ISUZU AXIOM 2002 Service Repair Manual

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

6A±62
ENGINE MECHANICAL (6VE1 3.5L)
3. Place the camshaft on V±blocks.
Slowly rotate the camshaft and measure the runout
with a dial indicator.
Replace the camshaft if the runout exceeds the
specified limit.
Runout
Limit : 0.1 mm (0.0039 in)
014RW044
4. Measure the camshaft journal oil clearance.
1. Measure the camshaft bracket housing inside
diameter.
NOTE: Tighten camshaft bracket (2) to specified torque
before measuring the camshaft bracket inside diameter.
Torque : 10 N´m (89 lb in)
014RW031
2. Subtract the camshaft outside diameter from the
camshaft bracket housing inside diameter.
Oil Clearance
Standard : 0.027 mm±0.078 mm
(0.0011 in±0.0031 in)
Limit : 0.11 mm (0.0043 in)
014RW037
5. Replace the cylinder head and/or camshaft if the
measured oil clearance exceeds the specified limit.
1. Carefully clean the camshaft journal, the
camshaft bracket, and the cylinder head.
2. Install camshaft assembly and camshaft brackets
(2), tighten twenty bolts (1) on one side bank to
the specified torque.
Torque: 10 N´m (89 lb in)
014RW031

6A±63
ENGINE MECHANICAL (6VE1 3.5L)
3. Measure the camshaft thrust clearance with a dial
indicator. Replace the camshaft and/or the
cylinder head if the camshaft thrust clearance
exceeds the specified limit.
Camshaft thrust Clearance
Standard : 0.03 mm±0.08 mm
(0.0012 in.±0.0031 in.)
Limit : 0.12 mm (0.0047 mm)
014RW035
Reassembly
1. Install camshaft drive gear assembly and tighten
three bolts to specified torque.
Torque: 10 N´m (89 lb in)
2. Install the spring ; camshaft gear(1) into the camshaft
assembly.
Ensure the clearance is between the right side of the
spring; camshaft gear (1) and the dowel pin (2).
014R100017
3. Align the dowel pin on the sub gear to the clearance of
the spring ; camshaft gear made in step 2 and install
the sub gear (3).
4. Install the wave washer (2). Use snap ring pliers to
install the snap ring (1).
014R100018
5. Tighten sub gear setting bolt.
a. Use J±42686 gear spring lever to pre-load the sub
gear. Turn the sub gear in a clockwise direction
until the M5 bolt hole aligns with the hole in the
camshaft driven gear.
b. Install the M5 bolt and tighten to a suitable torque to
prevent the sub gear from moving.
014RW041
6. Align the timing mark on the retainer and dowel pin of
the camshaft drive gear.
7. Install camshaft assembly and camshaft brackets,
tighten twenty bolts on one side bank to the specified
torque.

6A±64
ENGINE MECHANICAL (6VE1 3.5L)
a. Apply engine oil to camshaft journal and bearing
surface of camshaft bracket.
b. Align timing mark on intake camshaft (one dot for
right bank, two dots for left bank) and exhaust
camshaft (one dot for right bank, two dots for left
bank) to timing mark on camshaft drive gear (one
dot).
014R100016
Legend
(1) Alignment Mark on the Camshaft Gear
(2) Alignment Mark on the Camshaft Drive Gear
014R100025
Legend
(1) Discrimination Mark for Right Bank Intake
Camshaft Gear
(2) Alignment Mark for Right Bank (One Dot)
(3) Camshaft Timing Gear for Right Bank Intake
014R100026
Legend
(1) Alignment Mark for Left Bank (Two Dots)
(2) Discrimination Mark for Left Bank Intake
Camshaft Gear
(3) Camshaft Timing Gear for Left Bank Intake
014R100027
Legend
(1) Discrimination Mark
LE : Left Bank Exhaust
RE : Right Bank Exhaust
(2) Alignment Mark
One Dot for Right Bank
Two Dots for Left Bank
(3) Camshaft Timing Gear for Exhaust

6A±65
ENGINE MECHANICAL (6VE1 3.5L)
014R100023
Legend
(1) Timing Mark on the Camshaft Drive Gear for
Right Bank Exhaust Camshaft
(2) Timing Mark on the Camshaft Drive Gear for
Right Bank Intake Camshaft
(3) Dowel Pin
014R100024
Legend
(1) Timing Mark on the Camshaft Drive Gear for
Left Bank Intake Camshaft
(2) Timing Mark on the Camshaft Drive Gear for
Left Bank Exhaust Camshaft
(3) Dowel Pin
c. Tighten twenty bolts in numerical order on one side
bank as shown in the illustration.
Torque: 10 N´m (89 lb in)
014RW031
8. If the oil seal requires replacement, use the J±42985
to install the oil seal.
014RW034

6A±66
ENGINE MECHANICAL (6VE1 3.5L)
9. If the camshaft end plug requires replacement, use
the J±42985 to install the camshaft end plug.
014R100031
10. Tighten bolt for camshaft drive gear pulley to the
specified torque using the J±43041 universal holder.
Torque: 98 N´m (72 lb ft)
014RW060

6A±67
ENGINE MECHANICAL (6VE1 3.5L)
Crankshaft
Crankshaft and Associated Parts
013RW009
Legend
(1) Cylinder Head Assembly
(2) Crankcase with Oil Pan
(3) Oil Pipe and O-ring
(4) Oil Strainer and O-ring
(5) Oil Pump Assembly
(6) Cylinder Block Side Bolts
(7) Oil Gallery(8) Piston and Connecting Rod Assembly
(9) Flywheel
(10) Rear Oil Seal Retainer and Oil Seal
(11) Main Bearing Cap
(12) Crankshaft
(13) Main Bearing Cap Fixing Bolts
(14) Oil Gallery Fixing Bolts
Disassembly
1. Remove cylinder head assembly (1). Refer to
ªCylinder Headº in this manual.
2. Remove crankcase with oil pan (2). Refer to ªOil Pan
and Crankcaseº in this manual.CAUTION: Take care not to damage or deform the
sealing flange surface of crankcase.
3. Remove oil pipe and O-ring (3).
4. Remove oil strainer and O-ring (4).
5. Remove oil pump assembly (5).
6. Remove crankcase side bolts (6).

6A±68
ENGINE MECHANICAL (6VE1 3.5L)
7. Remove oil gallery (7).
8. Remove piston and connecting rod assembly (8).
Refer to ªPiston, Piston Ring and Connecting Rodº in
this manual.
9. Remove flywheel (9).
10. Remove rear oil seal retainer (10).
11. Remove main bearing cap (11).
12. Remove crankshaft (12).
Inspection and Repair for Bearings
1. Inspect Crankshaft
Set the dial indicator as shown in the illustration and
measure the crankshaft thrust clearance. If the thrust
clearance exceeds the specified limit, replace the
thrust bearings as a set.
Thrust Clearance
Standard : 0.06 mm±0.24 mm
(0.0024 in±0.0094 in)
Limit : 0.30 mm (0.0118 in)
015RS003
Main Bearing Clearance
1. Remove the bearing caps and measure the oil
clearance.
2. Remove the main bearing cap fixing bolts in the
sequence shown in the illustration.
Arrange the removed main bearing caps in the
cylinder number order.
Remove the main bearings.
015RS004
3. Remove the crankshaft.
Remove the main bearings.
4. Clean the upper and lower bearings as well as the
crankshaft main journal.
5. Check the bearings for damage or excessive wear.
The bearings must be replaced as a set if damage or
excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to their
original positions.
Carefully install the crankshaft.
7. Set the lower bearings to the bearing cap original
position.
8. Apply plastigage to the crankshaft journal unit as
shown in the illustration.
NOTE: Do not set the plastigage on the oil hole.
015RS005

6A±69
ENGINE MECHANICAL (6VE1 3.5L)
9. Install main bearing caps, oil gallery and crank case
bolts in the order shown, and tighten each bolt to the
specified torque.
NOTE: Do not apply engine oil to the crank case side
bolts.
Main bearing cap bolts.
Torque: 39 N´m (29lb ft)
Oil gallery fixing bolts.
Torque:
1st step: 29 N´m (22 lb ft)
2nd step 55
~ 65

Crank case side bolts
Torque : 39 N´m (29lb ft)
NOTE: Do not allow the crankshaft to rotate.
015RS006
10. Remove the main bearing caps in the sequence
shown in the illustration.
015RS004
11. Measure the plastigage width and determine the oil
clearance. If the oil clearance exceeds the specified
limit, replace the main bearings as a set and/or
replace the crankshaft.
Standard : 0.019 mm±0.043 mm
(0.0007 in±0.0017 in)
Limit : 0.08 mm (0.0031 in)
015RS008
12. Clean the plastigage from the bearings and the
crankshaft.
Remove the crankshaft and the bearings.
Crankshaft Inspection
Inspect the surface of the crankshaft journal and crank
pins for excessive wear and damage. Inspect the oil seal
fitting surfaces for excessive wear and damage. Inspect
the oil ports for obstructions.

6A±70
ENGINE MECHANICAL (6VE1 3.5L)
Inspection and Repair for Crankshaft
1. Carefully set the crankshaft on the V±blocks. Slowly
rotate the crankshaft and measure the runout. If the
crankshaft runout exceeds the specified limit, the
crankshaft must be replaced.
Runout : 0.04 mm (0.0016 in)
015RS007
2. Measure the diameter and the uneven wear of main
journal and crank pin. If the crankshaft wear exceeds
the specified limit, crankshaft must be replaced.
Main journal diameter : 63.918 mm±63.933 mm
(2.5165 in±2.5170 in)
Crank pin diameter : 53.922 mm±53.937 mm
(2.1229 in.±2.1235 in.)
Uneven wear limit : 0.005 mm (0.0002 in)
015RS009
Crankshaft Bearing Selection
When installing new crankshaft bearings or replacing
bearings, refer to the selection table below. Select and
install the new crankshaft bearings, paying close
attention to the cylinder block journal hole.
1. Diameter size mark (1) and the crankshaft journal.
015RS010
2. Diameter size mark (1).
The diameter size marks are stamped on the No.1
crankshaft balancer as shown in the illustration.
015RS011
NOTE: Take care to ensure the bearings are positioned
correctly.