oil level ISUZU AXIOM 2002 Service Service Manual

6E±520
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Poor Fuel Economy Symptom

StepActionValue(s)Ye sNo
1DEFINITION:
Fuel economy, as measured by an actual road test, is
noticeably lower than expected. Also, economy is
noticeably lower than it was on this vehicle at one time,
as previously shown by an actual road test.
(Non-standard tires will cause odometer readings to be
incorrect, and that may cause fuel economy to appear
poor when it is actually normal.)
Was the ªOn-Board Diagnostic (OBD) System Checkº
performed?
ÐGo to Step 2
Go to OBD
System
Check
21. 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 3
3Was a visual/physical check performed?
ÐGo to Step 4
Go to Visual/
Physical
Check
4Check owner's driving habits.

Is the A/C ªONº full time (defroster mode ªONº)?

Are tires at the correct pressure?

Are excessively heavy loads being carried?

Is acceleration too much, too often?
Was a problem found?
ÐGo to Step 5Go to Step 6
5Review the items in Step 4 with the customer and
advise as necessary.
Is the action complete?
ÐSystem OKÐ
61. Visually/physically check: Vacuum hoses for splits,
kinks, and improper connections and routing as
shown on the ªVehicle Emission Control
Informationº label.
2. If a problem is found, repair as necessary.
Was a problem found?
ÐVerify repairGo to Step 7
71. Remove and check the air filter element for dirt or for
restrictions. Refer to
Air Intake System.
2. Replace the air filter element if necessary.
Was a repair required?
ÐVerify repairGo to Step 8
81. Remove spark plugs and check for wet plugs,
cracks, wear, improper gap, burned electrodes, or
heavy deposits. Refer to
Spark Plug Replacement.
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 9
91. Check for low engine coolant level. Refer to Engine
Cooling
.
2. If a problem is found, repair as necessary.
Was a problem found?
ÐVerify repairGo to Step 10

6E±548
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Vehicle Speed Sensor (VSS)
Removal Procedure
CAUTION: The VSS is located on the right side of
the transfer case just ahead of the rear propeller
shaft and very close to the exhaust pipes for 4WD
and on the extension cover for 2WD. Be sure that the
exhaust pipes are cool enough to touch before trying
to remove the VSS. If the pipes are hot, you could be
burned.
1. Disconnect the negative battery cable.
2. Disconnect the VSS electrical connector.
TS23748
3. Remove the bolt and the clamp securing the VSS in
place.
IMPORTANT:Have a container ready to catch any fluid
that leaks out when the VSS is removed from the transfer
case for 4WD and on the extension cover for 2WD.
TS23780
4. Remove the VSS from the transfer case by wiggling it
slightly and pulling it straight out.
Inspection Procedure
1. Inspect the electrical connector for signs of corrosion
or warping. Replace the VSS if the electrical
connector is corroded or warped.
2. Inspect the VSS driven gear for chips, breaks, or worn
condition. Replace the VSS if the driven gear is
chipped, broken or worn.
3. Inspect the O-ring for wear, nicks, tears, or
looseness. Replace the O-ring if necessary.
Installation Procedure
1. Install the VSS in the transfer case with the notch for
the connector facing the rear.
2. Secure the VSS in place with the clamp and the bolt.
Tighten

Tighten the bolt to 16 N´m (12 lb ft.).
TS23780
3. Connect the VSS electrical connector.
TS23748
4. Check the transfer case oil level. Add fluid if
necessary.
5. Connect the negative battery cable.

6E±566
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Positive Crankcase Ventilation
(PCV) Valve
Removal Procedure
1. Remove the vacuum hose at the PCV valve.

Slide the clamp back to release the hose.
2. Pull the PCV valve from the rubber grommet in the
right valve cover.
014RW097
Inspection Procedure
Before inspecting the PCV valve, make sure that the
hoses are connected properly and are in good condition.
Also check that the oil pan and rocker cover gaskets are
sealing properly.
PCV Valve
1. Run the engine at normal operating temperature.
2. Disconnect the valve from the rocker cover.
RESULT: A hissing noise should be heard from the
valve. If no noise is heard, the PCV valve or hose is
plugged.
3. Remove the PCV valve from the engine.
a. Blow air into the rocker cover side of the valve.
RESULT: Air should pass freely.
b. Blow air into the air cleaner side of the valve.
RESULT: Air should not pass through the valve.
4. Re-install the PCV valve and remove the oil filler cap.
RESULT: A small vacuum should be felt at the oil filler
hole.
Installation Procedure
1. Push the PCV valve into the rubber grommet in the
left valve cover.2. Install the vacuum hose on the PCV valve and secure
the vacuum hose with the clamp.
014RW097
Wiring and Connectors
Wiring Harness Service
The control module harness electrically connects the
control module to the various solenoids, switches and
sensors in the vehicle engine compartment and
passenger compartment.
Replace wire harnesses with the proper part number
replacement.
Because of the low amperage and voltage levels utilized
in powertrain control systems, it is essential that all wiring
in environmentally exposed areas be repaired with crimp
and seal splice sleeves.
The following wire harness repair information is intended
as a general guideline only. Refer to
Chassis Electrical
section for all wire harness repair procedures.
Connectors and Terminals
Use care when probing a connector and when replacing
terminals. It is possible to short between opposite
terminals. Damage to components could result. Always
use jumper wires between connectors for circuit
checking. NEVER probe through Weather-Pack seals.
Use an appropriate connector test adapter kit which
contains an assortment of flexible connectors used to
probe terminals during diagnosis. Use an appropriate
fuse remover and test tool for removing a fuse and to
adapt the fuse holder to a meter for diagnosis.
Open circuits are often difficult to locate by sight because
oxidation or terminal misalignment are hidden by the
connectors. Merely wiggling a connector on a sensor, or
in the wiring harness, may temporarily correct the open
circuit. Intermittent problems may also be caused by
oxidized or loose connections.
Be certain of the type of connector/terminal before
making any connector or terminal repair. Weather-Pack
and Com-Pack III terminals look similar, but are serviced
differently.

6G±7
ENGINE LUBRICATION (6VE1 3.5L)
Oil Pan and Crankcase
Removal
1. Disconnect battery ground cable.
2. Lift vehicle by supporting the frame.
3. Remove under cover.
4. Drain engine oil.
5. Remove front wheels.
6. Remove oil level dipstick from level gauge tube.
7. Remove radiator under fan shroud.
8. Remove shift on the fly from axle housing.
9. Remove suspension cross member fixing bolts, 2 pcs
each per side and remove suspension cross member.
10. Remove axle housing assembly four fixing bolts from
housing isolator side and mounting bolts from wheel
side. At this time support the axle with a garage jack
and remove axle housing assembly. (for 4y4)
11. Remove the steering unit assembly.
12. Remove starter fixing bolts.
13. Remove oil pan fixing bolts.
14. Remove oil pan, using J-37228 sealer cutter, remove
oil pan.
013RS003
15. Remove crankcase fixing bolts.
16. Remove crankcase, using J-37228 sealer cutter,
remove crankcase.
NOTE: Do not deform or damage the flange of oil pan and
crankcase.
Replace the oil pan and/or crankcase if deformed or dam-
aged.
013RS003
Installation
1. Install crankcase.
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 crankcase.
Sealant bead must be continuous.

The crankcase must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.
013RW010

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±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±11
ENGINE LUBRICATION (6VE1 3.5L)
Oil Pump Oil Seal
Removal
1. Disconnect battery ground cable.
2. Drain engine oil.
3. Remove crankshaft pulley.

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

Refer to removal procedure for Timing Belt in this
manual.
5. Remove timing pulley from crankshaft.
6. Remove oil pump oil seal using a sealer puller.
NOTE: Take care not to damage sealing surfaces of oil
pump and crankshaft when removing oil seal.
Installation
1. Install oil pump oil seal, apply engine oil to oil seal lip,
then install oil seal using J-39202 installer.
015RS001
2. Install timing pulley to crankshaft.
3. Install timing belt.

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

Refer to installation procedure for CRANKSHAFT
PULLEY in this manual.
5. Refill engine oil until full level.

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.

7A±1 AUTOMATIC TRANSMISSION (4L30±E)
AXIOM
TRANSMISSION
CONTENTS
Automatic Transmission (4L30±E) 7A. . . . . . . . .
Transmission Control System (4L30±E) 7A1. . . .
AUTOMATIC TRANSMISSION (4L30±E)
CONTENTS
Service Precaution 7A±2. . . . . . . . . . . . . . . . . . . . . .
Construction 7A±3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Range Reference Chart 7A±4. . . . . . . . . . . . . . . . . .
Normal Operation Of 2002 4L30±E
Transmission 7A±5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis 7A±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driver Information 7A±5. . . . . . . . . . . . . . . . . . . . . . .
General Diagnosis Procedure 7A±8. . . . . . . . . . . . .
Preliminary Inspection Chart 7A±9. . . . . . . . . . . . . .
Checking Transmission Fluid Level and
Condition 7A±10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test Driving 7A±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical / Hydraulic Diagnosis Check
Trans Indicator Chart 7A±12. . . . . . . . . . . . . . . . . . . .
Mechanical / Hydraulic Diagnosis Symptoms
Index 7A±13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stall Test 7A±23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Pressure Test 7A±23. . . . . . . . . . . . . . . . . . . . . .
Shift Speed Chart 7A±24. . . . . . . . . . . . . . . . . . . . . . .
Lockup Speed Chart 7A±26. . . . . . . . . . . . . . . . . . . . .
Changing Transmission Fluid 7A±27. . . . . . . . . . . . .
Selector Lever 7A±27. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 7A±27. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 7A±27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A±29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Select Cable 7A±29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 7A±29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A±32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Lock Cable 7A±34. . . . . . . . . . . . . . . . . . . . . . . .
Removal 7A±34. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A±34. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode Switch 7A±35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 7A±35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A±36. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Assembly 7A±37. . . . . . . . . . . . . . . . . .
Transmission and Associated Parts 7A±37. . . . . .
Removal 7A±38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A±43. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid (Main Case Valve Body) 7A±47. . . . . . . . .
Removal 7A±47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 7A±47. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid (Adapter Case Valve Body) 7A±48. . . . . . .
Removal 7A±48. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A±48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Body Assembly (Main Case) 7A±49. . . . . . . .
Removal 7A±49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A±49. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Body Assembly (Adapter Case) 7A±50. . . . . .
Removal 7A±50. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A±50. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Powertrain Control Module (PCM) 7A±50. . . . . . . . .
Removal 7A±50. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A±50. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Sensor (Extension Assembly) 7A±51. . . . . .
Removal 7A±51. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A±51. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Oil Temperature Sensor
(Main Case) 7A±52. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 7A±52. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A±52. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Oil Seal (Converter Housing) 7A±53. . . . . . . .
Removal 7A±53. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A±53. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Oil Seal (Extension Assembly) 7A±53. . . . . . .
Removal 7A±53. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 7A±53. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission (4L30±E) 7A±54. . . . . . . . . . . . . . . . . .
Disassembly 7A±54. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 7A±58. . . . . . . . . . . . . . . . . . . . . . . . . .
Converter Housing And Oil Pump Assembly 7A±68
Disassembled View 7A±68. . . . . . . . . . . . . . . . . . . .
Disassembly 7A±68. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A±68. . . . . . . . . . . . . . . . . .
Reassembly 7A±68. . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump 7A±69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 7A±69. . . . . . . . . . . . . . . . . . . .
Disassembly 7A±69. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 7A±70. . . . . . . . . . . . . . . . . .
Reassembly 7A±70. . . . . . . . . . . . . . . . . . . . . . . . . .

7A±10
AUTOMATIC TRANSMISSION (4L30±E)
Checking Transmission Fluid Level
and Condition
Checking fluid level and condition (color and odor) at
regular intervals will provide early diagnosis information
about the transmission. This information may be used to
correct a condition that, if not detected early, could result
in major transmission repairs.
IMPORTANT:When new, automatic transmission fluid
is red in color. As the vehicle is driven, the transmission
fluid will begin to look darker in color. The color may
eventually appear light brown.
A dark brown color with burnt odor may indicate
excessive fluid deterioration and signal a need for fluid
change.
Fluid Level
When adding or changing fluid, use only DEXRON )±III.
Refer to
Maintenance and Lubrication in General
Information section for maintenance information and
servicing interval.
CAUTION: DO NOT OVERFILL.
Overfilling will cause foaming, loss of fluid, abnor-
mal shifting and possible damage to the transmis-
sion.
1. Park the vehicle on level ground and apply the parking
brake firmly.
2. Check fluid level with engine running at idle.
NOTE: Be sure that transmission fluid temperature is
below 30
C (86
F).
3. Move the selector lever through all gear ranges.
4. Move the selector lever to ªParkº.
5. Let engine idle for 3 minutes and open the overfill
screw (1).
6. Add released transmission fluid until it flows out over
the overfill screw opening.
7. Let engine idle until a fluid temperature between 32
C
(90
F) and 57
C (135
F) is reached, then close the
overfill screw (1).
Torque: 38 Nwm (28 lb ft)
NOTE: To prevent fluid leaks, the overfill screw and oil
drain screws gasket must be replaced each time these
screws are removed.NOTE: Check transmission fluid temperature with scan
tool.
Minimum fluid level " 57
C (135
F)
Maximum fluid level " 32
C (90
F)
242R200001
CAUTION: Do not open overfill screw with engine
stopped.
CAUTION: DO NOT CHECK FLUID LEVEL UNDER
THESE CONDITIONS:

Immediately after driving at sustained highway
speeds.

In heavy city traffic during hot weather.

If vehicle is towing a trailer.
If the vehicle has been operated under these conditions,
shut the engine off and allow the vehicle to ªcoolº for thirty
(30) minutes. After the cool down period, restart the
vehicle and continue from step 2 above.