torque ISUZU AXIOM 2002 Service Repair Manual

6F±6ENGINE EXHAUST (6VE1 3.5L)
Exhaust Silencer
Exhaust Silencer and Associated Parts
150RY00006
Legend
(1) Forked Exhaust Pipe
(2) Support Rubber Fixing Nuts(3) Exhaust Silencer
(4) Exhaust Silencer Fixing Nuts
(5) Rear Exhaust Pipe Fixing Nuts
Removal
1. Disconnect battery ground cable.
2. Lift up the vehicle and support with suitable safety
stands.
3. Remove the support rubber fixing nuts (2), the
exhaust silencer fixing nuts (4) and rear exhaust pipe
fixing nuts (5), then remove the exhaust silencer (3).
Installation
1. Install the exhaust silencer (3) and tighten the fixing
nuts (4) (5) to the specified torque.
Torque
Nuts: 43 N´m (32 lb ft)
2. Tighten the support rubber fixing nuts (2) to the
specified torque.
Torque
Bolts: 15 N´m (11 lb ft)

6F±7
ENGINE EXHAUST (6VE1 3.5L)
Rear Exhaust pipe
Rear Exhaust pipe and Associated
Parts
150RW028
Legend
(1) Mounting Rubber
(2) Rear Exhaust Pipe Fixing Nuts
(3) Mounting Rubber
(4) Rear Exhaust Pipe
Removal
1. Disconnect battery ground cable.
2. Lift up the vehicle and support with suitable safety
stands.
3. Remove the rear exhaust fixing nuts (2) and the
mounting rubbers (1) (3), then remove the rear
exhaust pipe (4).
Installation
1. Install the rear exhaust pipe (4) and the mounting
rubbers (1) (3), then tighten the fixing nuts (2) to the
specified torque.
Torque
Nuts: 43 N´m (32 lb ft)

6F±8ENGINE EXHAUST (6VE1 3.5L)
Main Data and Specifications
Torque Specifications
150RY00007

6G±1
ENGINE LUBRICATION (6VE1 3.5L)
AXIOM
ENGINE
ENGINE LUBRICATION (6VE1 3.5L)
CONTENTS
Service Precaution 6G±1. . . . . . . . . . . . . . . . . . . . . .
General Description 6G±2. . . . . . . . . . . . . . . . . . . . .
Oil Pump 6G±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump and Associated Parts 6G±3. . . . . . . . . .
Disassembly 6G±4. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6G±4. . . . . . . . . . . . . . . . . .
Reassembly 6G±5. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pan and Crankcase 6G±7. . . . . . . . . . . . . . . . . .
Removal 6G±7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6G±7. . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump 6G±9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6G±9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6G±9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Oil Seal 6G±11. . . . . . . . . . . . . . . . . . . . . . .
Removal 6G±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6G±11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter 6G±12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6G±12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6G±12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specification 6G±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.

6G±5
ENGINE LUBRICATION (6VE1 3.5L)

Measure the side clearance with a precision straight
edge and a feeler gauge.
Clearance
Standard : 0.03 mm±0.09 mm
(0.0011 in±0.0035 in)
Limit : 0.15mm (0.0059 in)
051RS005
Oil Strainer
Check the oil strainer for cracking and scoring. If cracking
and scoring are found, the oil strainer must be replaced.
051RS006
Reassembly
1. Install drive gear (11).
2. Install driven gear (10).
3. Install oil pump cover (9) and first, loosely tighten all of
the attaching screws. Next, tighten the attaching
screws to the specified torque.
Torque : 10 N´m (87 lb in)
After installation, check that the gear rotates
smoothly.4. Install relief valve (8) and apply engine oil to the relief
valve and spring (7).
5. Install spring (7).
6. Install the plug (6).
Torque : 8 N´m (69 lb in)
051RS007
7. Install oil pump assembly (5).

Carefully remove any oil from the cylinder body and
the pump. Apply sealant (TB±1207B or equivalent)
to the pump fitting face as shown in illustration. Take
care that sealant is not applied to oil port surfaces.
The oil pump assembly must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.
CAUTION: Do not apply an excessive amount of
sealant to the contact surface. Applying too much
sealant will overflow the contact surfaces. This
could cause serious damage to the engine.

Attach oil pump assembly to cylinder body.

Tighten the oil pump fixing bolts.
Torque : 25 N´m (18 lb´ft)
051RW002

6G±6
ENGINE LUBRICATION (6VE1 3.5L)
051RW001
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin
8. Install the new oil seal (12). Apply engine oil to the oil
seal lip before installation then use J±39202 oil seal
Installer, install oil seal.
015RS001
9. Install oil strainer (4) with O-ring (13).
Torque: 25 N´m (18 lb ft)
10. Install oil pipe (3) with O-ring (13).
Torque: 25 N´m (18 lb ft)
11. Install crankcase with oil pan (2).

Remove oil on crankcase mounting surface and dry
the surface.

Apply a proper 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
12. Install crankshaft timing pulley.

6G±8
ENGINE LUBRICATION (6VE1 3.5L)
C. Install crankcase, tighten crankcase fixing bolts to
the specified torque.
Torque : 10 N´m (87 lb in)
013RW004
2. Install oil pan
A. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
B. Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB-1207C or equivalent) to mounting
surface of oil pan.
Sealant beat must be continuous.

The crankcase must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.
013RW003
C. Install oil pan, tighten oil pan fixing bolts to the
specified torque.
Torque : 10 N´m (87 lb in)
3. Install starter and tighten fixing bolts.
Torque: 40 N´m (30 lb ft)4. Install axle housing assembly and tighten fixing bolts
to the specified torque. (for 4y4)
Axle case bolts
Torque : 82 N´m (61 lb ft)
Mounting bolts
Torque : 152 N´m (112 lb ft)
013RW005
5. Install the shift on the fly.
6. Install relay lever assembly and tighten fixing bolts.
Torque: 44 N´m (33 lb ft)
7. Install suspension cross member and tighten fixing
bolts to the specified torque.
Torque : 78 N´m (58 lb ft)
013RW007
8. Install radiator under fan shroud.
9. Install under cover.
10. Install engine oil level dipstick.
11. Fill engine oil until full level on engine oil gauge
dipstick.

6G±9
ENGINE LUBRICATION (6VE1 3.5L)
Oil Pump
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove crankcase assembly.

Refer to removal procedure for Oil Pan and
Crankcase in this manual.
4. Remove crankshaft pulley.

Refer to removal procedure for Crankshaft Pulley in
this manual.
5. Remove timing belt.

Refer to removal procedure for Timing Belt in this
manual.
6. Remove timing pulley from crankshaft.
7. Remove four fixing bolts from oil filter assembly.
8. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.
9. Remove three bolts from oil pipe and O-ring.
10. Remove eight oil pump fixing bolts, then oil pump
assembly.
11. Remove sealant from mounting surface of oil pump
assembly, cylinder block and take care not to damage
mounting surfaces of oil pump and cylinder block.
Installation
1. Install oil pump assembly

Apply sealant (TB-1207B or equivalent) to the oil
pump mounting surfaces as shown in the
illustration.

The oil pump assembly must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.
NOTE: Do not apply sealant to the oil ports.
051RW002

Use J-39202 installer when installing new oil seal.

Apply engine oil to oil seal lip.

Install oil pump assembly to the cylinder block.
NOTE: Do not damage oil seal during installation of oil
pump assembly.
015RS001

Tighten fixing bolts to the specified torque.
Torque : 25 N´m (18 lb ft)
051RW001
2. Install oil pipe with O-ring, tighten fixing bolt to the
specified torque.
Torque : 10 N´m (87 lb in)
3. Install oil strainer with O-ring, tighten fixing bolt to the
specified torque.
Torque : 25 N´m (18 lb ft)

6G±10
ENGINE LUBRICATION (6VE1 3.5L)
4. Install oil filter assembly and tighten bolts to the
specified torque.
Torque : 25 N´m (18 lb ft)
050RW001
Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter
5. Install timing pulley on crankshaft.
Install timing belt.

Refer to installation procedure for Timing Belt in this
manual.
6. Install crankshaft pulley.

Refer to install procedure for Crankshaft Pulley in
this manual.
7. Install crankcase assembly.

Refer to installation procedure for Oil Pan and
Crankcase in this manual.
8. Refill engine oil until full level on engine oil dipstick.

6G±12
ENGINE LUBRICATION (6VE1 3.5L)
Oil Filter
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove oil filter using J-36390 filter wrench.
Installation
1. Apply a light coat of engine oil to the oil filter gasket.
2. Hand tighten the filter until the gasket contacts the
sealing face.
3. Using J±36390 filter wrench, tighten the filter an
additional 7/8 turn or by torque 22 N´m (16 lb ft).
050RW001
Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Filter
(5) To Filter
4. Fill the oil to the proper lever by following the oil level
check procedures.
5. Reconnect battery ground cable.
6. Run the engine and inspect for leaks.