torque ISUZU AXIOM 2002 Service Repair Manual

6A±43
ENGINE MECHANICAL (6VE1 3.5L)

Apply engine oil to oil seal lip.

Install oil pump in the cylinder block and tighten
fixing bolts to the specified torque.
Torque : 25 N´m (18 lb ft)
051RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin
051RW001
9. Install oil strainer with O-ring, tighten to the specified
torque.
Torque : 25 N´m (18 lb ft)
10. Install oil pipe with O-ring, tighten fixing bolts to the
specified torque.
Torque : 25 N´m (18 lb ft)
11. Install crankcase.

Remove oil on crankcase mounting surface and dry
the surface.
Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB1207C or equivalent) to the crankcase
mounting surface. The bead must be continuous.

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

Tighten fixing bolts to the specified torque.
Torque : 10 N´m (87 lb in)
013RW010
013RW004
12. Install oil pan

Remove oil on oil pan mounting surface and dry the
surface.

Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB1207C or equivalent) to the oil pan
mounting surface. The bead must be continuous.

The oil pan must be installed within 5 minutes after
sealant application to prevent premature hardening
of sealant.

6A±44
ENGINE MECHANICAL (6VE1 3.5L)

Tighten fixing bolts to the specified torque.
Torque : 25 N´m (18 lb ft)
013RW003
013RW002
13. Install timing belt.

Refer to installation procedure for Timing Belt in this
manual.
14. Install engine assembly.

Refer to installation procedure for Engine
Assembly in this manual.

6A±45
ENGINE MECHANICAL (6VE1 3.5L)
Rear Oil Seal
Removal
1. Remove transmission assembly.

See Transmission section in this manual.
2. Remove flywheel.
3. Remove rear oil seal using a seal remover.
NOTE: Take care not to damage the crankshaft or oil seal
retainer when removing oil seal.
Installation
1. Apply engine oil to oil seal lip and install oil seal using
J-39201.
015RS017
2. Install flywheel.

Clean tapped holes in the crankshaft.

Remove oil on the crankshaft and flywheel
mounting surface.

Tighten fixing bolts to the specified torque.
NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
Torque : 54 N´m (40 lb ft)
015RS018
3. Install transmission.

See Transmission section in this manual.
CAUTION: W h e n assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side.
NOTE: Take care that dowel positions are different
between the manual transmission and the automatic
transmission.
Otherwise, the transmission may be damaged.
012RS009

6A±47
ENGINE MECHANICAL (6VE1 3.5L)
Installation
CAUTION: W h e n assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side.
NOTE: Take care that dowel positions are different
between the manual transmission and the automatic
transmission.
If the engine is assembled in the condition that the dowels
have not been mounted in the specified positions, the
transmission may be damaged.
012RS009
1. Install engine assembly. Tighten engine mount fixing
bolts to frame to the specified torque.
Torque: 41 N´m (30 lb ft)
2. Reconnect fuel hose to fuel pipe on engine.
3. Install transmission assembly. Refer to Transmission
section in this manual.
4. Reconnect two heater hoses to engine.
5. Install flywheel dust covers.
6. Install exhaust pipe and temporally tighten two (each
bank) rear exhaust flange nuts then tighten three stud
nuts (each bank) between exhaust manifold and
exhaust pipe, finally tighten rear side nuts to the
specified torque.
Torque:
Nuts: 43 N´m (32 lb ft)
Stud nuts: 67 N´m (49 lb ft)
150R200002
Legend
(1) Exhaust Front Pipe RH
(2) O
2 Sensor
150R200003
Legend
(1) O
2 Sensor
(2) Exhaust Front Pipe LH
7. Reconnect O2 sensor connector.
8. 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.

6A±48
ENGINE MECHANICAL (6VE1 3.5L)
9. Install air conditioner compressor to engine and
tighten to the specified torque.
Torque :
M8 bolts : 22 N´m (16 lb ft)
M10 bolts : 43 N´m (32 lb ft)
10. Install power steering pump, tighten fixing bolt to the
specified torque.
Torque :
M8 bolts : 22N´m (16 lb ft)
M10 bolts : 46 N´m (34 lb ft)
11. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
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) Drive Belt
12. Install upper fan shroud.
13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back of right
dash panel.
19. Reconnect ground cable between engine and
chassis.
20. Reconnect harness connector to transmission and
install transmission harness bracket on engine left
side.
21. Reconnect three engine harness connectors.
22. Reconnect vacuum booster hose.
23. Reconnect canister vacuum hose.24. Install air cleaner assembly.
25. Reconnect air duct.
26. Reconnect throttle position sensor harness
connector.
025RY001
Legend
(1) Throttle Position Sensor Connector
(2) Throttle Valve Assembly
27. Reconnect manifold absolute pressure sensor
harness connectors.
28. Reconnect ion sensing module connectors as shown
in the illustration.
060RY00111
Legend
(1) Green Connector
(2) Blue Connector
(3) Identification Mark (6VE1 Engine Only)
29. Install engine hood to the original position.

Refer to installation procedure for Body section in
this manual.

6A±50
ENGINE MECHANICAL (6VE1 3.5L)
Disassembly
NOTE:

During disassembly, be sure that the valve train
components are kept together and identified so that
they can be reinstalled in their original locations.

Before removing the cylinder head from the engine
and before disassembling the valve mechanism,
perform a compression test and note the results.
1. Remove camshaft drive gear pulley fixing bolt (3),
then pulley (4).
2. Remove camshaft bearing cap fixing bolt (5),
camshaft bearing cap (6), then camshaft exhaust (7),
and intake side (8).
3. Remove tappet with shim (11).
4. Use the J±8062 valve spring compressor and
J±42898 valve spring compressor adapter to remove
the split collar (12), valve spring with upper seat (13)
and valve (14).
014RW042
5. Remove spark plug (1).
CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use surface conditioning disc on any
gasket sealing surface.
Inspection and Repair
1. Inspect cylinder head gasket and mating surfaces for
leaks, corrosion and blow±by. If the gasket has failed,
determine the cause.
± Insufficient torque on head bolts
± Improper installation
± Loose or warped cylinder head
± Missing dowel pins
± Warped case surface
2. Inspect cylinder head for cracks, especially between
valve seats and in the exhaust ports.
3. Inspect cylinder head deck for corrosion, sand
particles in head and porosity.
CAUTION:

Do not attempt to weld the cylinder head. Replace
it.

Do not reuse cylinder head bolts.
4. Inspect cylinder head deck, common chamber and
exhaust manifold mating surfaces for flatness. These
surfaces may be reconditioned by milling. If the
surfaces are ªout of flatº with ªroundº by more than
specification, the surface should be ground to within
specifications. Replace the head if it requires
machining beyond the repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362 in)
011RW019
5. Water jacket sealing plugs seating surfaces.

6A±51
ENGINE MECHANICAL (6VE1 3.5L)
Reassembly
1. Install Spark plug and tighten all the spark plugs to
specified torque.
Torque: 18 N´m (13 lb ft)
2. Tighten sub gear setting bolt.
1. Use J±42686 gear spring lever to turn sub gear to
right direction until the M5 bolt aligns with the hole
between camshaft driven gear and sub gear.
2. Tighten the M5 bolt to a suitable torque to prevent
the sub gear from moving.
014RW025
3. Install camshaft drive gear assembly and tighten
three bolts to the specified torque.
Torque: 10 N´m (87 lb in)
4. Install camshaft assembly and camshaft bearing cap,
tighten twenty bolts on one side bank to the specified
torque.
1. Apply engine oil to camshaft journal and bearing
surface of camshaft bearing cap.
2. Align timing mark on intake camshaft (one dot for
right bank, two dots for left bank) and exhaust
camshaft (one dot for right bank, two dots for left
bank) to timing mark on camshaft drive gear (one
dot).
014RW020
Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discrimination Mark
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust
014RW023
Legend
(1) Right Bank Camshaft Drive Gear
(2) Left Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin

6A±52
ENGINE MECHANICAL (6VE1 3.5L)
014RW024
Legend
(1) Right Bank
(2) Left Bank(3) Alignment Mark on Camshaft Drive Gear
(4) Alignment Mark on Camshaft
(5) Alignment Mark on Retainer
3. Tighten twenty bolts in numerical order on each
bank as shown in the illustration.
Torque: 10 N´m (87 lb in)
014RW031
5. Tighten bolt for camshaft drive gear assembly pulley
to the specified torque.
Torque: 98 N´m (72 lb ft)

6A±62
ENGINE MECHANICAL (6VE1 3.5L)
3. Place the camshaft on V±blocks.
Slowly rotate the camshaft and measure the runout
with a dial indicator.
Replace the camshaft if the runout exceeds the
specified limit.
Runout
Limit : 0.1 mm (0.0039 in)
014RW044
4. Measure the camshaft journal oil clearance.
1. Measure the camshaft bracket housing inside
diameter.
NOTE: Tighten camshaft bracket (2) to specified torque
before measuring the camshaft bracket inside diameter.
Torque : 10 N´m (89 lb in)
014RW031
2. Subtract the camshaft outside diameter from the
camshaft bracket housing inside diameter.
Oil Clearance
Standard : 0.027 mm±0.078 mm
(0.0011 in±0.0031 in)
Limit : 0.11 mm (0.0043 in)
014RW037
5. Replace the cylinder head and/or camshaft if the
measured oil clearance exceeds the specified limit.
1. Carefully clean the camshaft journal, the
camshaft bracket, and the cylinder head.
2. Install camshaft assembly and camshaft brackets
(2), tighten twenty bolts (1) on one side bank to
the specified torque.
Torque: 10 N´m (89 lb in)
014RW031

6A±63
ENGINE MECHANICAL (6VE1 3.5L)
3. Measure the camshaft thrust clearance with a dial
indicator. Replace the camshaft and/or the
cylinder head if the camshaft thrust clearance
exceeds the specified limit.
Camshaft thrust Clearance
Standard : 0.03 mm±0.08 mm
(0.0012 in.±0.0031 in.)
Limit : 0.12 mm (0.0047 mm)
014RW035
Reassembly
1. Install camshaft drive gear assembly and tighten
three bolts to specified torque.
Torque: 10 N´m (89 lb in)
2. Install the spring ; camshaft gear(1) into the camshaft
assembly.
Ensure the clearance is between the right side of the
spring; camshaft gear (1) and the dowel pin (2).
014R100017
3. Align the dowel pin on the sub gear to the clearance of
the spring ; camshaft gear made in step 2 and install
the sub gear (3).
4. Install the wave washer (2). Use snap ring pliers to
install the snap ring (1).
014R100018
5. Tighten sub gear setting bolt.
a. Use J±42686 gear spring lever to pre-load the sub
gear. Turn the sub gear in a clockwise direction
until the M5 bolt hole aligns with the hole in the
camshaft driven gear.
b. Install the M5 bolt and tighten to a suitable torque to
prevent the sub gear from moving.
014RW041
6. Align the timing mark on the retainer and dowel pin of
the camshaft drive gear.
7. Install camshaft assembly and camshaft brackets,
tighten twenty bolts on one side bank to the specified
torque.