torque ISUZU AXIOM 2002 Service Manual PDF

WHEEL AND TIRE SYSTEM3E±5
Condition CorrectionPossible cause
Erratic Steering When BrakingWorn wheel bearings.Replace wheel bearings.
Broken or sagging springs.Replace spring (pairs).
Leaking caliper.Repair or replace caliper.
Warped discs.Replace brake disc.
Badly worn brake pads.Replace brake pads.
Tires are inflated unequally.Inflate tires to proper pressure.
Low or Uneven Trim HeightBroken or sagging springs.Replace springs (In pairs).
Vehicle overloaded.Reduce load.
Incorrect springs.Adjust or replace torsion bar.
Suspension BottomsVehicle overloaded. Reduce load.
Faulty shock absorber.Replace shock absorber.
Incorrect, broken or sagging springs.Replace springs.
Body LeansLoose stabilizer bar.Tighten stabilizer bar bolts or replace
bushings.
Faulty shock absorber, struts or
mounting.Replace shock absorber.
Broken or sagging springs.Replace springs (In pairs).
Vehicle overloaded.Reduce load.
Cupped TiresWorn wheel bearings.Replace wheel bearing.
Excessive tire or wheel run out.Replace tire or wheel.
Worn ball joints.Replace ball joints.
Tire out of balance.Adjust tire balance.
Irregular and Premature Wear
480RS001
Irregular and/or premature wear has many causes.
Some of them are incorrect inflation pressures, lack of tire
rotation, poor driving habits or improper wheel alignment.
Incorrect inflation is common cause of tire premature
wear.NOTE: Due to their design, radial tires tend to wear faster
in the shoulder area, particularly on the front tires. This
makes regular rotation especially necessary. After
rotation, be sure to check wheel nut torque, and set tire
pressures.

WHEEL AND TIRE SYSTEM3E±11
Wheel
Wheel and Associated Parts
480R200004
Legend
(1) Wheel Lug Nut
(2) Alumi Wheel and Tire
Removal
1. Loosen wheel lug nut by approximately 180
(half a
rotation), then raise the vehicle and remove the nuts.
2. Remove wheel and tire.
NOTE: Never use heat to loosen a tight wheel lug nut.
The application of heat to the hub can shorten the life of
the wheel and may cause damage to wheel bearings.
Installation
1. Install wheel and tire.
2. Install wheel lug nut, and lower the vehicle. Tighten
the wheel lug nuts to the specified torque in numerical
order.
Torque: 118 N´m (87 lb ft)
CAUTION: Before installing wheels, remove any
build-up of corrosion on the wheel mounting surface
and brake disc mounting surface by scraping and
wire brushing. Installing wheels without good
metal-to-metal contact at mounting surfaces can
cause wheel nuts to loosen, which can later allow a
wheel to come off while the vehicle is moving.NOTE: Valve caps should be on the valve stems to keep
dust and water out.
480R200003

3E±14WHEEL AND TIRE SYSTEM
Main Data and Specifications
General Specifications
WheelsSize17 y 7JJ
Offset38.0 mm (1.50 in)
P.C.D., wheel studs139.7 mm (5.50 in)
Standard tireSizeP235/65R17
Pressure(Front)180 kPa (26 psi)
Pressure(Rear)180 kPa (26 psi)
Torque Specifications
480R200005

3F±2INTELLIGENT SUSPENSION
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
Intellignet suspension control uses a microcomputer as a
control unit to judge running conditions including engine
revolution from Powertrain Control Module, vehicle speed
from vehicle speed sensor, a brake switch signal, and
vertical and lateral G-sensor signal, then sets optimum
damping force so that best running stability can be
achieved.

INTELLIGENT SUSPENSION3F±33
Removal
1. Disconnect the battery ground cable.
2. Remove the front console assembly.
Refer to
Consoles in Body and Accessories section.
3. Disconnect the connector from the control unit.
View A
828RY00002
Legend
(1) Nut
(2) Screw(3) Control Unit
(4) Bracket
4. Remove 4 nuts.
5. Disconnect the control unit with brackets.
6. Remove 4 screws.
7. Disconnect the control unit from brackets.
Installation
To install, follow the removal steps in the reverse order,
noting the following points.
Torque:
Nut (1) 8N´m (69 lb in)

INTELLIGENT SUSPENSION3F±35
Removal
1. Disconnect the battery ground cable.
2. Disconnect the connector from the harness and
remove the connector from the bracket.
3. Remove the clip.
View B
450RY00005
Legend
(1) Screw
(2) Actuator
(3) Nut
(4) Bracket
(5) Nut
(6) Washer
(7) Shock Absorber
1. Remove 2 screws.
2. Remove the actuator.
3. Remove the nut (3).
4. Disconnect bracket.
5. Remove the nut (5).
6. Disconnect the washer.
7. Remove the shock absorber.
Refer to
Shock Absorber in this section.
Inspection and Repair
Refer to shock Abosorber in this section.
Installation
1. Install the shock absorber.
Refer to
Shock Absorber in this section.
2. Install the washer and nut (5), then tighten it to the
specified torque.
Torque: 15 N´m (11 lb ft)
3. Install the bracket and nut (3), then tighten it to the
specified torque.
Torque: 39 N´m (29 lb ft)
NOTE: Fix the lower nut with wrench not to turn and
tighten upper nut.
4. Fit the top of the shock absorber rod in the connection
part of the actuator.
NOTE:
The mating section is width fitting across flats.
If these normally fit, the distance between the
actuator lower face and the bracket upper face is
about 1 mm.
5. Install 2 screws then tighten it to the specified torque.
3 N´m (26 lb in)
6. Connect the connector to the harness and insert the
connector to the bracket.
7. Connect the actuator harness with the clip.
8. Connect the battery ground cable.

INTELLIGENT SUSPENSION3F±37
Removal
1. Disconnect the battery ground cable.
2. Disconnect the connector (1) from the harness and
remove the connector (1) from the bracket (4).
3. Remove the clip (2).
4. Remove the rear shock absorber (3).
Refer to
Shock Absorber in this section.
5. Disconnect the connector (10) from the harness and
remove the connector (10) from the gusset (11).
6. Remove the 2 bolts (5).
7. Disconnect the G-sensor (6).
Inspection and Repair
Refer to Shock Absorber in this section.
Installation
1. Set the G-sensor on the gusset (11).
2. Install 2 bolts (5) then tighten it to the specified torque.
Torque: 7 N´m (61 lb in)
3. Connect the connector (10) to the harness and insert
the connector (10) to the gusset (11).
4. Install the rear shock absorber (3).
Refer to
Shock Absorber in this section.
5. Connect the connector (1) to the harness and insert
the connector (1) to the bracket (4).
6. Insert the clip (2) to the bracket (4).
7. Connect the battery ground cable.

4A1±1 DIFFERENTIAL (FRONT)
AXIOM
DRIVELINE/AXLE
CONTENTS
Differential (Front) 4A1. . . . . . . . . . . . . . . . . . . . . . .
Differential (Rear) 4A2. . . . . . . . . . . . . . . . . . . . . . .
Driveline Control System 4B1. . . . . . . . . . . . . . . . . Driveline Control System (TOD) 4B2. . . . . . . . . . .
Drive Shaft System 4C. . . . . . . . . . . . . . . . . . . . . .
Transfer Case (TOD) 4D2. . . . . . . . . . . . . . . . . . . .
Differential (Front)
CONTENTS
Service Precaution 4A1±1. . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle 4A1±2. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis 4A1±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Shaft Oil Seal 4A1±3. . . . . . . . . . . . . . . . . . . . .
Pinion Shaft Oil Seal and Associated Parts 4A1±3
Removal 4A1±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A1±4. . . . . . . . . . . . . . . . . .
Installation 4A1±4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle Assembly 4A1±5. . . . . . . . . . . . . . .
Front Drive Axle Assembly and
Associated Parts 4A1±5. . . . . . . . . . . . . . . . . . . . . .
Removal 4A1±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 4A1±6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly 4A1±8. . . . . . . . . . . . . . . . . . . .
Disassembled View 4A1±8. . . . . . . . . . . . . . . . . . . .
Disassembly 4A1±9. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4A1±11. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Cage Assembly 4A1±20. . . . . . . . . . . . . . .
Disassembled View 4A1±20. . . . . . . . . . . . . . . . . . . .
Disassembly 4A1±20. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A1±21. . . . . . . . . . . . . . . . . .
Reassembly 4A1±21. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4A1±23. . . . . . . . . . .
Special Tools 4A1±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 REFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFOMATION. 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 specification. Following these
instructions can help you avoid damage to parts and
systems.

4A1±7 DIFFERENTIAL (FRONT)
3. Tighten the mounting bolts and nuts to the specified
torque.
Torque: 168 N´m (124 lb ft)
412R200004
4. Install the right side knuckle with lower control arm to
the upper control arm.
Refer to
Knuckle in Suspension section.
CAUTION: Carefully insert the drive shaft into the
knuckle, to avoid damaging the oil seal.
5. Align the bolt hole of the lower control arm, then install
the bolts and nuts.
NOTE: Adjust the buffer clearance before tightening the
bolts and nuts of the lower control arm.
6. Install the hose of the shift on the fly.
7. Install the actuator connector of the shift on the fly.
8. Install the tie-rod end of the power steering unit to the
knuckle, tighten the nut to the specified torque.
Torque: 118 N´m (87 lb ft)
9. Install lower bolts and nuts of the shock absorber,
tighten it to the specified torque.
Torque: 93 N´m (69 lb ft)
10. Install lower nuts of the stabilizer link, tighten it to the
specified torque.
11. Install the suspension crossmember.
12. Install the torsion bar.
Refer to
Torsion Bar in Suspension section.
13. Install the front propeller shaft.
Refer to
Front Propeller Shaft in this section.
14. Install the hub and disc assembly and adjust the
bearing preload.
Refer to
Front Hub and Disc in this section.
15. Install the wheel speed sensor of the antilock brake
system.
16. Install the brake caliper. Tighten the bolt of the caliper
bracket to the specified torque.
Torque: 50 N´m (37 lb ft)
17. Install the stone guard.18. Install the tire and wheel.
19. Lower the vehicle, adjust the trim height.
Refer to
Trim Height Adjustment in Steering section.
20. Tighten the bolts and nuts of the lower control arm to
the specified torque.
Refer to
Lower Control Arm in Suspension section.

DIFFERENTIAL (FRONT) 4A1±12
2. Tighten the nut to the specified torque.
Torque: 2.3 N´m (20 lb in)
425RW030
Legend
(1) Pilot : J±21777±42
(2) Pilot : J±42479±2
(3) Gauge Plate : J±42479±1
(4) Nut and Stud : J±21777±43
3. Clean the side bearing bores. Install the dial
indicator with the discs and arbor. Install and
tighten the bearing caps to the specified torque.
Torque: 97 N´m (72 lb ft)
425RW031
Legend
(1) Dial Indicator: J±8001
(2) Gauge Plate: J±42479±1
(3) Disc (2 pcs.): J±23597±8
(4) Arbor: J±23597±1
4. Set the dial indicator to ª0º. Place it on the
mounting post of the gauging arbor with the
contact button touching the indicator pad. Force
the dial indicator downward until the needle has
made a half turn clockwise. Tighten down the dial
indicator in this position.
425RS020
Legend
(1) Dial Indicator
(2) Ganging Arbor
(3) Plunger
(4) Gauge Plate
5. Position the plunger on the gauge plate. Move the
gauging arbor slowly back and forth and locate
the position at which the dial indicator shows the
greatest defection. At this point, once again set
the dial indicator to ª0º.
Repeat the procedure to verify the ª0º setting.
425RS021