torque ISUZU AXIOM 2002 Service Repair Manual

5A±2BRAKE CONTROL SYSTEM
Chart B-13 FR Isolation Solenoid Coil Failure
(DTC 43 (Flash out) / C0241, C0243
(Serial communications)) 5A±44. . . . . . . . . . . . . . .
Chart B-14 FR Dump Solenoid Coil Failure
(DTC 44(Flash out) / C0242, C0244
(Serial communications)) 5A±44. . . . . . . . . . . . . . .
Chart B-15 Rear Isolation Solenoid Coil
Failure (DTC 45 (Flash out) / C0251, C0253
(Serial communications)) 5A±44. . . . . . . . . . . . . . .
Chart B-16 Rear Dump Solenoid Coil Failure
(DTC 46 (Flash out) / C0252, C0254
(Serial communications)) 5A±45. . . . . . . . . . . . . . .
Chart B-17 FL Speed Sensor Open or Shorted
(DTC 51 (Flash out) / C0225
(Serial communications)) 5A±45. . . . . . . . . . . . . . .
Chart B-18 FR Speed Sensor Open or Shorted
(DTC 52 (Flash out) / C0221
(Serial communications)) 5A±46. . . . . . . . . . . . . . .
Chart B-19 Rear Speed Sensor Open or
Shorted (DTC 53 (Flash out) / C0235
(Serial communications)) 5A±47. . . . . . . . . . . . . . .
Chart B-20 FL Speed Sensor Missing Signal
(DTC 61 (Flash out) / C0226, C0227
(Serial communications)) 5A±48. . . . . . . . . . . . . . . Chart B-21 FR Speed Sensor Missing Signal
(DTC 62 (Flash out) / C0222, C0223
(Serial communications)) 5A±49. . . . . . . . . . . . . . .
Chart B-22 Rear Speed Sensor Missing Signal
(DTC 63 (Flash out) / C0236, C0237
(Serial communications)) 5A±50. . . . . . . . . . . . . . .
Chart B-23 Simultaneous Drop-out of Front
Speed Sensor Signal (DTC 64 (Flash out) /
C0229 (Serial communications)) 5A±51. . . . . . . .
Chart B-24 Wheel Speed Input Abnormality
(DTC 65 (Flash out) / C0238 (Serial
communications)) 5A±52. . . . . . . . . . . . . . . . . . . . .
Unit Inspection Procedure 5A±53. . . . . . . . . . . . . . . .
Chart C-1-1 FL Sensor Output Inspection
Procedure 5A±53. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart C-1-2 FR Sensor Output Inspection
Procedure 5A±54. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart C-1-3 Rear Sensor Output Inspection
Procedure 5A±54. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart TC-1 Sensor Output Inspection
Procedure 5A±55. . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 5A±56. . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

5B±1 ANTI±LOCK BRAKE SYSTEM
AXIOM
BRAKES
ANTI-LOCK BRAKE SYSTEM
CONTENTS
Service Precaution 5B±1. . . . . . . . . . . . . . . . . . . . . .
Electronic Hydraulic Control Unit 5B±2. . . . . . . . . .
Electronic Hydraulic Control Unit and
Associated Parts 5B±2. . . . . . . . . . . . . . . . . . . . . .
Removal 5B±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 5B±3. . . . . . . . . . . . . . . . . . . .
Disassembly 5B±3. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 5B±3. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5B±3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Speed Sensor 5B±4. . . . . . . . . . . . . . . Front Wheel Speed Sensor and Associated
Parts 5B±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5B±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5B±4. . . . . . . . . . . . . . . . . .
Installation 5B±4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wheel Speed Sensor 5B±5. . . . . . . . . . . . . . .
Removal 5B±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5B±5. . . . . . . . . . . . . . . . . .
Installation 5B±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

5B±3 ANTI±LOCK BRAKE SYSTEM
4. Remove harness connector.
5. Remove EHCU ASM.
6. Remove EHCU.
Disassembled View
350RW025
Legend
(1) Fixing Bolts
(2) Coil Integrated Module
(3) Hydraulic Unit (H/U)
Disassembly
1. Remove fixing bolts from EHCU.
2. Remove coil integrated module from hydraulic unit.
Reassembly
To reassembly, follow the disassembly steps in the
reverse order, noting the following points:
Torque
Fixing bolts: 4.4 N´m (39 lb in)
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
Torque
Hydraulic unit fixing nuts : 22 N´m (16 lb ft)
Ground cable : 14 N´m (10 lb ft)
Brake pipe (joint bolts) : 16 N´m (12 lb ft)

After installing the hydraulic unit, bleed brakes
completely. See
Section 5A ªHydraulic Brakesº.

5B±4ANTI±LOCK BRAKE SYSTEM
Front Wheel Speed Sensor
Front Wheel Speed Sensor and Associated Parts
350RS033
Legend
(1) Speed Sensor Connector
(2) Sensor Cable Fixing Bolt (Upper side)(3) Sensor Cable Fixing Bolt (Lower side)
(4) Sensor Cable Fixing Bolt (Sensor side)
(5) Speed Sensor
Removal
1. Remove speed sensor connector.
2. Remove sensor cable fixing bolt (Upper side).
3. Remove sensor cable fixing bolt (Lower side).
4. Remove the speed sensor cable fixing bolt.
5. Remove speed sensor.
Inspection and Repair
1. Check the speed sensor pole piece for presence of
foreign materials; remove any dirt, etc.
2. Check the pole piece for damage; replace speed
sensor if necessary.
3. Check the speed sensor cable for short or open
circuit, and replace with a new one if necessary.
To check for cable short or open, bend or stretch the
cable while checking for continuity.
4. Check the sensor ring for damage including tooth
chipping, and if damaged, replace the sensor ring
assembly. Refer to removal of the sensor ring in
Section
4C ªFront hub and discº.
Installation
1. Install speed sensor and take care not to hit the speed
sensor pole piece during installation.
2. Install speed sensor fixing bolt and tighten the fixing
bolt to the specified torque.
Torque: 11 N´m (95 lb in)
3. Install speed sensor cable fixing bolt (Lower side) and
tighten the fixing bolt to the specified torque.
Torque : 24 N´m (17 lb ft)
4. Install speed sensor cable fixing bolt (Upper side) and
tighten the fixing bolt to the specified torque.
Torque : 6 N´m (52 lb in)
NOTE: Confirm that a white line marked on the cable is
not twisted when connecting the speed sensor cable.
5. Install speed sensor connector.

5B±5 ANTI±LOCK BRAKE SYSTEM
Rear Wheel Speed Sensor
Removal
1. Disconnect harness connector (1).
2. Remove sensor fixing bolt (2) .
3. Remove speed sensor (3).
350R100004
Inspection and Repair
1. Check speed sensor pole piece for presence of
foreign materials; remove any dirt, etc.
2. Check the pole piece for damage, and replace speed
sensor if necessary.
3. Check speed sensor cable for short or open, and
replace with a new one if necessary. To check for
cable short or open, bend or stretch the cable while
checking for continuity.
4. Check the sensor ring for damage including tooth
chipping, and if damaged, replace the axle shaft
assembly. Refer to removal of the sensor ring in
Section
4A2 ªDifferential (Rear)º.
Installation
1. Install speed sensor (3).
2. Tighten the sensor fixing bolt (2) to the specified
torque.
Torque : 24 N´m (17 lb ft)
3. Connect harness connector (1).
350R100004

5C±2
POWER±ASSISTED BRAKE SYSTEM
Inspection and Repair 5C±40. . . . . . . . . . . . . . . . . .
Reassembly 5C±40. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 5C±42. . . . . . . . . . .
Rear Disc Brake Pads (4y4 Model) 5C±43. . . . . . . .
Brake Pads Inspection 5C±43. . . . . . . . . . . . . . . . .
Brake Pads and Associated Parts 5C±43. . . . . . .
Removal 5C±44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±44. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Disc Brake Rotor (4y4 Model) 5C±46. . . . . . . .
Inspection 5C±46. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Brake Rotors 5C±46. . . . . . . . . . . . . . . .
Refinishing Brake Rotors 5C±46. . . . . . . . . . . . . . .
Rear Drum (In Disc) Inside Diameter Check 5C±47
Rear Disc Brake Caliper Assembly
(4y4 Model) 5C±48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Disc Brake Caliper Assembly and
Associated Parts 5C±48. . . . . . . . . . . . . . . . . . . . . .
Removal 5C±48. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±49. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Disc Brake Caliper (4y4 Model) 5C±50. . . . . .
Rear Disc Brake Caliper Disassembled
View 5C±50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 5C±51. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5C±51. . . . . . . . . . . . . . . . . .
Reassembly 5C±51. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications (4y4 Model) 5C±53
Brake Lining 5C±54. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lining and Associated Parts 5C±54. . . . . . .
Removal 5C±54. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Lining Inspection 5C±55. . . . . . . . . . . . . . . .
Installation 5C±55. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Brake Adjustment (4y2 Model) 5C±56. . . . .
Servicing The Brake Drum 5C±56. . . . . . . . . . . . . .
Wheel Cylinder Assembly (4y2 Model) 5C±57. . . . .
Wheel Cylinder Assembly and Associated
Parts 5C±57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C±57. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C±57. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 5C±58. . . . . . . . . . . . . . . . . . . .
Disassembly 5C±58. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5C±58. . . . . . . . . . . . . . . . . .
Reassembly 5C±58. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 5C±60. . . . . . . . . . .
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.
General Description
Master Cylinder Assembly
330RS001

5C±3 POWER±ASSISTED BRAKE SYSTEM
The master cylinder contains two pistons that supply the
hydraulic pressure for a dual±circuit braking system. The
primary piston provides the fluid pressure to the front
brakes, while the secondary piston provides the fluid
pressure to the rear brakes. If the pressure is lost from
either system, the remaining system will function to stop
the vehicle.CAUTION:
1. The master cylinder is not repairable. If found
defective, it must be replaced as a complete
assembly.
2. If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or
part of the brake system. (Refer to
Bleeding Brake
Hydraulic System
in this section.)
3. The torque values specified are for dry,
unlubricated fasteners.
4. Perform service operations on a clean bench free
from all mineral oil materials.
Brake Booster
331RS001
This booster is a tandem vacuum unit with a diaphragm
effective diameter 205mm (8.072 in) + 230mm (9.056 in).
In normal operating mode, with the service brakes in the
released position, the tandem vacuum booster operates
with vacuum on both sides of its diaphragms. When the
brakes are applied, air at atmospheric pressure is
admitted to both sides of the diaphragm to provide the
power assist. When the service brake is released, the
atmospheric air is shut off from both sides of the
diaphram. The air is then drawn from the booster through
the vacuum check valve to the vacuum source.CAUTION:
1. If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or
part of the brake system.
2. The torque values specified are for dry,
unlubricated fasteners.
3. The vacuum booster is not repairable and must be
replaced as complete assembly.

5C±4
POWER±ASSISTED BRAKE SYSTEM
Disc Brake
Front Disc Brake
A05RW001
Rear Disc Brake (4y4 Model)
A05RW002
The disc brake assembly consists of a caliper, piston,
rotor, pad assembly and support bracket. The caliper
assembly has a single bore and is mounted to the support
bracket with two mounting bolts. The support bracket
allows the caliper to move laterally against the rotor. The
caliper is a one±piece casting with the inboard side
containing the piston bore. A square cut rubber seal is
located in a groove in the piston bore which provides the
hydraulic seal between the piston and the cylinder wall.
NOTE:
1. Replace all components included in repair kits used to
service this caliper.
2. Lubricate rubber parts with clean brake fluid to ease
assembly.3. If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or part
of the brake system.
4. Replace pads in axle sets only.
5. The torque values specified are for dry, unlubricated
fasteners.
6. Perform the service operation on a clean bench free
from all mineral oil materials.
Operation
Hydraulic pressure, created by applying the brake pedal,
is converted by the caliper to a stopping force. This force
creates a clamping action of the piston pressing towards
the rotors (outward) and the caliper slides inward toward
the vehicle. This clamping action forces the linings
against the rotor, creating friction to stop the vehicle.

5C±12
POWER±ASSISTED BRAKE SYSTEM
Front Caliper Brake Hose
Front Caliper Brake Hose and
Associated Parts
352RW001
Legend
(1) Bolt and Gasket
(2) Clip
(3) Hose
(4) Brake Pipe
Removal
1. Raise the vehicle and support it with suitable safety
stands.
2. Remove the wheel and tire assembly.
3. Clean dirt, grease, and other foreign material off the
hose fittings at both ends.
4. Disconnect brake pipe.
5. Remove clip.
6. Remove bolt and gasket.
7. Remove hose.
Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Tighten the brake pipes to the specified torque
Torque: 19 N´m (14 lb ft)
2. Tighten the bolt to the specified torque.
Torque: 35 N´m (26 lb ft)
NOTE: Always use new gaskets and be sure to put the
hooked edge of the flexible hose end into the anti±rotation
cavity.
After installing the brake hoses, bleed the brakes as
described in this section.

5C±13 POWER±ASSISTED BRAKE SYSTEM
Rear Axle Brake Hose
Rear Axle Brake Hose and Associated
Parts
352RW002
Legend
(1) Brake Pipe
(2) Clip
(3) Bolt
(4) Brake Pipe
(5) Hose
Removal
1. Raise the vehicle and support it with suitable safety
stands.
2. Remove wheel and tire assembly.
3. Clean dirt, grease, and other foreign material off the
hose fittings at both ends.
4. Disconnect brake pipe.
5. Remove clip.
6. Remove brake pipe.
7. Remove bolt.
8. Remove hose.
Installation
To install, follow the removal steps in the reverse order,
noting the following points.
1. Tighten the brake pipes to the specified torque
Torque: 19 N´m (14 lb ft)
2. Tighten the bolt to the specified torque.
Torque: 15 N´m (11 lb ft)
After installing the brake hoses, bleed the brakes as
described in this section.