ISUZU AXIOM 2002 Service Repair Manual

6A±21
ENGINE MECHANICAL (6VE1 3.5L)
Cylinder Head Cover RH
Removal
1. Disconnect battery ground cable.
2. Remove engine cover from the dowele on the
common chamber.
F06RY001
3. Disconnect ventilation hose from cylinder head cover.
4. Disconnect three ignition coil connectors from ignition
coils and remove harness bracket bolts on cylinder
head cover then remove ignition coil fixing bolts on
ignition coils and remove ignition coils.
5. Disconnect fuel injector harness connector then
remove fuel injector harness bracket bolt.
6. Remove eight fixing bolts then the cylinder head
cover.
010RW002
Installation
1. Install cylinder head cover.

Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.
Apply sealant (TB-1207B or equivalent) bead
(diameter 2-3 mm) at eight places of arched areas
of camshaft bracket on front and rear sides.

The cylinder head cover must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.

Tighten bolts to the specified torque.
Torque : 9 N´m (78 lb in)
014RW019
2. Tighten fuel injector harness bracket bolts to
specified torque then reconnect fuel injector harness
connector.
Torque : 7.8 N´m (69 lb in)
3. Connect ignition coil connector and tighten ignition
coil fixing bolts to specified torque.
Torque : 4 N´m (35 lb in)
4. Connect ventilation hose to cylinder head.
5. Install engine cover mating with the dowels.

6A±22
ENGINE MECHANICAL (6VE1 3.5L)
Common Chamber
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner duct assembly.
013RY00001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Flow Sensor
3. Disconnect vacuum booster hose from common
chamber.
4. Disconnect connector from manifold absolute
pressure sensor, Ion sensing module, throttle
position sensor, solenoid valve, electric vacuum
sensing valve, and EGR valve.
5. Disconnect vacuum hose on canister VSV and
positive crankcase ventilation hose, fuel rail
assembly with pressure control valve bracket.
6. Remove ventilation hose from throttle valve and
intake duct and remove water hose.
7. Remove the four throttle body fixing bolts.
8. Remove exhaust gas recirculation valve assembly
fixing bolt and nut on common chamber and remove
EGR valve assembly.9. Remove two bolts from common chamber rear side
to remove fuel hose bracket.
10. Remove common chamber four bolts and four nuts
then remove the common chamber.
025RY002
Legend
(1) Common Chamber
(2) Throttle Valve Assembly
(3) Bolt
Installation
1. Install common chamber and tighten bolts and nuts to
the specified torque.
Torque :
Bolt : 25 N´m (18 lb ft)
Nut : 25 N´m (18 lb ft)
2. Install fuel hose bracket and tighten bolts to specified
torque.
Torque : 10 N´m (87 lb in)
3. Install exhaust gas recirculation valve assembly and
tighten bolt and nut to the specified torque.
Torque : 25 N´m (18 lb ft)
4. Install throttle body and tighten bolts to the specified
torque.
Torque : 25 N´m (18 lb ft)
5. Install ventilating hose to throttle valve and intake
duct.
6. Connect vacuum hoses on canister VSV and positive
crankcase ventilation hose. Tighten bolts for fuel rail
assembly with pressure control valve bracket.
Torque : 25 N´m (18 lb ft)

6A±23
ENGINE MECHANICAL (6VE1 3.5L)
7. Connect each connector.
8. Connect vacuum booster hose.
9. Connect the Ion sensing module connectors as
shown in the illustration.
060RY00111
Legend
(1) Green Connector
(2) Blue Connector
(3) Identification Mark (6VE1 Engine Only)
10. Install air cleaner duct assembly.
013RY00001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Mass Air Flow Sensor

6A±24
ENGINE MECHANICAL (6VE1 3.5L)
Exhaust Manifold LH
Removal
1. Disconnect battery ground cable.
2. Disconnect O
2 sensor connector.
3. Remove exhaust front pipe three stud nuts from
exhaust side and two bolts from rear end of exhaust
front pipe.
150R100011
Legend
(1) Exhaust Front Pipe LH
(2) O
2 Sensor
4. Remove exhaust manifold eight fixing nuts and
remove exhaust manifold from the engine.
Installation
1. Install exhaust manifold and tighten exhaust manifold
fixing nuts to the specified torque with new nuts.
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)
150R100011
Legend
(1) O
2 Sensor
(2) Exhaust Front Pipe LH
3. Reconnect O2 sensor connector.

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±26
ENGINE MECHANICAL (6VE1 3.5L)
Crankshaft Pulley
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
013RY00001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Air Flow Sensor
3. Remove radiator upper fan shroud from radiator.
4. Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Driver Belt
5. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
6. Remove crankshaft pulley assembly using J-8614-01
crankshaft holder, hold crankshaft pulley then
remove center bolt and pulley.
Installation
1. Install crankshaft pulley using J-8614-01 crankshaft
holder, hold the crankshaft pulley and tighten center
bolt to the specified torque.
Torque : 167 N´m (123 lb ft)
2. 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.
3. Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
4. Install radiator upper fan shroud.
5. Install air cleaner assembly.

6A±27
ENGINE MECHANICAL (6VE1 3.5L)
Timing Belt
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move drive belt tensioner to loose side using wrench
then remove drive belt.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Idle Pulley
(8) Drive Belt
5. Remove cooling fan assembly four nuts, then the
cooling fan assembly.
6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.
10. Remove crankshaft pulley assembly using J-8614-01
crankshaft holder, hold crankshaft pulley remove
center bolt, then the pulley.11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover
13. Remove pusher.
CAUTION: The pusher prevents air from entering
the oil chamber. Its rod must always be facing
upward.
014R100020
Legend
(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin
(5) Apply a force of 980 N (220 lb) when
compressing the pusher rod.
14. Remove timing belt.
CAUTION:
1. Do not bend or twist the belt, otherwise its core
could be damaged. The belt should not be bent at
a radius less than 30 mm (1.1811 in).
2. Do not allow oil or other chemical substances to
come in contact with the belt. They will shorten
the life.
3. Do not attempt to pry or stretch the belt with a
screw driver or any other tool during installation.
4. Store timing belt in a cool and dark place. Never
expose the belt direct sunlight or heat.

6A±28
ENGINE MECHANICAL (6VE1 3.5L)
Installation
NOTE: For correct belt installation, the letter on the belt
must be able to be read as viewed from the front of the
vehicle.
014RW005
Legend
(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley
(4) Idle Pulley
(5) LH Bank Camshaft Drive Gear Pulley
(6) Tension Pulley
(7) Alignment Mark on Oil Pump.
(8) Alignment Mark on Timing Belt
014RW006
Legend
(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side
1. Install timing belt.
1. Align groove of crankshaft timing pulley (2) with
mark on oil pump (1).
Align the mark on the crankshaft timing pulley (3)
with alignment mark (white dotted line) on the tim-
ing belt (4).
Secure the belt with a double clip or equivalent
clip.
NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.
014RW003
Legend
(1) Alignment Mark on Oil Pump
(2) Groove on Crankshaft Timing Pulley
(3) Alignment Mark on Crankshaft Timing Pulley
(4) Alignment Mark on Timing Belt
2. Align the alignment mark on the RH bank
camshaft drive pulley (2) to the alignment mark of
the cylinder head cover RH (3).
The camshaft pulley is not 1:1 with the camshafts.
It is necessary to rotate the camshaft pulley until
the camshaft lobes are in the position as shown
in the diagram on page 6A±34.
The camshaft pulley alignment mark should also
align with alignment mark on the cylinder head
cover.
It may require up to four revolutions of the
camshaft pulley to achieve alignment of all marks.

6A±29
ENGINE MECHANICAL (6VE1 3.5L)
3. Align the alignment mark (white line) on the timing
belt (1) with alignment mark on the RH bank
camshaft drive pulley (2) (on the left side as
viewed from the front of the vehicle) and put the
timing belt on the camshaft drive pulley.
Secure the belt with a double clip or equivalent
clip.
014RW00004
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Pulley.
(3) Alignment Mark on Cylinder Head Cover RH.
4. Align the alignment mark on the LH bank
camshaft drive pulley (2) to the alignment mark of
the cylinder head cover LH (3).
The camshaft pulley is not 1:1 with the camshafts.
It is necessary to rotate the camshaft pulley until
the camshaft lobes are in the position as shown
in the diagram on page 6A±34.
The camshaft pulley alignment mark should also
align with alignment mark on the cylinder head
cover.
It may require up to four revolutions of the cam-
shaft pulley to achieve alignment of all marks.
5. Align the alignment mark (white line) on the timing
belt (1) with the alignment mark on the LH bank
camshaft drive pulley (2).
When aligning the timing marks, use a wrench to
turn the camshaft drive pulley, then set the timing
mark between timing belt and camshaft drive
pulley and put the timing belt on the camshaft
drive pulley.
Secure the belt with a double clip or equivalent
clip.NOTE: It is recommended for easy installation that the
belt be secured with a double clip or equivalent clips after
it is installed to each pulley.
014RW00005
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Pulley.
(3) Alignment Mark on Cylinder Head Cover LH.
6. Install crankshaft pulley temporarily and tighten
center bolt by hand (do not use a wrench).
Turn the crankshaft pulley clockwise to give some
belt slack between the crankshaft timing pulley
and the RH bank camshaft drive pulley.
2. Install pusher and tighten bolt to the specified torque.
Torque : 25 N´m (2.5 kg´m/18 lb ft)
1. Install the pusher while pushing the tension pulley
to the belt.
2. Pull out pin from the pusher.
NOTE: When reusing the pusher, press the pusher with
approximately 100Kg to retract the rod, and insert a pin
(1.4 mm (0.055 in) piano wire).

6A±30
ENGINE MECHANICAL (6VE1 3.5L)
014R100020
Legend
(1) Up Side
(2) Down Side
(3) Direction for Installation
(4) Locking Pin
(5) Apply a force of 980 N (220 lb) when
compressing the pusher rod.
After release the push rod from the locking pin,
the rod projection is approximate 5 mm (0.1969
in).
014R100032
Legend
(1) Tensioner Pulley
(2) Crankshaft Pulley Rotation Direction
(3) Crankshaft Pulley
(4) Pusher Assembly
3. Remove double clips or equivalent clips from
timing belt pulleys.
Turn the crankshaft pulley by six turns and check
for timing mark alignment.3. Install timing belt cover.
Remove crankshaft pulley that was installed in step
1 item 5.
Tighten bolts to the specified torque.
Torque: 19 N´m (14 lb ft)
020RW004
Legend
(1) Timing Belt Cover RH
(2) Timing Belt Cover LH
(3) Timing Belt Cover Lower
020RW003
Legend
(1) Timing Belt Cover
(2) Rubber Bushing
(3) Sealing Rubber
(4) Cylinder Body
4. Install crankshaft pulley using J-8614-01, hold the
crankshaft pulley and tighten center bolt to the
specified torque.
Torque : 167 N´m (123 lb ft)