torque ISUZU AXIOM 2002 Service Repair Manual

6D3±24
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
1. Using a press with a socket wrench attached,
reassemble rotor and rear end cover assembly in the
front cover.
066RS022
2. Install pulley on the rotor.
Secure the pulley directly in the vise between two
copper plates, and tighten nut to the specified torque.
Torque: 111 N´m (82 lb ft)
066RS010
Bench Test
Conduct a bench test of the generator.
066RS023
Preparation
Remove generator from the vehicle (see ªGenerator
removalº).
1. Secure generator to the bench test equipment and
connect wires.
Terminal ªIGº for energization
Terminal ªLº for neutral (warning lamp)
Terminal ªBº for output
2. Conduct the generator characteristic test.
Characteristics of generator are shown in illustration.
Repair or replace the generator if its outputs are
abnormal.
066RX001

6E±509
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Surges and/or Chuggles Symptom

StepActionValue(s)Ye sNo
1DEFINITION:
Engine power variation under steady throttle or cruise.
Feels like the vehicle speeds up and slows down with
no change in the accelerator pedal.
Was the ªOn-Board Diagnostic (OBD) System Checkº
performed?
ÐGo to Step 2
Go to OBD
System
Check
2Was the ªElectric Throttle Control (ETC) System
Checkº performed?
ÐGo to Step 3
Go to ETC
System
Check
31. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom?
ÐVerify repairGo to Step 4
4Was a visual/physical check performed?
ÐGo to Step 5
Go to Visual/
Physical
Check
5Be sure that the driver understands transmission
torque converter clutch and A/C compressor operation
as explained in the owner's manual.
Inform the customer how the TCC and the A/C clutch
operate.
Is the customer experiencing a normal condition?
ÐSystem OKGo to Step 6
61. Check the fuel control heated oxygen sensors
(HO2S, B1S1 and B2S1). The fuel control heated
oxygen sensors (HO2S) should respond quickly to
different throttle positions. If they don't, check them
for silicone or other contaminants from fuel or use of
improper RTV sealant. The sensors may have a
white powdery coating.
Silicon contamination causes a high but false
HO2S signal voltage (rich exhaust indication).
The PCM will then reduce the amount of fuel
delivered to the engine, causing a severe
driveability problem. For more information, refer
to
Powertrain Control Module (PCM) and Sensors.
2. If a problem is found, repair as necessary.
Was a problem found?
ÐVerify repairGo to Step 7
71. Check the fuel pressure. Refer to Fuel System
Pressure Test
.
2. If a problem is found, repair as necessary.
Was a problem found?
ÐVerify repairGo to Step 8
8Monitor the long term fuel trim on the Tech 2.
Is the long term fuel trim significantly in the negative
range (rich condition)?
ÐGo to Step 9Go to Step 10
91. Check items that can cause the engine to run rich.
Refer to
Diagnostic Aids in DTC P0172 Diagnostic
Support
.
2. If a problem is found, repair as necessary.
Was a problem found?
ÐGo to Step 11Verify repair

6E±513
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Lack of Power, Sluggish, or Spongy Symptoms

 
StepNo Ye s Value(s) Action
101. Remove the spark plugs and check for wet plugs,
cracks, wear, improper gap, burned electrodes, or
heavy deposits. Refer to
Electronic Ignition
System
.
NOTE: If spark plugs are gas or oil fouled, the cause of
the fouling must be determined before replacing the
spark plugs.
2. If a problem is found, repair as necessary.
Was a problem found?
ÐVerify repairGo to Step 11
111. Check the ignition coils for cracks or carbon
tracking.
2. If a problem is found, repair as necessary.
Was a problem found?
ÐVerify repairGo to Step 12
121. Check the PCM grounds for cleanliness, tightness
and proper locations. Refer to the PCM wiring
diagrams in
Electrical Diagnosis.
2. If a problem is found, repair as necessary.
Was a problem found?
ÐVerify repairGo to Step 13
131. Check the exhaust system for possible restriction:

Inspect the exhaust system for damaged or
collapsed pipes.

Inspect the muffler for heat distress or possible
internal failure.

Check for a possible plugged three-way
catalytic converter by checking the exhaust
system back pressure. Refer to
Restricted
Exhaust System Check
.
2. If a problem is found, repair as necessary.
Was a problem found?
ÐVerify repairGo to Step 14
141. Check the torque converter clutch (TCC) for proper
operation. Refer to
4L30-E Transmission
Diagnosis
.
2. If a problem is found, repair as necessary.
Was a problem found?
ÐVerify repairGo to Step 15
151. Check for an engine mechanical problem. Check
for low compression, incorrect or worn camshaft,
loose timing belt, etc. Refer to
Engine Mechanical.
2. If a problem is found, repair as necessary.
Was a problem found?
ÐVerify repairGo to Step 16
161. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:

Visual/physical inspection

Tech 2 data

Freeze Frame data/Failure Records buffer

All electrical connections within a suspected
circuit and/or system.
3. If a problem is found, repair as necessary.
Was a problem found?
ÐVerify repair
Contact
Technical
Assistance

6E±560
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Electronic Ignition System
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the ignition coil connector at the ignition
coil assemblies.
3. Remove the two screws that secure the ignition coil
assemblies to the rocker cover.
060RY022
Legend
(1) Ignition Coil Connectors
(2) Bolts
(3) Ignition Coil Assemblies
4. Remove the ignition coil assemblies and the spark
plug boot from the spark plug.

Twist the ignition coil assemblies while pulling it
straight up.
5. Use the appropriate spark plug socket in order to
remove the spark plug from the engine.
Installation Procedure
NOTE: The plug must thread smoothly into the cylinder
head and be fully seated. Use a thread chaser if
necessary to clean the threads in the cylinder head.
Cross-threading or failure to fully seat the spark plug can
cause plug overheating, exhaust blow-by gases, or
thread damage. Do not overtighten the spark plugs. Over
tightening can cause aluminum threads to strip.
1. Install the spark plug in the engine. Use the
appropriate spark plug socket.
Tighten

Tighten the spark plug to 18 N´m (13 lb ft.).
2. Install the ignition coil assemblies and spark plug boot
over the spark plug.CAUTION: Ignition coil assembly #6 is different
from ignition coil assembly #1 to #5. Ignition coil
assemblies #6 is short type. Be careful 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)
3. Install ignition coil assemblies and tighten the fixing
bolts to the specified torque.
Torque: 4 N´m (35.4 Ib in)
060RY022
Legend
(1) Ignition Coil Connectors
(2) Bolts
(3) Ignition Coil Assemblies
4. Connect the ignition coil connector at the ignition coil
assemblies.
5. Connect the negative battery cable.

6E±565
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Fuel Tank Vent Valve
(Vent Solenoid Valve)
Removal and Installation Procedure
Refer to Fuel Pump section.
Linear Exhaust Gas
Recirculation (EGR) Valve
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector at the EGR valve.
014RW139
3. Remove the bolts from the common chamber.
014RW098
4. Remove the EGR valve from the common chamber
manifold.
5. Remove the gasket from the common chamber
manifold.
Installation Procedure
1. Install the gasket on the common chamber.
2. Install the EGR valve on the common chamber.
3. Secure the EGR valve and the gasket with the bolts.
Torque: 25 N´m (18 Ib ft)
NOTE: It is possible to install the EGR valve rotated 180

from the correct position. Make sure that the base of the
valve is placed so that it aligns with the mounting flange.
014RW098
4. Connect the electrical connector at the EGR valve.
014RW139
5. Connect the negative battery cable.

6E±582
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Crankshaft position (CKP) sensor.
Spark Plug
Although worn or dirty spark plugs may give satisfactory
operation at idling speed, they frequency fail at higher
engine speeds. Faulty spark plugs may cause poor fuel
economy, power loss, loss of speed, hard starting and
generally poor engine performance. Follow the
scheduled maintenance service recommendations to
ensure satisfactory spark plug performance. Refer to
Maintenance and Lubrication section.
Normal spark plug operation will result in brown to
grayish-tan deposits appearing on the insulator portion of
the spark plug. A small amount of red-brown, yellow, and
white powdery material may also be present on the
insulator tip around the center electrode. These deposits
are normal combustion by-products of fuels and
lubricating oils with additives. Some electrode wear will
also occur. Engines which are not running properly are
often referred to as ªmisfiring.º This means the ignition
spark is not igniting the air/fuel mixture at the proper time.
While other ignition and fuel system causes must also be
considered, possible causes include ignition system
conditions which allow the spark voltage to reach ground
in some other manner than by jumping across the air gap
at the tip of the spark plug, leaving the air/fuel mixture
unburned. Refer to
DTC P0300. Misfiring may also occur
when the tip of the spark plug becomes overheated and
ignites the mixture before the spark jumps. This is
referred to as ªpre-ignition.º
Spark plugs may also misfire due to fouling, excessive
gap, or a cracked or broken insulator. If misfiring occurs
before the recommended replacement interval, locate
and correct the cause.
Carbon fouling of the spark plug is indicated by dry, black
carbon (soot) deposits on the portion of the spark plug in
the cylinder. Excessive idling and slow speeds under
light engine loads can keep the spark plug temperatures
so low that these deposits are not burned off. Very rich
fuel mixtures or poor ignition system output may also be
the cause. Refer to DTC P0172.
Oil fouling of the spark plug is indicated by wet oily
deposits on the portion of the spark plug in the cylinder,
usually with little electrode wear. This may be caused by
oil during break-in of new or newly overhauled engines.
Deposit fouling of the spark plug occurs when the normal
red-brown, yellow or white deposits of combustion by
products become sufficient to cause misfiring. In some
cases, these deposits may melt and form a shiny glaze on
the insulator around the center electrode. If the fouling is
found in only one or two cylinders, valve stem clearances
or intake valve seals may be allowing excess lubricating
oil to enter the cylinder, particularly if the deposits are
heavier on the side of the spark plug facing the intake
valve.
TS23995Excessive gap means that the air space between the
center and the side electrodes at the bottom of the spark
plug is too wide for consistent firing. This may be due to
improper gap adjustment or to excessive wear of the
electrode during use. A spark plug gap that is too small
may cause an unstable idle condition. Excessive gap
wear can be an indication of continuous operation at high
speeds or with engine loads, causing the spark to run too
hot. Another possible cause is an excessively lean fuel
mixture.
TS23992Low or high spark plug installation torque or improper
seating can result in the spark plug running too hot and
can cause excessive center electrode wear. The plug
and the cylinder head seats must be in good contact for
proper heat transfer and spark plug cooling. Dirty or
damaged threads in the head or on the spark plug can
keep it from seating even though the proper torque is
applied. Once spark plugs are properly seated, tighten
them to the torque shown in the Specifications Table. Low
torque may result in poor contact of the seats due to a
loose spark plug. Overtightening may cause the spark
plug shell to be stretched and will result in poor contact

6F±1
ENGINE EXHAUST (6VE1 3.5L)
AXIOM
ENGINE
ENGINE EXHAUST (6VE1 3.5L)
CONTENTS
Service Precaution 6F±1. . . . . . . . . . . . . . . . . . . . . .
General Description 6F±2. . . . . . . . . . . . . . . . . . . . .
Three Way Catalytic Converter RH and
Forked Exhaust Pipe 6F±3. . . . . . . . . . . . . . . . . . . .
Three Way Catalytic Converter RH and
Forked Exhaust Pipe and Associated Parts 6F±3
Removal 6F±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6F±3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Three Way Catalytic Converter LH and
Forked Exhaust Pipe 6F±4. . . . . . . . . . . . . . . . . . . .
Three Way Catalytic Converter LH and
Forked Exhaust Pipe and Associated Parts 6F±4
Removal 6F±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6F±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . Forked Exhaust Pipe 6F±5. . . . . . . . . . . . . . . . . . . .
Forked Exhaust Pipe and Associated
Parts 6F±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6F±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6F±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Silencer 6F±6. . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Silencer and Associated Parts 6F±6. . .
Removal 6F±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6F±6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Exhaust pipe 6F±7. . . . . . . . . . . . . . . . . . . . . . .
Rear Exhaust pipe and Associated Parts 6F±7.
Removal 6F±7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6F±7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6F±8. . . . . . . . . . . . .
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.

6F±3
ENGINE EXHAUST (6VE1 3.5L)
Three Way Catalytic Converter RH and Forked Exhaust Pipe
Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated
Parts
150RY00003
Legend
(1) Front Exhaust Pipe Assembly Fixing Nuts
(2) O
2 Sensor Terminal Connector
(3) Three Way Catalytic Converter RH
(4) Mounting Rubber
(5) Forked Exhaust Pipe Fixing Bolts(6) O
2 Sensor Terminal Connector
(7) Forked Exhaust Pipe
(8) Forked Exhaust Pipe Fixing Nuts
(9) Exhaust Silencer Fixing Nuts
(10) Forked Exhaust Pipe Fixing Bolts
Removal
1. Disconnect battery ground cable.
2. Lift up the vehicle and support with suitable safety
stands.
3. Disconnect O
2 sensor harness connectors (2) (6).
4. Remove the forked exhaust pipe fixing bolts and nuts
(5) (8) (10) and the exhaust silencer fixing nuts (9),
then remove the forked exhaust pipe (7) and the
mass damper.
5. Remove the front exhaust pipe assembly fixing nuts
(1) and the mounting rubber (4), then remove the
three way catalytic converter (3).
Installation
1. Install the three way catalytic converter (3) and the
mounting rubber (4), and tighten the fixing nuts (1) to
the specified torque.
Torque
Nuts : 67 N´m (49 lb ft)
2. Install the forked exhaust pipe (7), and tighten the
fixing bolts (5) & nuts (8) (9) to the specified torque.
Torque
Bolts&Nuts : 43 N´m (32 lb ft)
Nuts : 43 N´m (32 lb ft)
3. Connect the O
2 sensor connectors (2) (6).

6F±4ENGINE EXHAUST (6VE1 3.5L)
Three Way Catalytic Converter LH and Forked Exhaust Pipe
Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated
Parts
150RY00004
Legend
(1) Forked Exhaust Pipe Fixing Bolts
(2) Forked Exhaust Pipe
(3) Forked Exhaust Pipe Fixing Nuts
(4) Exhaust Silencer Fixing Nuts
(5) Forked Exhaust Pipe Fixing Bolts(6) Mounting Rubber
(7) O
2 Sensor Terminal Connector
(8) Three Way Catalytic Converter LH
(9) O
2 Sensor Terminal Connector
(10) Front Exhaust Pipe Assembly Fixing Nuts
Removal
1. Disconnect battery ground cable.
2. Lift up the vehicle and support with suitable safety
stands.
3. Disconnect O
2 sensor harness connectors (7) (9).
4. Remove the forked exhaust pipe fixing bolts and nuts
(1) (3) (5) and the exhaust silencer fixing nuts (4), then
remove the forked exhaust pipe (2).
5. Remove the front exhaust pipe assembly fixing nuts
(10) and the mounting rubber (6), then remove the
three way catalytic converter (8).
Installation
1. Install the three way catalytic converter (8) and the
mounting rubber (6), and tighten the fixing nuts (10) to
the specific torque.
Torque
Nuts: 67 N´m (49 lb ft)
2. Install the forked exhaust pipe (2) and tighten the
fixing bolts (1) (5) and nuts (3) (4) to the specified
torque.
Torque
Bolts&Nuts: 43 N´m (32 lb ft)
Nuts: 43 N´m (32 lb ft)
3. Connect the O
2 sensor connectors (7) (9).

6F±5
ENGINE EXHAUST (6VE1 3.5L)
Forked Exhaust Pipe
Forked Exhaust Pipe and Associated Parts
150RY00005
Legend
(1) Forked Exhaust Pipe Fixing Bolts
(2) Forked Exhaust Pipe(3) Forked Exhaust Pipe Fixing Nuts
(4) Exhaust Silencer Fixing Nuts
(5) Forked Exhaust Pipe Fixing Bolts
Removal
1. Disconnect battery ground cable.
2. Lift up the vehicle and support with suitable safety
stands.
3. Remove the forked exhaust pipe fixing bolts & nuts
(1) (3) (5) and the exhaust silencer fixing nuts (4), then
remove the forked exhaust pipe (2).
Installation
1. Install the forked exhaust pipe (2), and tighten the
fixing bolts (1) (5) and the nuts (3) (4) to the specified
torque.
Torque
Bolts&nuts : 43 N´m (32 lb ft)
Nuts : 43 N´m (32 lb ft)