torque ISUZU AXIOM 2002 Service Repair Manual

8E±10METER AND GAUGE
Main Data and Specifications
Torque Specifications
ApplicationN´mLb FtLb In
Vehicle Speed Sensor Fixing2720Ð

8F±1 BODY STRUCTURE
AXIOM
BODY AND ACCESSORIES
BODY STRUCTURE
CONTENTS
Service Precaution 8F±2. . . . . . . . . . . . . . . . . . . . . .
Frame 8F±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 8F±2. . . . . . . . . . . . . . . . . . . . .
Frame Dimensions 8F±3. . . . . . . . . . . . . . . . . . . .
General Description (Bumper) 8F±4. . . . . . . . . . . .
Front Bumper 8F±4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±4. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Bumper 8F±7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±7. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description (Sheet Metal) 8F±10. . . . . . . . .
Engine Hood 8F±10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±10. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Hood Lock 8F±13. . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±13. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Fender Panel 8F±15. . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±15. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body Mounting 8F±18. . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±18. . . . . . . . . . . . . . . . . . . . . . . .
Tightening Torque 8F±18. . . . . . . . . . . . . . . . . . . . . . .
Body Dimension 8F±19. . . . . . . . . . . . . . . . . . . . . . . .
Front Section 8F±19. . . . . . . . . . . . . . . . . . . . . . . . .
Room Section (Front Side) 8F±22. . . . . . . . . . . . . .
Room Section (Rear Side) 8F±24. . . . . . . . . . . . . .
Rear Section 8F±26. . . . . . . . . . . . . . . . . . . . . . . . . .
Side Body Section (Front side) 8F±28. . . . . . . . . .
Side Body Section (Rear side) 8F±30. . . . . . . . . .
General Description (Body) 8F±32. . . . . . . . . . . . . . .
Instrument Panel Assembly 8F±32. . . . . . . . . . . . . . .
Parts Location 8F±32. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 8F±34. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Door Assembly 8F±35. . . . . . . . . . . . . . . . . . . .
Parts Location 8F±35. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±36. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Door Assembly 8F±37. . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±37. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±38. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Window Regulator, Glass and Glass
Run 8F±39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±39. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Window Regulator, Glass and Glass
Run 8F±42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±42. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±43. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±45. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tailgate 8F±46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±46. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spare Tire Hanger 8F±49. . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±49. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±50. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±50. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windshield 8F±51. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±51. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±51. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±52. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Quarter Glass 8F±55. . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±55. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±55. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±56. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tailgate Glass 8F±57. . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±57. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±57. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±58. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 8F±59. . . . . . . . . . . . .

8F±2BODY STRUCTURE
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.
Frame
General Description
Proper frame alignment is important to assure normal
vehicle life and performance of many other parts of the
vehicle. If the vehicle has been involved in a fire, collision
or has been overloaded, it is necessary to check the
frame alignment.

8F±6BODY STRUCTURE
Installation
To install, follow the removal steps in reverse order noting
the following points:
1. Tight the front bumper back bar assembly fixing bolts
to the specified torque.
Torque : 147 N´m (108 lb ft)
2. Front bumper adjustment.

When the bolts fixing front bumper assembly are
tightened, adjustment should be made between the
back bar and front side bumper so that there is a
clearance of 3 mm (0.12 in) between the top of the
bumper and the fender. The angled portion of the
bumper must be flush with the fender.
601R200001

8F±9 BODY STRUCTURE
9. Remove the rear bumper back bar assembly.

Remove the two bolts from both sides.
690R200007
10. Remove the reflector assembly.

Remove the two nuts.
Installation
To install, follow the removal steps in reverse order, noting
the following points:
1. Tighten the rear bumper back bar assembly fixing
bolts to the specified torque.
Torque : 147 N´m (108 lb ft)
2. Rear bumper adjustment.

When the bolts fixing rear bumper assembly are
tightened, adjustment should be made with shims
so that clearances shown in the figure below are
provided between the body (tailgate) (1) and the
rear bumper (2).
690R200008

8F±11 BODY STRUCTURE
Removal
1. Open the hood.
2. Support the hood.
3. Remove the windshield washer nozzle tube.
860R200005
4. Remove the hood hinge bolts.

Before removing the hinges from the engine hood,
scribe a mark showing location of the hinges to
facilitate installation in the original position.
610R200002
5. Remove the engine hood.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Tighten the engine hood hinge fixing bolts to the
specified torque.
Torque : 10 N´m (87 lb in)2. Check the engine hood and fender(1).
Clearance: 4.5 mm (0.18 in)
Height (step): 0.5 mm (0.02 in)

Adjust clearance with the hinges on the engine
hood.

Adjust height (step) with the hood rests(2).
610R200003
610RX001

8F±14BODY STRUCTURE
Installation
To install, follow the removal steps in the reverse order
noting the following points:
1. Reroute the control cable to its original position, and
check and see if the lock assembly and control lever
work normally.
2. Tighten the hood lock assembly fixing bolts to the
specified torque.
Torque : 10 N´m (87 lb in)

8F±16BODY STRUCTURE
Removal
1. Disconnect the battery ground cable.
2. Remove the front bumper fascia assembly.

Refer to
Front Bumper in this section.
3. Remove the front turn signal light assembly.

Remove the fixing screw and disconnect the
connector.
610R200008
4. Remove the rocker cover assembly.

Refer to
Rocker Cover Assembly in Exterior/Interior
Trim section.
5. Remove the inner liner.
647RY00003
6. Remove the antenna assembly.

Refer to
Rod Type Antenna in Entertainment
section.
7. Remove the front fender panel (1).

Remove the eight fixing bolts.
8. Remove the engine compartment upper extension
(2).
614R200002
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Tighten the front fender panel fixing bolts to the
specified torque.
Torque : 7 N´m (61 lb in)
2. Check the fender and front door (1).
Clearance: 5.0 mm (0.196 in)
Height (step): Flush
610R200009

8F±18BODY STRUCTURE
Body Mounting
Parts Location
501R200002
Legend
(1) No.1 Body Mounting
(2) No.2 Body Mounting
(3) No.3 Body Mounting(4) No.4 Body Mounting
(5) No.5 Body Mounting
(6) Body Side Mounting Bracket
(7) Frame Side Mounting Bracket
Tightening Torque
1. Tighten the body mounting bolts to specified torque.
Torque : 50 N´m (41 lb ft)

8F±36BODY STRUCTURE
4. Remove the upper and lower hinge bolts.

Position a wood block under the door for protection
and support the door assembly with hands during
removal or installation.
635R200013
5. Remove the door harness connector.

Pull the door harness grommet out in order to
disconnect the harness connector.
630R200012
6. Remove the front door assembly.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Align the door fitting to the body.

Check the fender and front door (1).
Clearance: 5.0 mm (0.196 in)
Height (step): Flush

Check the front door and rear door (2).
Clearance: 5.0 mm (0.196 in)
Height (step): Flush

Check the rear door and body (3).
Clearance: 5.0 mm (0.196 in)
Height (step): Flush
Adjust clearance with door hinges.
Adjust height (step) by tapping on the fender lightly
with a rubber hammer.
610R200005
2. Tighten the door hinge bolts to the specified torque.
Torque : 34 N´m (25 lb ft)
3. Tighten the door check arm bolt and nuts to the
specified torque.
Torque : 9 N´m (78 lb in)