height ISUZU AXIOM 2002 Service Owner's Guide

5C±80
POWER±ASSISTED BRAKE SYSTEM
Main Data and Specifications
General Specifications
Pedal free play6±10 mm (0.23 ±0.39 in)
Pedal Height173±185 mm (6.81±7.28 in)
Torque Specifications
310RY00007

6A±25
ENGINE MECHANICAL (6VE1 3.5L)
Exhaust Manifold RH
Removal
1. Disconnect battery ground cable.
2. Remove torsion bar. Refer to removal procedure in
Front Suspension section.
3. Remove exhaust front pipe three stud nuts and two
bolts then disconnect exhaust front pipe.
150R100013
Legend
(1) Exhaust Front Pipe RH
(2) O
2 Sensor
4. Remove exhaust manifold eight fixing nuts then the
exhaust manifold.
Installation
1. Install exhaust manifold and tighten nuts to the
specified torque.
Torque : 57 N´m (42 lb ft)
2. Install exhaust front pipe and tighten three stud nuts
and two bolts to the specified torque.
Torque:
Stud nuts: 67 N´m (49 lb ft)
Bolts: 43 N´m (32 lb ft)
3. Install the torsion bar and readjust the vehicle height.
Refer to installation and vehicle height adjustment
procedure for front suspension.

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±54
ENGINE MECHANICAL (6VE1 3.5L)
5. Use the J±8062 valve spring compressor and
J±42898 valve spring compressor adapter to remove
split collar.
014RW042
6. Remove valve spring.
7. Remove valve.
8. Remove oil controller and spring lower seat.
9. Remove the valve guide using the J±42899 valve
guide replacer.
Inspection and Repair
Valve Spring
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is evident.
1. Measure the free height of the springs. The springs
must be replaced if the free height is below the
specified limit.
Standard : 44.6 mm (1.756 in)
Limit : 43.6 mm (1.717 in)
014RS004
2. Measure the valve spring squareness with a steel
square and replace the valve springs if the measured
value exceeds the specified limit.
Limit : 2 mm (0.079 in)
014RS005
3. Using a spring tester to compress the springs to the
installed height, measure the compressed spring
tension, and replace the springs if the measured
tension is below the specified limit.
At installed height: 35.0 mm (1.38 in)
Standard: 196 N (44 lb)
Limit: Less than 181 N (41 lb)
014RS006
Valve Guide
CAUTION: Take care not to damage the valve seat
contact surface, when removing carbon adhering to
the valve head. Carefully inspect the valve stem for
scratches or abnormal wear. If these conditions are
present, the valve and the valve guide must be
replaced as a set.

6A±55
ENGINE MECHANICAL (6VE1 3.5L)
1. Measure the valve stem diameter with a micrometer.
If the valve stem diameter is less than the specified
limit, the valve and the valve guide must be replaced
as a set.
Diameter of Valve Stem
Intake
Standard : 5.977 mm±5.959 mm
(0.2353 in±0.2346 in)
Limit : 5.90 mm (0.2323 in)
Exhaust
Standard : 5.952 mm±5.970 mm
(0.2343 in±0.2350 in)
Limit : 5.90 mm (0.2323 in)
014RS007
2. Measure the inside diameter of the valve guide with a
micrometer. Subtract the measured outer diameter of
the valve stem from the measured inner diameter of
the valve guide. If the value exceeds the specified
limit, the valve and the valve guide must be replaced
as a set.
Inside Diameter of the Vale Guide
Inlet clearance
Standard : 0.023 mm±0.056 mm
(0.0009 in±0.0002 in)
Limit : 0.20 mm (0.00787 in)
Exhaust clearance
Standard : 0.030 mm±0.063 mm
(0.0012 in±0.0025 in)
Limit : 0.20 mm (0.00787 in)
Valve Guide Replacement
1. Using Valve guide replacer: J±42899, drive out the
valve guide from the combustion chamber side.
014RS008
2. Apply engine oil to the outside of the valve guide.
Using valve guide replacer J±42899, drive in a new
valve guide from the camshaft side, and check the
valve guide height.
Valve guide upper end height: 13.0 mm (0.5118
in)
(Measured from the cylinder head upper face)
014RW046
3. Check the clearance. If the clearance is less than the
specified value, ream the inside diameter of valve
guide. Using a sharp 6 mm reamer, ream the valve
guide to obtain the specified clearance.

6A±61
ENGINE MECHANICAL (6VE1 3.5L)
2. Remove twenty fixing bolts from intake and exhaust
camshaft bracket on one side bank, then camshaft
brackets (2).
014RW027
3. Remove camshaft assembly (3), (4) with camshaft
end plug.
4. Remove three fixing bolts (7) from camshaft drive
gear retainer (8), then camshaft drive gear assembly.
5. Use the snap ring pliers to remove the snap ring(1).
6. Remove the wave washer(2), sub gear(3) and spring
camshaft gear(4) from the camshaft assembly(5).
014R100018
Legend
(1) Snap Ring
(2) Wave Washer
(3) Sub Gear
(4) Spring; Camshaft Gear
(5) Camshaft Assembly
Inspection and Repair
1. Use a micrometer to measure the cam lobe height
and uneven wear. Replace the camshaft if either the
lobe height or the uneven wear exceeds the specified
limit.
Lobe height : 44.709 mm (1.7602 in)
Uneven wear : 0.05 mm (0.0020 in)
014RW043
2. Use a micrometer to measure the diameter and the
uneven wear of the camshaft journals.
Replace the camshaft if the diameter or the uneven
wear exceeds the specified limit.
Journal Diameter
Standard : 25.972 mm±25.993 mm
(1.0225 in±1.0233 in)
Limit : 25.8 mm (1.0157 in)
Uneven wear : 0.05 mm (0.0020 in)
014RS023

7A±58
AUTOMATIC TRANSMISSION (4L30±E)
36. Separate second (40) and third clutch (41)
assemblies.
37. Remove thrust washer (42).
38. Remove reverse clutch plates (43 and 44) and
reverse clutch pressure plate (45).
39. Remove bearing (46) and washer (47).
40. Remove planetary carrier assembly (48).
41. Remove thrust bearing (49).
42. Remove reaction sun gear (50)
43. Remove needle bearing (51).
44. Remove brake drum (52).
45. Remove brake band (53).
46. Remove thrust bearing (54).
242RS003
47. Rotate case to horizontal position, valve body side
facing up.

Remove spring pin (55), using cutting pliers, then
remove parking lock and selector lever assembly
(56).NOTE: Insert wire in the center of the spring pin to
prevent it from collapsing during removal. Be aware of pin
height. Protect machined face of main case.
48. Remove parking lock and range selector lever 17 mm
nut (57).
49. Remove parking lock and range selector lever (56),
and actuator assembly.
50. Remove selector shaft (58).
NOTE: Inspect the shaft for burrs before removing to
prevent damaging seal. If necessary, remove burrs by
lightly sanding with an oilstone.
249RS004
Reassembly
1. Inspect selector shaft seal, and replace it if
necessary.
NOTE: Use a seal installer when replacing the seal.

Install selector shaft.
NOTE: Spring pin groove must be positioned inside the
case.
2. Install spring pin. Be sure the selector shaft can move
freely. Do not push the pin flush with the case surface.
Leave enough height for removal.
3. Install actuator assembly (1).
4. Install parking lock and range selector lever (2) and
new 17 mm nut. Tighten the nut to the specified
torque.
Torque: 22 Nwm (16 lb ft)

8F±11 BODY STRUCTURE
Removal
1. Open the hood.
2. Support the hood.
3. Remove the windshield washer nozzle tube.
860R200005
4. Remove the hood hinge bolts.

Before removing the hinges from the engine hood,
scribe a mark showing location of the hinges to
facilitate installation in the original position.
610R200002
5. Remove the engine hood.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Tighten the engine hood hinge fixing bolts to the
specified torque.
Torque : 10 N´m (87 lb in)2. Check the engine hood and fender(1).
Clearance: 4.5 mm (0.18 in)
Height (step): 0.5 mm (0.02 in)

Adjust clearance with the hinges on the engine
hood.

Adjust height (step) with the hood rests(2).
610R200003
610RX001

8F±16BODY STRUCTURE
Removal
1. Disconnect the battery ground cable.
2. Remove the front bumper fascia assembly.

Refer to
Front Bumper in this section.
3. Remove the front turn signal light assembly.

Remove the fixing screw and disconnect the
connector.
610R200008
4. Remove the rocker cover assembly.

Refer to
Rocker Cover Assembly in Exterior/Interior
Trim section.
5. Remove the inner liner.
647RY00003
6. Remove the antenna assembly.

Refer to
Rod Type Antenna in Entertainment
section.
7. Remove the front fender panel (1).

Remove the eight fixing bolts.
8. Remove the engine compartment upper extension
(2).
614R200002
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Tighten the front fender panel fixing bolts to the
specified torque.
Torque : 7 N´m (61 lb in)
2. Check the fender and front door (1).
Clearance: 5.0 mm (0.196 in)
Height (step): Flush
610R200009

8F±36BODY STRUCTURE
4. Remove the upper and lower hinge bolts.

Position a wood block under the door for protection
and support the door assembly with hands during
removal or installation.
635R200013
5. Remove the door harness connector.

Pull the door harness grommet out in order to
disconnect the harness connector.
630R200012
6. Remove the front door assembly.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Align the door fitting to the body.

Check the fender and front door (1).
Clearance: 5.0 mm (0.196 in)
Height (step): Flush

Check the front door and rear door (2).
Clearance: 5.0 mm (0.196 in)
Height (step): Flush

Check the rear door and body (3).
Clearance: 5.0 mm (0.196 in)
Height (step): Flush
Adjust clearance with door hinges.
Adjust height (step) by tapping on the fender lightly
with a rubber hammer.
610R200005
2. Tighten the door hinge bolts to the specified torque.
Torque : 34 N´m (25 lb ft)
3. Tighten the door check arm bolt and nuts to the
specified torque.
Torque : 9 N´m (78 lb in)