engine ISUZU AXIOM 2002 Service Repair Manual

6A±77
ENGINE MECHANICAL (6VE1 3.5L)
015RV014The size mark (1) for piston outside diameter is
represented as shown in Figure.
Outside Diameter
Size Mark A : 93.360 mm±93.370 mm
(3.6756 in±3.6760 in)
Size Mark B : 93.371 mm±93.380 mm
(3.6760 in±3.6764 in)
Size Mark C : 93.381 mm±93.390 mm
(3.6764 in±3.6768 in)
015RS025Measure the cylinder bore inside diameter (refer to
ªCylinder Blockº in this manual).
012RS002
Piston Rings
Any worn or damaged part discovered during engine
overhaul must be replaced with a new one.
1. Ring end gap measurement

Insert the piston ring into the bore.

Push the ring by the piston, at a right angle to the
wall, into the point at which the cylinder bore
diameter is the smallest.

Measure the ring end gap.
Compression Ring
1st ring
Standard:
0.300 mm±0.400 mm
(0.0118 in±0.0157 in)
Limit: 1.0 mm (0.0394 in)
2nd ring
Standard:
0.450 mm±0.600 mm
(0.0177 in±0.0236 in)
Limit: 1.2 mm (0.0472 in)
Oil ring
Standard:
0.150 mm±0.450 mm
(0.0059 in±0.0177 in)
Limit: 1.05 mm (0.0413 in)

6A±78
ENGINE MECHANICAL (6VE1 3.5L)
015RS026

Positioning mark (1) is painted as shown in the
illustration.
Marked T : No.1 Compression ring
Marked T2 : No.2 Compression ring
015RS027
2. Measure the clearance between the piston ring
groove and the piston ring with a feeler gauge. If the
piston ring groove / piston ring clearance exceeds the
specified limit, the piston must be replaced.
Compression Ring Clearance
Standard : 0.025 mm±0.065 mm
(0.0006 in.±0.0015 in)
Limit : 0.1mm (0.0059 in)
015RS028
Piston Pin
NOTE: Do not reuse the old piston pin.
1. Use a micrometer to measure the new piston pin
outside diameter in both directions at three different
positions.
2. Measure the inside diameter of the connecting rod
small end. If the fitting interference between the small
end and pin does not conform to the specified value,
the connecting rod must be replaced.
Standard : 0.023 mm±0.038 mm (0.0009
in±0.0015 in)
015RS029

6A±79
ENGINE MECHANICAL (6VE1 3.5L)
3. Insert the new pin into the piston and rotate it. If the
pin rotates smoothly with no backlash, the clearance
is normal. If there is backlash or roughness, measure
the clearance. If the clearance exceeds the specified
limit, the piston must be replaced.
Clearance
Standard : 0.010 mm±0.017 mm
(0.0004 in.±0.0007 in)
Limit : 0.040 mm (0.0016 in)
Connecting Rods
1. Check the connecting rod alignment If either the bend
or the twist exceeds the specified limit, the connecting
rod must be replaced.
Bend per 100 mm (3.937 in)
Limit: 0.15 (0.0059)
Twist per 100 mm (3.937 in)
Limit: 0.20 (0.0078)
015RS030
2. Measure the connecting rod thrust clearance. Use a
feeler gauge to measure the thrust clearance at the
large end of the connecting rod If the clearance
exceeds the specified limit, the connecting rod must
be replaced.
Standard : 0.16 mm±0.35 mm
(0.0063 in.±0.0138 in)
Limit : 0.40 mm (0.0157 in)
015RS031
3. Measure the oil clearance between the connecting
rod and the crankshaft.
1. Remove the connecting rod cap nuts and the rod
caps (12).
Arrange the removed rod caps in the cylinder
number order.
2. Clean the rod bearings and the crankshaft pins.
3. Carefully check the rod bearings. If even one
bearing is found to be damaged or badly worn, the
entire bearing assembly must be replaced as a
set. Reinstall the bearings in their original
positions. Apply plastigage to the crank pin.
015RS032
4. Reinstall the rod caps (12) to their original
positions.
Tighten the rod cap nuts.
Torque: 54 N´m (40 lb ft)
NOTE: Do not allow the crankshaft to rotate.

6A±80
ENGINE MECHANICAL (6VE1 3.5L)
5. Remove the rod caps.
6. Measure the width of the plastigage and
determine the oil clearance. If the oil clearance
exceeds the limit, replace the rod bearing as a
set.
Standard : 0.019 mm±0.043 mm
(0.0007 in±0.0017 in)
Limit : 0.08 mm (0.0031 in)
015RS008
7. Clean the plastigage from the bearings and the
crankshaft pins.
Con±rod Bearing Selection
Select and install the new connecting rod bearings,
paying close attention to the connecting rod big end
diameter size mark (1).
NOTE: Take care not to confuse the alignment mark (2)
and the size mark (1) during the installation procedure.
015RS034
mm ( in)
1 Size MarkBig end Bore
DiameterCrankshaft Pin
DiameterConnecting Rod
Bearing Thickness
(Reference)Color of
Size
MarkOil Clearance
(Reference)
A56.994-57.000
(2.2439-2.2441)1.512-1.516
(0.0595-0.0597)Yellow0.025-0.054
(0.0010-0.0021)
B56.988-56.994
(2.2436-2.2439)53.922-53.937
(2.1229-2.1235)1.508-1.512
(0.0594-0.0595)Green0.027-0.056
(0.0011-0.0022)
C56.982-56.988
(2.2434-2.2436)1.504-1.508
(0.0592-0.0594)Pink0.029-0.058
(0.0011-0.0023)
Reassembly
1. Install connecting rod
2. Install piston
3. Install piston pin

Apply a thin coat of engine oil to the piston pin. Try to
insert the piston pin into the piston pin hole with
normal finger pressure.
NOTE: W h e n changing piston / connecting rod
combinations, do not change the piston / piston pin
combination and do not reuse the old piston pin.

Attach the piston to the connecting rod with the
piston front mark and the connecting rod front mark
on the same side.
015RS036

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.

6A±82
ENGINE MECHANICAL (6VE1 3.5L)
Cylinder Block
Cylinder Block and Associated Parts
012RW010
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 Pump Assembly
(7) Cylinder Block Side Bolts(8) Oil Gallery
(9) Piston and Connecting Rod Assembly
(10) Flywheel
(11) Rear Oil Seal Retainer Assembly
(12) Main Bearing Cap
(13) Crankshaft
(14) Cylinder Block
Disassembly
1. Remove cylinder head assembly.
2. Remove cylinder head gasket.
3. Remove crankcase with oil pan.
4. Remove oil pipe and O-ring.5. Remove oil strainer and O-ring.
6. Remove oil pump assembly.
7. Remove crankcase side bolts.
8. Remove oil gallery.
9. Remove piston and connecting rod assembly.
10. Remove flywheel.

6A±83
ENGINE MECHANICAL (6VE1 3.5L)
11. Remove rear oil seal retainer assembly.
12. Remove main bearing cap.
13. Remove crankshaft.
14. Remove cylinder block.
Inspection and Repair
1. Remove the cylinder head gasket and any other
material adhering to the upper surface of the cylinder
block. Be very careful not to allow any material to
accidentally drop into the cylinder block. Be very
careful not to scratch the cylinder block.
2. Carefully remove the oil pump, rear oil seal retainer,
and crankcase assembly installation surface seal.
3. Wipe the cylinder block clean.
4. Visually inspect the cylinder block. If necessary, use a
flaw detector to perform a dye penetrate and
hydraulic (or air pressure) test. If cracking or other
damage is discovered, the cylinder block must either
be repaired or replaced.
Flatness
1. Using a straight±edge and feeler gauge, check that
the upper surface of the cylinder block is not warped.
CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
upper surface of the cylinder block.
2. The cylinder block must be reground or replaced if the
warpage exceeds the limit.
Warpage
Limit : 0.15 mm (0.0059 in)
Maximum repairable limit: 0.15 mm (0.0059 in)
012RS004
Cylinder Bore
Use a cylinder gauge to measure the cylinder bore
diameter in both the axial and thrust directions. Each
measurement should be made at six points.
CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
upper surface of the cylinder block.
Cylinder Bore Inside Diameter
Limit : 93.530 mm (3.6823 in)
If the measurement exceed the specified limit, the
cylinder block must be replaced.
Diameter
Grade A : 93.400 mm±93.410 mm
(3.6772 in±3.6776 in)
Grade B : 93.411 mm±93.420 mm
(3.6776 in±3.6779 in)
Grade C : 93.421 mm±93.430 mm
(3.6780 in±3.6783 in)
012RS005
NOTE: For information on piston diameter, please refer
to the section ºInspection of the Piston and Connecting
Rod Assemblyº in this manual.

The ºGradeº mark (1) is stamped at the position
illustrated.

6A±84
ENGINE MECHANICAL (6VE1 3.5L)
012RS006
Reassembly
1. Install cylinder block.
2. Install crankshaft.

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 bearing back faces.
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.

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
3. Install rear oil seal retainer.

Remove oil on cylinder block and retainer fitting
surface.

Apply sealant (TB1207B or equivalent) to retainer
fitting surface as shown in illustration.

The oil seal 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

6A±85
ENGINE MECHANICAL (6VE1 3.5L)

Apply engine oil to oil seal lip and align a dowel pin
hole in the cylinder block with that in the retainer.

Tighten retainer fixing bolts to the specified torque.
Torque: 25 N´m (18 lb ft)
015RW001
4. Install flywheel
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.
4. Holding the crankshaft stationary, tighten the
flywheel bolts in the order shown.
Torque: 54 N´m (40 lb ft)
NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
015RS018
5. Install piston and connecting rod assembly.

Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft pins.
NOTE: Do not apply engine oil to the bearing back faces.

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 (1) must be facing the front of the
engine.
015RS020

6A±86
ENGINE MECHANICAL (6VE1 3.5L)
6. Install oil gallery and tighten the bolts in 2 steps in the
order shown.
1st step : 29 N´m (22 lb ft)
2nd step : 55
~ 65

012RS007
7. Install cylinder block side bolts (1) and tighten
crankcase bolts in sequence shown in the illustration.
Torque : 39 N´m (29 lb ft)
012RW005
8. Install oil pump assembly. Refer to ªOil Pumpº in this
manual.
9. Install oil strainer and O-ring.
10. Install oil pipe and O-ring.
11. Install crankcase with oil pan.
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 (TB± 1207C
or its equivalent) to the contact surfaces of the
crankcase. There must be no gaps in the bead.
3. The oil pan must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.
4. Tighten the bolts and nuts to the specified torque.
Torque : 10 N´m (87 lb in)
013RW010
Legend
(1) Portion Between Both Holes
(2) Bolt Hole Portions
12. Install cylinder head gasket.
13. Install cylinder head assembly. Refer to ªCylinder
Headº in this manual.