torque ISUZU AXIOM 2002 Service Repair Manual

6A±88
ENGINE MECHANICAL (6VE1 3.5L)
Torque Specifications
Ignition coil, Spark plug, Crankshaft position sensor and Under cover
E06R100001

ENGINE COOLING (6VE1 3.5L)6B±1
AXIOM
ENGINE
ENGINE COOLING (6VE1 3.5L)
CONTENTS
Service Precaution 6B±1. . . . . . . . . . . . . . . . . . . . . .
General Description 6B±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 6B±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Refilling Cooling System 6B±5. . . . .
Water Pump 6B±6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump and Associated Parts 6B±6. . . . . . .
Removal 6B±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6B±6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6B±6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat 6B±7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat and Associated Parts 6B±7. . . . . . . .
Removal 6B±7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6B±7. . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 6B±7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator 6B±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator and Associated Parts 6B±8. . . . . . . . . .
Removal 6B±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6B±9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6B±10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Belt and Cooling Fan 6B±11. . . . . . . . . . . . . . .
Drive Belt and Associated Parts 6B±11. . . . . . . . .
Removal 6B±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6B±11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6B±11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6B±12. . . . . . . . . . . . .
Special Tool 6B±13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

6B±6
ENGINE COOLING (6VE1 3.5L)
Water Pump
Water Pump and Associated Parts
030RS002
Legend
(1) Timing Belt
(2) Idle Pulley(3) Water Pump Assembly
(4) Gasket
Removal
1. Disconnect battery ground cable.
2. Drain coolant.
3. Radiator hose (on inlet pipe side).
4. Remove timing belt. Refer to ªTiming Beltº in this
manual.
5. Remove Idle pulley.
6. Remove water pump assembly.
7. Remove gasket.
Inspection
Make necessary repair and parts replacement if extreme
wear or damage is found during inspection. Should any of
the following problems occur, the entire water pump
assembly must be replaced.

Crack in the water pump body

EC leakage from the seal unit

Play or abnormal noise in the bearing

Cracks or corrosion in the impeller
Installation
1. Install gasket, clean the mating surface of gasket
before installation.
2. Install water pump assembly and tighten bolts to the
specified torque.
Torque: 25 N´m (18 lb ft)

Tightening order
The tightening order are in the illustrate.NOTE: To prevent the oil leakage, apply the LOCTITE
262 or an equivalent, to the arrow marked fixing bolt
thread.
030RW008
3. Idle pulley

Install idle pulley and tighten bolt to the specified
torque.
Torque: 52 N´m (38 lb ft)
4. Timing belt

Install timing belt. Refer to timing belt installation
step in ªTiming Beltº in this manual.
5. Connect radiator inlet hose and replenish EC.
6. Connect battery ground cable.

ENGINE COOLING (6VE1 3.5L)6B±7
Thermostat
Thermostat and Associated Parts
031RW001
Legend
(1) Thermostat Housing
(2) Thermostat
(3) Outlet Pipe
Removal
1. Disconnect battery ground cable.
2. Drain engine coolant from the radiator and engine.
3. Disconnect radiator hose from the inlet pipe.
4. Remove thermostat housing.
5. Remove thermostat(2).
Inspection
Suspend the thermostat in a water±filled container using
thin wire. Place a thermometer next to the thermostat.
Do not directly heat the thermostat.
Gradually increase the water temperature. Stir the water
so that the entire water is same temperature.
031RS003Confirm the temperature when the valve first begins to
open.
Valve opening temperature 74.5C ~ 78.5
C
(166.1
F ~ 173.3
F)
Confirm the temperature when the valve is fully opened.
Valve full open temperature and lift More than
8.5mm (0.33 in) at 90
C (194
F)
Make necessary repair and parts replacement if extreme
wear or damage is found during inspection.
Installation
1. Install thermostat into the outlet pipe(4) making sure
that the air hole is in the up position.
2. Install thermostat housing and tighten bolts to the
specified torque.
Torque: 25 N´m (18 lb ft)
3. Installation rubber hose.
4. Replenish engine coolant (EC).
5. Start engine and check for EC leakage.

ENGINE COOLING (6VE1 3.5L)6B±11
Drive Belt and Cooling Fan
Drive Belt and Associated Parts
015RW005
Legend
(1) Crankshaft Pulley
(2) Generator
(3) Power Steering Pump(4) Water Pump and Cooling Fan Pulley
(5) Idle Pulley
(6) Tension Pulley
(7) Drive Belt
The drive belt adjustment is not required as automatic
drive belt tensioner is equipped.
Removal
Move the tension pulley drive belt loosen side, remove the
drive belt.
Inspection
Check drive belt for wear or damage, and replace with a
new one as necessary.
Installation
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.

6B±12
ENGINE COOLING (6VE1 3.5L)
Main Data and Specifications
General Specifications
A/T
Cooling systemEngine coolant forced circulation
RadiatorTube type corrugated (2 tube in row)
Heat radiation capacity85,500 kcal/h
Heat radiation area14.02m
(150.9ft
)
Radiator front area0.263m
(2.83ft
)
Radiator dry weight56N (12.6lb)
Radiator cap valve opening pressure93.3 ~ 122.7kpa (13.5 ~ 17.8psi)
Engine coolant capacity2.4lit (0.6 US gal)
Engine coolant pumpCentrifugal impeller type
Delivery300 (317) or more
Pump speed5000 + 50 rpm
ThermostatWax pellet type with air hole
Valve opening temperature74.5 ~ 78.5
C (166.1 ~ 173.3
F)
Engine coolant total capacity10.0lit (2.64 US gal)
Torque Specifications
E06RW004

6C±1 ENGINE FUEL (6VE1 3.5L)
AXIOM
ENGINE
ENGINE FUEL
CONTENTS
Service Precaution 6C±1. . . . . . . . . . . . . . . . . . . . . .
General Description 6C±2. . . . . . . . . . . . . . . . . . . . .
Fuel Metering 6C±3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Filter 6C±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6C±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6C±4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6C±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
In±Tank Fuel Filter 6C±5. . . . . . . . . . . . . . . . . . . . .
Fuel Pump Flow Test 6C±5. . . . . . . . . . . . . . . . . . .
Fuel Pump 6C±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump and Associated Parts 6C±6. . . . . . . .
Removal 6C±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C±7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tube / Quick ± Connector Fittings 6C±8. . . . .
Precautions 6C±8. . . . . . . . . . . . . . . . . . . . . . . . . . .
Cautions During Work 6C±8. . . . . . . . . . . . . . . . . . Removal 6C±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reuse of Quick±Connector 6C±9. . . . . . . . . . . . .
Assembling Advice 6C±9. . . . . . . . . . . . . . . . . . . .
Fuel Pump Relay 6C±10. . . . . . . . . . . . . . . . . . . . . . . .
General Description 6C±10. . . . . . . . . . . . . . . . . . . .
Fuel Tank 6C±10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank and Associated Parts 6C±10. . . . . . . . .
Removal 6C±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6C±11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Gauge Unit 6C±12. . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation 6C±12. . . . . . . . . . . . . . .
Fuel Filler Cap 6C±12. . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6C±12. . . . . . . . . . . . . . . . . . . .
Inspection 6C±12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6C±13. . . . . . . . . . . . .
Special Tool 6C±13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

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±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.