ISUZU AXIOM 2002 Service Repair Manual

6D2±6
IGNITION SYSTEM (6VE1 3.5L)
Crankshaft Position Sensor
Removal
1. Disconnect battery ground cable
2. Wiring connector from crankshaft position sensor.
3. Remove crankshaft position sensor from cylinder
block.
012RS008
Installation
1. Install crankshaft position sensor into the cylinder
block.
Before installation,apply small amount of engine oil to
the O±ring.
Torque: 10 N´m (87 lb in)
2. Reconnect wiring connector to crankshaft position
sensor.

6D2±7
IGNITION SYSTEM (6VE1 3.5L)
Main Data and Specifications
General Specifications
Ignition System
Ignition FormElectronic Ignition System (El system) with Crankshaft position Sensor
Spark Plug
TypeK16PR±P11
RC10PYP4
PK16PR11
Plug gap1.0 mm ± 1.1 mm (0.0394 in ± 0.0433 in)
Torque18 N´m (13lb ft)
Torque Specifications
E06R100003

6D3±1
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
AXIOM
ENGINE
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
CONTENTS
Service Precaution 6D3±1. . . . . . . . . . . . . . . . . . . . . .
Starting System 6D3±2. . . . . . . . . . . . . . . . . . . . . . . . .
General Description 6D3±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 6D3±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter 6D3±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6D3±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6D3±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 6D3±7. . . . . . . . . . . . . . . . . . . .
Disassembly 6D3±8. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D3±10. . . . . . . . . . . . . . . . . .
Reassembly 6D3±13. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D3±14. . . . . . . . . . .
Charging System 6D3±17. . . . . . . . . . . . . . . . . . . . . . . . General Description 6D3±17. . . . . . . . . . . . . . . . . . . .
General On±Vehicle Inspection 6D3±17. . . . . . . . . . .
Generator 6D3±18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6D3±18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 6D3±18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6D3±19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 6D3±19. . . . . . . . . . . . . . . . . . . .
Disassembly 6D3±20. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 6D3±21. . . . . . . . . . . . . . . . . .
Reassembly 6D3±23. . . . . . . . . . . . . . . . . . . . . . . . . .
Bench Test 6D3±24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 6D3±25. . . . . . . . . . . . .
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.

6D3±2
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Starting System
General Description
Cranking Circuit
The cranking system consists of a battery, starter, starter
switch, starter relay, etc. These main components are
connected.
Starter
The cranking system employs a magnetic type reduction
starter in which the motor shaft is also used as a pinion
shaft. When the starter switch is turned on, the contacts of
magnetic switch are closed, and the armature rotates. At
the same time, the plunger is attracted, and the pinion is
pushed forward by the shift lever to mesh with the ring
gear.
Then, the ring gear runs to start the engine. When the
engine starts and the starter switch is turned off, the
plunger returns, the pinion is disengaged from the ring
gear, and the armature stops rotation. When the engine
speed is higher than the pinion, the pinion idles, so that
the armature is not driven.

6D3±3
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
060R200062

6D3±4
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Diagnosis
ConditionPossible causeCorrection
Starter does not runCharging failureRepair charging system
Battery FailureReplace Battery
Terminal connection failureRepair or replace terminal connector
and/or wiring harness
Starter switch failureRepair or replace starter switch
Starter relay failureReplace
Starter failureRepair or replace starter

6D3±5
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Starter
Removal
1. Battery ground cable.
2. Disconnect Heated O
2 Sensor connector (1).
3. Remove exhaust front left pipe(2).
150R100011
4. Disconnect starter wiring connector from terminals
ª30º (1) and ª50º (2).
5. Remove starter assembly mounting bolts on inside
and outside(3).
6. Remove starter assembly (4) toward the bottom of
engine.
065RY00050
Legend
(1) Terminal ª30º
(2) Terminal ª50º
(3) Fixing Bolts
(4) Starter Assembly
Installation
1. Install starter assembly(4).
2. Install mounting bolts and tighten bolts to specified
torque(3).
Torque: 40 N´m (30 lb ft)
3. Reconnect the connectors to terminals ª50º (2)
tighten terminals ª30º (1) to specified torque.
Torque: 9 N´m (78 lb in)
065RY00050
Legend
(1) Terminal ª30º
(2) Terminal ª50º
(3) Fixing Bolts
(4) Starter Assembly
4. Install exhaust front left pipe (2) and tighten bolts and
nuts to specified torque.
Stud Nuts
Torque: 67 N´m (49 lb ft)
Bolts
Torque: 43 N´m (32 lb ft)

6D3±6
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
5. Connect two Heated O2 Sensor connector (1).
150R100011
6. Reconnect the battery ground cable.

6D3±7
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Disassembled View
065R100012
Legend
(1) Lead Wire
(2) Through Bolt
(3) Yoke Assembly
(4) Yoke Cover
(5) Brush and Brush Holder
(6) Armature(7) Housing
(8) Over Running Clutch
(9) Return Spring
(10) Steel Ball
(11) Idle Pinion
(12) Retainer
(13) Magnetic Switch

6D3±8
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Disassembly
1. Remove the lead wire (1) from the magnetic switch.
2. Remove the through bolts (2).
065RY00053
Legend
(1) Lead Wire
(2) Through Bolt
3. Remove the yoke from the magnetic.
4. Remove the yoke cover.
5. Use the long nose pliers to remove the brush and
brush holder.
065RY00054
065RY00055
Legend
(1) Spring
(2) Brush
6. Remove the armature.
7. Remove the housing.
8. Remove the overrunning clutch from the housing.
065RY00056