torque ISUZU AXIOM 2002 Service Repair Manual

5D2±4
PARKING BRAKE SYSTEM (4X2 Model)
Removal
1. Remove rear wheels (1) and drums (2).
2. Remove bolt (3) (4) (5).
3. Remove nut (6).
4. Remove nut (7) and retainer (8).
5. Remove rear brake shoe assemblies. Refer to
ªBrake
Lining Assembly and Associated Partsº in Power
Assisted Brake System
section.
6. Use offset box wrench (13 mm hex.) to compress the
locking lugs on the cable, then remove the rear cable
(9) from the Backing plate.
311RS012
Legend
(1) Offset Box Wrench
Installation
1. Install rear cable (9).
2. Install retainer (8).
3. Tighten nut (7) to the specified torque.
Torque : 41 N´m (30 lb ft)

To adjust the parking brake, refer to
Parking Brake
Adjustment
in this section.
4. Tighten nut (6) to the specified torque.
Torque : 15 N´m (11 lb ft)
5. Tighten bolt (5) (4) (3) to the specified torque.
Torque : 6.5 N´m (57 lb in)
6. Install rear drums (2) and wheels (1).
Parking Brake Adjustment
NOTE: All brakes are self adjusting. Brakes are adjusted
by repeated stepping on the brake pedal. (After stepping
on the pedal and releasing it, the rear auto±adjuster, in the
rear brake, produces a clicking sound. The same
operation should be repeated until the sound
disappears.)
Take the following steps after overhauling the rear brake
assembly.
1. Move the parking brake lever to its fully released
position.
2. Parking cable must be loosened sufficiently. (Loosen
the adjust nut and the lock nut.).
3. Repeat stepping on the brake pedal firmly, and
releasing it until the clicking sound can no longer be
heard.
If the difference between the brake drum inside
diameter and diameter of the brake shoes is adjusted
to be 0.5 mm, the number of times for depressing the
brake pedal can be reduced.
4. Remove the drum. Measure the brake drum inside
diameter and diameter of the brake shoes.
Shoe clearance: 0.25 mm to 0.40 mm
(0.0098 in to 0.0157 in)
If incorrect, check the brake auto±adjusting system.
5. Rotate the adjust nut of hand brake lever until all slack
disappears from the cable. Set the adjust nut.
6. Applying about 30 kg (66 lb) of force, pull the parking
brake lever to its fully set position three or four times.
7. If the parking brake is properly adjusted, the travel
between the fully disengaged position and the fully
engaged position will be 6 notches.
If the traveling range is not within these limits, repeat
steps 1 through 5 again .
After adjusting has been done, check to see if the rear
wheel rotates smoothly without drag when turned by
hand.

PARKING BRAKE SYSTEM (4X2 Model)
5D2±5
Main Data and Specifications
General Specifications
Model
TypeLeading±Trailing
Drum inside diameter295 mm (11.6 in)
Parking brake lever stroke6±8 notches
When pulled with a force of 30 kg (66 lb)
Torque Specifications
311R200003

6A±2
ENGINE MECHANICAL (6VE1 3.5L)
Piston and Connecting Rod 6A±75. . . . . . . . . . . . . . .
Piston, Connecting Rod and Associate
Parts 6A±75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 6A±75. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A±76. . . . . . . . . . . . . . . . . .
Reassembly 6A±80. . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Block 6A±82. . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block and Associated Parts 6A±82. . . . .
Disassembly 6A±82. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6A±83. . . . . . . . . . . . . . . . . .
Reassembly 6A±84. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specification 6A±87. . . . . . . . . . . . . .
Special Tool 6A±93. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

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±20
ENGINE MECHANICAL (6VE1 3.5L)
Installation
1. Install cylinder head cover.

Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.

Apply sealant (TB-1207B or equivalent) of bead
diameter 2-3 mm at eight place of arched area of
camshaft bearing cap on front and rear sides.

The cylinder head cover must be installed with in 5
minutes after sealant application to prevent
hardening of sealant.

Tighten bolts to the specified torque.
Torque : 9 N´m (78 lb in)
010RW008
2. Install fuel injection harness bracket and tighten bolt
to the specified torque.
Torque : 9 N´m (78 lb in)
3. Connect ignition coil connector and ignition coil, then
tighten bolt to the specified torque.
Torque : 4 N´m (35 lb in)
060RY022
Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assembly
CAUTION: Ignition coil assembly #6 is different
from ignition coil assembly from #1 to #5. Ignition
coil assembly #6 is short type. So, note it when
installing ignition coil assembly of #6.
060RY00002
Legend
(1) Long Type Ignition Coil Assemblies (# 1 ~ # 5)
(2) Short Type Ignition Coil Assembly (# 6)
4. Connect ground cable and tighten bolts to the
specified torque.
Torque : 9 N´m (78 lb in)
5. Install positive crankcase ventilation hose.
6. Install engine cover mating with the dowels.

6A±21
ENGINE MECHANICAL (6VE1 3.5L)
Cylinder Head Cover RH
Removal
1. Disconnect battery ground cable.
2. Remove engine cover from the dowele on the
common chamber.
F06RY001
3. Disconnect ventilation hose from cylinder head cover.
4. Disconnect three ignition coil connectors from ignition
coils and remove harness bracket bolts on cylinder
head cover then remove ignition coil fixing bolts on
ignition coils and remove ignition coils.
5. Disconnect fuel injector harness connector then
remove fuel injector harness bracket bolt.
6. Remove eight fixing bolts then the cylinder head
cover.
010RW002
Installation
1. Install cylinder head cover.

Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.
Apply sealant (TB-1207B or equivalent) bead
(diameter 2-3 mm) at eight places of arched areas
of camshaft bracket on front and rear sides.

The cylinder head cover must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.

Tighten bolts to the specified torque.
Torque : 9 N´m (78 lb in)
014RW019
2. Tighten fuel injector harness bracket bolts to
specified torque then reconnect fuel injector harness
connector.
Torque : 7.8 N´m (69 lb in)
3. Connect ignition coil connector and tighten ignition
coil fixing bolts to specified torque.
Torque : 4 N´m (35 lb in)
4. Connect ventilation hose to cylinder head.
5. Install engine cover mating with the dowels.

6A±22
ENGINE MECHANICAL (6VE1 3.5L)
Common Chamber
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner duct assembly.
013RY00001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Flow Sensor
3. Disconnect vacuum booster hose from common
chamber.
4. Disconnect connector from manifold absolute
pressure sensor, Ion sensing module, throttle
position sensor, solenoid valve, electric vacuum
sensing valve, and EGR valve.
5. Disconnect vacuum hose on canister VSV and
positive crankcase ventilation hose, fuel rail
assembly with pressure control valve bracket.
6. Remove ventilation hose from throttle valve and
intake duct and remove water hose.
7. Remove the four throttle body fixing bolts.
8. Remove exhaust gas recirculation valve assembly
fixing bolt and nut on common chamber and remove
EGR valve assembly.9. Remove two bolts from common chamber rear side
to remove fuel hose bracket.
10. Remove common chamber four bolts and four nuts
then remove the common chamber.
025RY002
Legend
(1) Common Chamber
(2) Throttle Valve Assembly
(3) Bolt
Installation
1. Install common chamber and tighten bolts and nuts to
the specified torque.
Torque :
Bolt : 25 N´m (18 lb ft)
Nut : 25 N´m (18 lb ft)
2. Install fuel hose bracket and tighten bolts to specified
torque.
Torque : 10 N´m (87 lb in)
3. Install exhaust gas recirculation valve assembly and
tighten bolt and nut to the specified torque.
Torque : 25 N´m (18 lb ft)
4. Install throttle body and tighten bolts to the specified
torque.
Torque : 25 N´m (18 lb ft)
5. Install ventilating hose to throttle valve and intake
duct.
6. Connect vacuum hoses on canister VSV and positive
crankcase ventilation hose. Tighten bolts for fuel rail
assembly with pressure control valve bracket.
Torque : 25 N´m (18 lb ft)

6A±24
ENGINE MECHANICAL (6VE1 3.5L)
Exhaust Manifold LH
Removal
1. Disconnect battery ground cable.
2. Disconnect O
2 sensor connector.
3. Remove exhaust front pipe three stud nuts from
exhaust side and two bolts from rear end of exhaust
front pipe.
150R100011
Legend
(1) Exhaust Front Pipe LH
(2) O
2 Sensor
4. Remove exhaust manifold eight fixing nuts and
remove exhaust manifold from the engine.
Installation
1. Install exhaust manifold and tighten exhaust manifold
fixing nuts to the specified torque with new nuts.
Torque: 57 N´m (42 lb ft)
2. Install exhaust front pipe and tighten three stud nuts
and two bolts to the specified torque.
Torque :
Stud nuts: 67 N´m (49 lb ft)
Bolts: 43 N´m (32 lb ft)
150R100011
Legend
(1) O
2 Sensor
(2) Exhaust Front Pipe LH
3. Reconnect O2 sensor connector.

6A±25
ENGINE MECHANICAL (6VE1 3.5L)
Exhaust Manifold RH
Removal
1. Disconnect battery ground cable.
2. Remove torsion bar. Refer to removal procedure in
Front Suspension section.
3. Remove exhaust front pipe three stud nuts and two
bolts then disconnect exhaust front pipe.
150R100013
Legend
(1) Exhaust Front Pipe RH
(2) O
2 Sensor
4. Remove exhaust manifold eight fixing nuts then the
exhaust manifold.
Installation
1. Install exhaust manifold and tighten nuts to the
specified torque.
Torque : 57 N´m (42 lb ft)
2. Install exhaust front pipe and tighten three stud nuts
and two bolts to the specified torque.
Torque:
Stud nuts: 67 N´m (49 lb ft)
Bolts: 43 N´m (32 lb ft)
3. Install the torsion bar and readjust the vehicle height.
Refer to installation and vehicle height adjustment
procedure for front suspension.

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.