engine ISUZU AXIOM 2002 Service Repair Manual

6C±10
ENGINE FUEL (6VE1 3.5L)
Fuel Pump Relay
General Description
In order to control the fuel pump and sender (FPS)
operation, the FPS relay is provided. When the starter
switch is turned to ªONº position, the FPS relay operates
the FPS for 2 seconds.
When the key is turned to ªSTARTº position, the Engine
Control Module receives the reference pulse from the
Ignition Control Module and it operates the relay, again
causing the FPS to feed fuel.
Fuel Tank
Fuel Tank and Associated Parts
140R200006
Legend
(1) Fuel Tank Assembly
(2) Fuel Tank Fixing Bolt (QTY: 5)
(3) Fuel Tank Fixing Nut (QTY: 1)
(4) Separator Fixing Bolt (QTY: 2)
(5) Fuel Filler Hose(6) Fuel Vent Hose
(7) Fuel Feed Hose
(8) Fuel Return Hose
(9) Vapor Pressure Sensor Connector
(10) Fuel Feed Pump Connector

6C±11 ENGINE FUEL (6VE1 3.5L)
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system
diagnosis, see Section ªDriveability and Emissionº.
1. Drain the fuel from the fuel tank, refer to the ªFuel
Pump Flow Testº in this section.
2. Disconnect battery ground cable.
3. Loosen fuel filler cap to reduce the pressure in fuel
tank.
4. Support underneath of the fuel tank assembly (1) with
a lifter.
5. Disconnect fuel feed hose (7) and fuel return hose (8)
near the fuel filter.
NOTE: Plug both ends of the fuel hoses to prevent fuel
leakage.
6. Disconnect fuel filler hose (5) and fuel vent hose (6) at
the fuel filler neck.
NOTE: Cover fuel hoses to prevent any dust entering.
7. Remove two bolts (4) and remove separator.
8. Remove the five fuel tank assembly fixing bolts (2)
and one nut (3).
9. Lower the tank and disconnect the wiring connectors
(9, 10).
Installation
1. Raise the fuel tank assembly (1) and connect the
wiring connectors (9, 10).
2. Install fuel tank assembly along with protectors and
tighten the five fixing bolts (2) and one nut (3) to the
specified torque.
Torque: 68 N´m (50 lb ft)
3. Install the separator and tighten two bolts (4).
Torque: 10 N´m (95 lb in)
4. Connect fuel filler hose (5) and fuel vent hose and clip
them firmly.
5. Connect fuel feed hose (7) and fuel return hose(8),
and clip them firmly.
6. Tighten fuel filler cap until at least three clicks are
heard.
7. Connect battery ground cable.

6C±12
ENGINE FUEL (6VE1 3.5L)
Fuel Gauge Unit
Removal and Installation
Refer to ªFuel Pumpº in this section for removal and
installation of the Fuel Gauge Unit, since the fuel gauge
unit is linked to the fuel pump and sender assembly.
Fuel Filler Cap
General Description
A vacuum valve and pressure valve are built into the fuel
filler cap which adjusts the fuel pressure in the fuel tank to
prevent fuel tank damage.
140R100029
Legend
(1) Vacuum Valve
(2) Pressure Valve
(3) Seal Ring
Inspection
The fuel filler cap must be inspected for seal condition.
The fuel filler cap must be replaced if found defective.
CAUTION:
A replacement fuel filler cap must be the same as the
original. The fuel filler cap valve was designed pri-
marily for this application and must be replaced with
the same type or decreased engine performance may
occur.

6C±13 ENGINE FUEL (6VE1 3.5L)
Main Data and Specifications
Torque Specification
140R200023
Special Tool
ILLUSTRATIONTOOL NO.
TOOL NAME
J±39765
Remover; fuel pump
retainer

ENGINE ELECTRICAL (6VE1 3.5L)6D1±1
AXIOM
ENGINE
ENGINE ELECTRICAL (6VE1 3.5L)
CONTENTS
Service Precaution 6D1±1. . . . . . . . . . . . . . . . . . . . . .
Battery 6D1±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6D1±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 6D1±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charging 6D1±3. . . . . . . . . . . . . . . . . . . . . . Jump Starting 6D1±3. . . . . . . . . . . . . . . . . . . . . . . . .
Battery Removal 6D1±4. . . . . . . . . . . . . . . . . . . . . .
Battery Installation 6D1±4. . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D1±5. . . . . . . . . . .
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.

6D1±2
ENGINE ELECTRICAL (6VE1 3.5L)
Battery
General Description
The battery is completely sealed except for the two small
vent holes (2) on the side. These vent holes (2) permit the
escape of small amounts of gas generated by the battery.
This type of battery has the following advantages over
conventional batteries:
1. There is no need to add water during the entire
service life of the battery.
2. The battery is much less vulnerable to self discharge
than a conventional type battery.
Diagnosis
1. Visual Inspection
Inspect the battery for obvious physical damage, such as
a cracked or broken case, which would permit electrolyte
loss.
Replace the battery if obvious physical damage is
discovered during inspection.
Check for any other physical damage and correct it as
necessary.
2. Hydrometer Check
There is a built±in hydrometer (Charge test indicator(1))
at the top of the battery. It is designed to be used during
diagnostic procedures.
Before trying to read the hydrometer, carefully clean the
upper battery surface.
If your work area is poorly lit, additional light may be
necessary to read the hydrometer.
a. BLUE RING OR DOT VISIBLE(4) ± Go to Step 3.
b. BLUE RING OR DOT NOT VISIBLE(3) ± Replace
the battery.
061R200001
3. Voltage Check
1. Put voltmeter test leads to battery terminals.
a. VOLTAGE IS 12.4V OR ABOVE ± Go to Step 4
Load Test.
b. VOLTAGE IS UNDER 12.4V ± Go to procedure (2)
below.
2. Determine fast charge amperage from specification.
(See Main Data and Specifications in this section).
Fast charge battery for 30 minutes at amperage rate
no higher than specified value.
Take voltage and amperage readings after charge.
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
AMPERAGE RATE ± Replace battery.
b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF
AMPERAGE RATE ± Drop charging voltage to 15V
and charge for 10 ± 15 hours. Then go to Step 4
Load Test.
c. VOLTAGE IS BETWEEN 12V AND 16V ±
Continue charging at the same rate for an
additional 3±1/2 hours. Then go to Step 4 Load
Test.
d. VOLTAGE BELOW 12V ± Replace the Battery.
4. Load Test
1. Connect a voltmeter and a battery load tester across
the battery terminals.
2. Apply 300 ampere load for 15 seconds to remove
surface charge from the battery. Remove load.
3. Wait 15 seconds to let battery recover. Then apply
specified load from specifications (See Main Data
and Specifications in this section).
Read voltage after 15 seconds, then remove load.
a. VOLTAGE DOES NOT DROP BELOW THE
MINIMUM LISTED IN THE TABLE ± The battery is
good and should be returned to service.
b. VOLTAGE IS LESS THAN MINIMUM LISTED ±
Replace the battery.
ESTIMATED TEMPERATURE
MINIMUM
VOLTAGE

F
CV
70219.6
60169.5
50109.4
4049.3
30±19.1
20±78.9
10±128.7
0±188.5
The battery temperature must be estimated by feel
and by the temperature the battery has been
exposed to for the preceding few hours.

ENGINE ELECTRICAL (6VE1 3.5L)6D1±3
Battery Charging
Observe the following safety precautions when charging
the battery:
1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during charging
procedure.
Battery charging should be discontinued or the rate of
charge reduced if the battery feels hot to the touch.
Battery charging should be discontinued or the rate of
charge reduced if the battery begins to gas or spew
electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue dot
or ring, it may be necessary to jiggle or tilt the battery.
4. Battery temperature can have a great effect on
battery charging capacity.
5. The sealed battery used on this vehicle may be either
quick charged or slow charged in the same manner as
other batteries.
Whichever method you decide to use, be sure that
you completely charge the battery. Never partially
charge the battery.
Jump Starting
Jump Starting with an Auxiliary (Booster)
Battery
CAUTION: Never push or tow the vehicle in an
attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.
Treat both the discharged battery and the booster
battery with great care when using jumper cables.
Carefully follow the jump starting procedure, being
careful at all times to avoid sparking.
WARNING: FAILURE TO CAREFULLY FOLLOW THE
JUMP STARTING PROCEDURE COULD RESULT IN
THE FOLLOWING:
1. Serous personal injury, particularly to your eyes.
2. Property damage from a battery explosion, battery
acid, or an electrical fire.
3. Damage to the electronic components of one or both
vehicles particularly.
Never expose the battery to an open flame or electrical
spark. Gas generated by the battery may catch fire or
explode.
Remove any rings, watches, or other jewelry before
working around the battery. Protect your eyes by wearing
an approved set of goggles.
Never allow battery fluid to come in contact with your eyes
or skin.Never allow battery fluid to come in contact with fabrics or
painted surfaces.
Battery fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes, skin,
fabric, or a painted surface, immediately and thoroughly
rinse the affected area with clean tap water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any other
metal surface of the vehicle. This will protect against a
short circuit.
Always keep batteries out of reach of young children.
Jump Starting Procedure
1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission, place the selector level in the ªPARKº
position.
If the vehicle is equipped with a manual transmission,
place the shift lever in the ªNEUTRALº position.
Turn ªOFFº the ignition.
Turn ªOFFº all lights and any other accessory
requiring electrical power.
2. Look at the built±in hydrometer.
If the indication area of the built±in hydrometer is
completely clear, do not try to jump start.
3. Attach the end of one jumper cable to the positive
terminal of the booster battery.
Attach the other end of the same cable to the positive
terminal of the discharged battery.
Do not allow the vehicles to touch each other. This will
cause a ground connection, effectively neutralizing
the charging procedure.
Be sure that the booster battery has a 12 volt rating.
4. Attach one end of the remaining cable to the negative
terminal of the booster battery.
Attach the other end of the same cable to a solid
engine ground (such as the air conditioning
compressor bracket or the generator mounting
bracket) of the vehicle with the discharged battery.
The ground connection must be at least 450 mm (18
in.) from the battery of the vehicle whose battery is
being charged.
WARNING: NEVER ATTACH THE END OF THE
JUMPER CABLE DIRECTLY TO THE NEGATIVE
TERMINAL OF THE DEAD BATTERY.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical accessories
have been turned ªOFFº.
6. Start the engine of the vehicle with the dead battery.

6D1±4
ENGINE ELECTRICAL (6VE1 3.5L)
7. To remove the jumper cables, follow the above
directions in reverse order.
Be sure to first disconnect the negative cable from the
vehicle with the discharged battery.
Battery Removal
061RX002
1. Remove negative cable (1).
2. Remove positive cable (2).
3. Remove retainer screw and rods (3).
4. Remove retainer (4).
5. Remove battery (5).
Battery Installation
1. Install battery (5).
2. Install retainer (4).
3. Install retainer screw and rods (3).
NOTE: Make sure that the rod is hooked on the body
side.
4. Install positive cable (2).
5. Install negative cable (1).

ENGINE ELECTRICAL (6VE1 3.5L)6D1±5
Main Data and Specifications
General Specifications
Model24R±600
Voltage (V)12
Cold±Cranking Performance (Amp)600
Reserve Capacity (Min)11 8
Load Test (Amp)300
BCI Group No.24

6D2±1
IGNITION SYSTEM (6VE1 3.5L)
AXIOM
ENGINE
IGNITION SYSTEM (6VE1 3.5L)
CONTENTS
Service Precaution 6D2±1. . . . . . . . . . . . . . . . . . . . . .
General Description 6D2±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 6D2±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Coil 6D2±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6D2±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D2±3. . . . . . . . . . . . . . . . . .
Installation 6D2±3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Plug 6D2±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 6D2±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D2±5. . . . . . . . . . . . . . . . . .
Installation 6D2±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Position Sensor 6D2±6. . . . . . . . . . . . . . .
Removal 6D2±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6D2±6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D2±7. . . . . . . . . . . . .
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.