
Oil Pump

Remove foreign materials from the strainer. If the
strainer is damaged, replace it.

If the area into which the shaft is inserted is
excessively worn or damaged, replace the oil pump
assembly.

6A±5
ENGINE MECHANICAL (6VE1 3.5L)
4. Engine Lacks Compression
Condition
Possible causeCorrection
Engine lacks compressionSpark plug loosely fitted or spark
plug gasket defectiveTighten to specified torque or replace
gasket
Valve timing incorrectAdjust
Cylinder head gasket defectiveReplace gasket
Valve incorrectly seatedLap valve
Valve stem seizedReplace valve and valve guide
Valve spring weakened or brokenReplace
Cylinder or piston rings wornOverhaul engine
Piston ring seizedOverhaul engine.
Engine Compression Test Procedure
1. Start and run the engine until the engine reaches
normal operating temperature.
2. Turn the engine off.
3. Remove all the spark plugs.
4. Remove ignition coil fuse (15A) and disable the
ignition system.
5. Remove the fuel pump relay from the relay and fuse
box.
6. Engage the starter and check that the cranking speed
is approximately 300 rpm.
7. Install cylinder compression gauge into spark plug
hole.
8. With the throttle valve opened fully, keep the starter
engaged until the compression gage needle reaches
the maximum level. Note the reading.
9. Repeat the test with each cylinder.
If the compression pressure obtained falls below the
limit, engine overhaul is necessary.
Limit; 1000 kPa (145 psi)

6A±7
ENGINE MECHANICAL (6VE1 3.5L)
Rough Engine Running
ConditionPossible causeCorrection
Engine misfires periodicallyIgnition coil layer shortedReplace
Spark plugs foulingClean or install hotter type plug
Spark plug(s) insulator nose leakingReplace
Fuel injector(s) defectiveReplace
Powertrain control module faultyReplace
Engine knocks periodicallySpark plugs running too hotInstall colder type spark plugs
Powertrain control module faultyReplace
Ion Sensing module faultyRefer or replace
Engine lacks powerSpark plugs fouledClean
Fuel injectors defectiveReplace
Mass Airflow Sensor or Intake
Airflow Sensor circuit defectiveCorrect or replace
Manifold Absolute Pressure (MAP)
Sensor or Manifold Absolute
Pressure Sensor circuit defectiveCorrect or replace
Engine Coolant Temperature Sensor
or Engine Coolant Temperature
Sensor circuit defectiveCorrect or replace
Powertrain Control Module faultyReplace
Intake Air Temperature Sensor or
Intake Air Temperature Sensor
circuit defectiveCorrect or replace
Throttle Position Sensor or Throttle
Position Sensor circuit defectiveCorrect or replace
ION Sensing Module or ION Sensing
Module circuits defectiveCorrect or replace

6A±10
ENGINE MECHANICAL (6VE1 3.5L)
Engine Lacks Power
ConditionPossible causeCorrection
Trouble in fuel systemFuel Pressure Control Valve not
working normallyReplace
Fuel injector cloggedClean or replace
Fuel pipe cloggedClean
Fuel filter clogged or fouledReplace
Fuel pump drive circuit not working
normallyCorrect or replace
Fuel tank not sufficiently breathing
due to clogged Evaporative
Emission Control System circuitClean or replace
Water in fuel systemClean
Inferior quality fuel in fuel systemUse fuel of specified octane rating
Powertrain Control Module supplied
poor voltageCorrect circuit
Throttle Position Sensor cable
broken or poor connectionsCorrect or replace
Throttle Position Sensor defectiveReplace
Mass Airflow Sensor not working
normallyReplace
Manifold Absolute Pressure Sensor
not working normallyReplace
Intake Air Temperature Sensor not
working normallyReplace
Engine Coolant Temperature Sensor
circuit open or shortedCorrect or replace
Engine Coolant Temperature Sensor
defectiveReplace
Powertrain Control Module defectiveReplace
Trouble in intake or exhaust systemAir Cleaner Filter cloggedReplace filter element
Air duct kinked or flattenedCorrect or replace
TWC defectiveRepair
Ignition failureÐÐÐÐRefer to Hard Start Troubleshooting
Guide
Heat range of spark plug inadequateInstall spark plugs of adequate heat
range
Ignition coil defectiveReplace

6A±17
ENGINE MECHANICAL (6VE1 3.5L)
Fuel Consumption Excessive
ConditionPossible causeCorrection
Trouble in fuel systemMixture too rich or too lean due to
trouble in fuel injection systemRefer to ªAbnormal Combustionº
Fuel cut function does not workRefer to ªAbnormal Combustionº
Trouble in ignition systemMisfiring or abnormal combustion
due to trouble in ignition systemRefer to ªHard Startº or ªAbnormal
Combustionº
OthersEngine idle speed too highReset Idle Air Control Valve
Fuel system leakageCorrect or replace
Clutch slippingCorrect
Brake dragCorrect
Selection of transmission gear
incorrectCaution operator of incorrect gear
selection
Excessive Exhaust Gas
Recirculation flow due to trouble in
Exhaust Gas Recirculation systemRefer to ªAbnormal Combustionº
Lubrication Problems
ConditionPossible causeCorrection
Oil pressure too lowWrong oil in useReplace with correct engine oil
Relief valve stickingReplace
Oil pump not operating properlyCorrect or replace
Oil pump strainer cloggedClean or replace strainer
Oil pump wornReplace
Oil pressure gauge defectiveCorrect or replace
Crankshaft bearing or connecting
rod bearing wornReplace
Oil contaminationWrong oil in useReplace with correct engine oil
Oil filter cloggedReplace oil filter
Cylinder head gasket damageReplace gasket
Burned gases leakingReplace piston and piston rings or
cylinder body assembly
Oil not reaching valve systemOil passage in cylinder head or
cylinder body cloggedClean or correct
Engine Oil Pressure Check
1. Check for dirt, gasoline or water in the engine oil.
a. Check the viscosity of the oil.
b. Check the viscosity of the oil.
c. Change the oil if the viscosity is outside the
specified standard.
d. Refer to the ªMaintenance and Lubricationº section
of this manual.
2. Check the engine oil level.
The level should fall somewhere between the ªADDº
and the ªFULLº marks on the oil level dipstick.
If the oil level does not reach the ªADDº mark on the
oil level dipstick, engine oil must be added.3. Remove the oil pressure unit.
4. Install an oil pressure gauge.
5. Start the engine and allow the engine to reach normal
operating temperature (About 80
C).
6. Measure the oil pressure.
Oil pressure should be:
392±550 kPa (56.9±80.4 psi) at 3000 rpm.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure unit.
10. Start the engine and check for leaks.

6A±26
ENGINE MECHANICAL (6VE1 3.5L)
Crankshaft Pulley
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
013RY00001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Flow Sensor
3. Remove radiator upper fan shroud from radiator.
4. Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.
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) Driver Belt
5. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
6. Remove crankshaft pulley assembly using J-8614-01
crankshaft holder, hold crankshaft pulley then
remove center bolt and pulley.
Installation
1. Install crankshaft pulley using J-8614-01 crankshaft
holder, hold the crankshaft pulley and tighten center
bolt to the specified torque.
Torque : 167 N´m (123 lb ft)
2. 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.
3. Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
4. Install radiator upper fan shroud.
5. Install air cleaner assembly.

6A±81
ENGINE MECHANICAL (6VE1 3.5L)

With J±24086±C Piston pin service set and a press,
press fit the piston pin.
NOTE: Heat the connecting rod small end to a suitable
temperature to ensure smooth installation.
015RS037
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
4. Install piston ring with the piston ring expander.
The compression ring must be set with the T mark (1)
facing up.
Marked T : No.1 Compression ring
Marked T2 : No.2 Compression ring
015RS027

Install piston rings in the following sequence.
1. Oil ring
1. Expander ring
2. Upper side rail
3. Lower side rail
2. 2nd compression ring
3. 1st compression ring

The compression rings must be set with the T or T2
mark facing up.
Marked T : No.1 Compression ring
Marked T2 : No.2 Compression ring

After installation, apply engine oil to the entire
circumference of the piston rings. Check to see that
all the rings rotate smoothly.
015RS038
5. Install piston and connecting rod assembly.

Insert the bearings into the connecting rods and
caps. Apply new engine oil to the bearing faces and
nuts.

Tighten the connecting rod cap nuts
Torque : 54 N´m (40 lb ft)
NOTE: Do not apply engine oil to the bearing back faces.
6. Oil gallery, refer to ªCrankshaft and main bearingº in
this manual.
7. Oil strainer and O-ring.
8. Oil pipe and O-ring.
9. Install crankcase with oil pan, refer to ªOil pan and
Crankcaseº in this manual.
10. Install cylinder head gasket.
11. Install Cylinder head assembly.

Refer to ªCylinder headº in this manual.

ENGINE COOLING (6VE1 3.5L)6B±3
Thermostat
The thermostat is a wax pellet type with a air hole(1) and is
installed in the thermostat housing.
031RW002
Radiator
The radiator is a tube type with corrugated fins. In order to
raise the boiling point of the coolant, the radiator is fitted
with a cap in which the valve is operated at 88.2 ~ 117.6
kPa (12.8 ~ 17.0 psi) pressure. (No oil cooler provided for
M/T)
110RW023
Antifreeze Solution

Relation between the mixing ratio and freezing
temperature of the EC varies with the ratio of
anti±freeze solution in water. Proper mixing ratio can
be determined by referring to the chart. Supplemental
inhibitors or additives claiming to increase cooling
capability that have not been specifically approved by
Isuzu are not recommended for addition to the cooling
system.
Calculating mixing ratio
F06RW005
NOTE: An t if r e e ze s o lu t io n + Water = Total cooling
system capacity.

Total Cooling System Capacity

A/T 10.0Lit (2.64Us gal)
B06RW002