stop start ISUZU AXIOM 2002 Service Repair Manual

1A±60
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Checking and Adjusting for
Compressor Replacement
150 cc (5.0 fl.oz.) of oil is charged in compressor (service
parts). So it is necessary to drain the proper amount of oil
from the new compressor.
1. Perform oil return operation.
2. Discharge and recover the refrigerant and remove the
compressor.
3. Drain the compressor oil and measure the extracted
oil.
4. Check the compressor oil for contamination.
5. Adjust the oil level as required.
(Amount of oil drained
from used compressor)
(Draining amount of oil
from new compressor)
less than 90 cc (3.0 fl.oz)Same as drained
amount
more than 90 cc (3.0
fl.oz)90 cc (3.0 fl.oz)
6. Evacuate, charge and perform the oil return
operation.
7. Check the system operation.
Contamination of Compressor Oil
Unlike engine oil, no cleaning agent is added to the
compressor oil. Even if the compressor runs for a long
period of time (approximately one season), the oil never
becomes contaminated as long as there is nothing wrong
with the compressor or its method of use.
Inspect the extracted oil for any of the following
conditions:

The capacity of the oil has increased.

The oil has changed to red.

Foreign substances, metal powder, etc., are present
in the oil.
If any of these conditions exists, the compressor oil
is contaminated. Whenever contaminated
compressor oil is discovered, the receiver/drier must
be replaced.
Oil Return Operation
There is close affinity between the oil and the refrigerant.
During normal operation, part of the oil recirculates with
the refrigerant in the system. When checking the amount
of oil in the system, or replacing any component of the
system, the compressor must be run in advance for oil
return operation. The procedure is as follows:
1. Open all the doors and the engine hood.
2. Start the engine and air conditioning switch to ªONº
and set the fan control knob at its highest position.
3. Run the compressor for more than 20 minutes
between 800 and 1,000 rpm in order to operate the
system.
4. Stop the engine.
Replacement of Component Parts
When replacing the system component parts, supply the
following amount of oil to the component parts to be
installed.
(Component parts to be
installed)
(Amount of Oil)
Evaporator 50 cc (1.7 fl. oz.)
Condenser30 cc (1.0 fl. oz.)
Receiver/dryer30 cc (1.0 fl. oz.)
Refrigerant line (one
piece)10 cc (0.3 fl. oz.)

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±81
Movement of Intake Actuator
The controller on the automatic heater/air conditioner
control unit selects an intake mode to be used.
As the Terminal No.5 C-33 is grounded via the sliding
contact on the terminal plate, the transistor on the driver is
activated, thus turning on the motor rotation. Then,
accompanying move of the motor, the sliding contact
rotates until grounding of the Terminal No.5 C-33 is
removed, thus stopping the motor.
Grounding
terminal
Rotation
directionRemarks
No.5 C-33ClockwiseRE-CIRCULATI
ON"MIX"
FRESH
C01RX006
Overview of Automatic Control of
Automatic Air Conditioner
The automatic air conditioner on this vehicle has the
following features:

Interior temperature control.

Air flow control.

Mode (blow port) control.

Intake (switching between fresh air and interior air)
control.

Heater start timing control.

Cooler start timing control.

Evaporator anti-freeze control.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±89
Performance and Movement
checklist for Automatic Air
Conditioner Related Parts
Start the engine, and when the engine coolant reached
50
C (122
F) check performance and movement of the
related parts according the following checklist.
Performance Check Using the Manual Switch
NoItemProcedureCriteriaNo.ItemConditionOperationCriteria
1
Air discharge
temperature
(Ai i d
Auto±switch ONSet temperature to
18
C (65
F).Cold air discharge.
1(Air±mix door
operation)Set temperature to
32
C (90
F).Hot air discharge.
2
Air discharge
volume (Fan
operation)Fan switch ON1. Set temperature to
25
C (77
F).
2. Press the OFF
switch.Fan does not operate. There is no
air discharge.
21. Set temperature to
25
C (77
F).
2. Press the fan 
switch.Fan operates. Fan speed increases
each time the switch is pressed (LO
to HI in 5 increments).
3
Air discharge
temperature
(Mode door
operation)Fan in manual
5±speed operation1. Set temperature to
25
C (77
F).
2. Press the mode
switch.
3. Move through the 5
modes
(VENT"BI±LEVEL
"FOOT"DEF/FO
OT"DEF).
Panel display lights for each
mode.

Air discharge outlet position
changes for each mode.
4
Inside/outside air
mode (Intake door
operation)Auto±switch ON1. Set temperature to
25
C (77
F).
2. Press the intake
switch.
3. Press the fan 
switch.
4. Set the fan to the
highest speed.
5. Press the intake
switch.
Intake switch LED turns from on
to off.

Air discharge sound changes.
5
CompressorOutside air
temperature above
0
C (32
F) and
vehicle interior at
normal temperature1. Set temperature to
25
C (77
F).
2. Press the OFF
switch.
3. Press the
auto±switch.
4. Press the air
conditioner switch.
When the auto±switch is
pressed, the LED in the air
conditioner switch turns on and
the compressor begins
operation.

When the air conditioner switch
is pressed, the LED in the air
conditioner switch turns off and
the compressor stops operation.

1A±114
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Chart D: Fan Does Not Stop
StepActionValue(s)Ye sNo
11. Disconnect the max high relay, the power transistor
connector C±34 and the auto A/C control unit
connector I±20.
2. Turn on the ignition switch.
Does the blower motor stop?
ÐGo to Step 3Go to Step 2
2Repair a short circuit between connector No.C36±2
and No.C35±5, No.C36±2 and No.C34±1, or
No.C36±2 and I20±17.
Is the action complete?
ÐVerify repairÐ
3Is the max high relay normal? (Refer to the later section
on ªindividual inspectionº.
)ÐGo to Step 4
Replace the
relay
4Reinstall the max high relay.
Does the blower motor start operating?
ÐGo to Step 6Go to Step 5
5Repair a short circuit between connector No.C35±4
and No.I19±2.
Is the action complete?
ÐGo to Step 4Ð
6Is the power transistor normal? (Refer to the later
section on ªindividual inspectionº.
)
ÐGo to Step 7
Replace the
power
transistor
7Reinstall the power transistor.
Does the blower motor start operating?
Ð
Replace the
auto A/C
control unit
Ð

2A±10
POWER±ASSISTED STEERING SYSTEM
The steering column has three important features in
addition to the steering function:
1. The column is energy absorbing, designed to
compress in a front-end collision to minimize the
possibility of injury to the driver of the vehicle.
2. The ignition switch and lock are mounted
conveniently on the column.
3. With the column mounted lock, the ignition and
steering operation can be locked to prevent theft of
the vehicle.The column can be disassembled and reassembled.
However, to insure the energy absorbing action, use only
the specified screws, bolts and nuts as designated, and
tighten them to the specified torque.
Handle the column with care when it is removed from the
vehicle. A sharp blow on the end of steering shaft or shift
lever, or dropping the assembly could shear or loosen the
fasteners that maintain column rigidity.
Power Steering System Test
Test Procedure
C02RW001
Legend
(1) Fluid Reservoir(2) Power Steering Unit
(3) Power Steering Pump
Test of fluid pressure in the power steering system is
performed to determine whether or not the oil pump and
power steering unit are functioning normally.
The power steering system test is used to identify and
isolate hydraulic circuit difficulties. Prior to performing
this test, the following inspections and corrections, if
necessary, must be made.

Inspect pump reservoir for proper fluid level.

Inspect pump belt for proper tension.

Inspect pump driver pulley condition. 1. Place a container under the pump to catch the fluid
when disconnecting or connecting the hoses.
2. With the engine NOT running, disconnect the
pressure hose at the power steering pump and install
power steering tester J-29877-A. The gage must be
between the shutoff valve and pump. Open the
shutoff valve.
3. Check the fluid level. Fill the reservoir with power
steering fluid, to the ªFullº mark. Start the engine,
then turn the steering wheel and momentarily hold it
against a stop (right or left). Turn the engine off and
check the connections at tester for leakage.

POWER±ASSISTED STEERING SYSTEM2A±11
4. Bleed the system. Refer to Bleeding the Power
Steering System
in this section.
5. Start the engine and check the fluid level. Add power
steering fluid if required. When the engine is at
normal operating temperature, increase engine
speed to 1500 rpm.
CAUTION: Do not leave shutoff valve fully closed
for more than 5 seconds, as the pump could become
damaged internally.
6. Fully close the shutoff valve. Record the highest
pressures.

If the pressure recorded is within 9300±9800 kPa
(1350±1420 psi), the pump is functioning within its
specifications.

If the pressure recorded is higher than 9800 kPa
(1420 psi), the valve in the pump is defective.

If the pressure recorded is lower than 9300 kPa
(1350 psi), the valve or the rotating group in the
pump is defective.
7. If the pump pressures are within specifications, leave
the valve open and turn (or have someone else turn)
the steering wheel fully in both directions. Record the
highest pressures and compare with the maximum
pump pressure recorded in step 6. If this pressure
cannot be built in either side of the power steering
unit, the power steering unit is leaking internally and
must be replaced.
8. Shut the engine off, remove the testing gauge.
9. Reconnect the pressure hose, check the fluid level
and make the needed repairs.
10. If the problem still exists, the steering and front
suspension must be thoroughly examined.
Maintenance
The hydraulic system should be kept clean and fluid level
in the reservoir should be checked at regular intervals and
fluid added when required. Refer to
Recommended
Fluids and Lubricants in General Information
section for
the type of fluid to be used and the intervals for filling.
If the system contains some dirt, flush it as described in
this section. If it is exceptionally dirty, the pump must be
completely disassembled before further usage. (The
steering unit cannot be disassembled.)
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight. Make
sure the clips, clamps and supporting tubes and hoses
are in place and properly secured.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. Air in the system will cause spongy
action and noisy operation. When a hose is disconnected
or when fluid is lost, for any reason, the system must be
bled after refilling. Refer to
Bleeding the Power Steering
System
in this section.

Inspect belt for tightness.

Inspect pulley for looseness or damage. The pulley
should not wobble with the engine running.

Inspect hoses so they are not touching any other
parts of the vehicle.

Inspect fluid level and fill to the proper level.
Fluid Level
1. Run the engine until the power steering fluid reaches
normal operating temperature, about 55
C (130
F),
then shut the engine off.
2. Check the level of fluid in the reservoir.
3. If the fluid level is low, add power steering fluid as
specified in General Information to the proper level
and install the receiver cap.
4. When checking the fluid level after the steering
system has been serviced, air must be bled from the
system. Refer to
Bleeding the Power Steering
System
in this section.
Bleeding The Power Steering System
When a power steering pump or unit has been installed,
or an oil line has been disconnected, the air that has
entered the system must be bled out before the vehicle is
operated. If air is allowed to remain in the power steering
fluid system, noisy and unsatisfactory operation of the
system may result.
Bleeding Procedure
When bleeding the system, and any time fluid is added to
the power steering system, be sure to use only power
steering fluid as specified in General Information.
1. Fill the pump fluid reservoir to the proper level and let
the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds. Do
not turn the steering wheel. Then turn the engine off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level
remains constant after running the engine.
5. Raise and support the front end of the vehicle so that
the wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel right
and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle, set the steering wheel at the
straight forward position after turning it to its full steer
positions 2 or 3 times, and stop the engine.
9. Check the fluid level and refill as required.
10. If the fluid is extremely foamy, allow the vehicle to set
a few minutes, then repeat the above procedure.
Flushing The Power Steering System
1. Raise and support the front end of the vehicle off the
ground until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet
connector and plug the connector port on the pump.
Position the line toward a large container to catch the
draining fluid.
3. While running the engine at idle, fill the reservoir with
new power steering fluid. Turn the steering wheel in
both directions. Do not contact or hold the steering
wheel to the wheel stops. This will cause the pump to
go to pressure relief mode, which may cause a
sudden fluid overflow at the reservoir.

4B1±4
DRIVELINE CONTROL SYSTEM
Functions of Indicator Lamp
TOD Switch and Indication of Drive Mode
The TOD switch sends signals to the TOD control unit
which selects drive modes and controls the shift on the fly
system (axle disconnect : ADC).
TOD
switch
tt
Drive modeTransfer shift conditionTransfer posi-
tion detectionShift on the flyTOD indicator
state
state4HSW4LSWAxle
SWADC circuit
2HRear-wheel
drive (RWD)Permissible during
driving (less than
100 km/h or 62 mph)OFFOFFOFFTurning on
electricity
TODElectronic
torque split
4WD (HIGH)
OFFOFFONTurning off
electricity
4WD (HIGH)
(TOD)AT: Neutral
Brake: Applied
Th t (l4LLow range
mechanical
direct 4WD
(LOW) (4L)The car stops (less
than 2 km/h or
1.2 mph and less than
1500 rpm)OFFONONTurning off
electricity
ADC: Shift on the fly
SW: Switch
Bulb check :The bulb of indicator lamp is checked for 2
seconds when ignition key is turned on.
Bulb Check
When the starter switch is turned on, the TOD indicator
lamps comes on as shown below.
NOTE: Once the starter switch is turned on, all the TOD
indicator lamps are lit for two seconds even if the transfer
lever is in any position.
C07RW016

DRIVE LINE CONTROL SYSTEM (TOD) 4B2±10
Motor Position and Encoder Position Code
High-Low Shift Motor PositionHigh-Low shift Motor Encoder SignalState of
MotorPosition aPosition bPosition cPosition dMotor
High EndAOFFOFFOFFONHigh Position
Near High EndBOFFONOFFON
High PositionCONONOFFON
Middle Zone (1)DONONONON
Middle Zone (2)EOFFONONON
Neutral PositionFOFFONONOFF
Middle Zone (3)GONONONOFF
Low PositionHONOFFONOFFLow Position
Low EndIONOFFONON
Encode Position Plate
F04R100005
Legend
(1) OFF Aria
(2) ON Aria(3) Low
(4) High
(5) Earth
Shift High Range and Low Range
When the car is stops (less than 2km/h or 1.2 mph and
less than 1500 rpm), the AT selector position is neutral,
the brake is applied, and the TOD switch is changed to 4L
from TOD (or to TOD from 4L), the high-low shift motor
starts by power applied from the TOD control unit and
turns the shift shaft through the worm gear.
The shift shaft turns the shift cam through the torsional
spring.
The end of the shift cam moves the lockup shift fork and
the spiral groove on the outside of the shift cam slides the
high±low shift fork.

DRIVE LINE CONTROL SYSTEM (TOD) 4B2±14
Diagnosis
General Information Diagnosis
The troubles on TOD are classified into the group that can
be identified by the lighting status of the TOD indicator
lamps and those that can be recognized as abnormal
phenomena of the vehicle by the driver.
The troubles that can be identified by the lighting status of
the TOD indicator lamps are examined by the procedures
ªDiagnosis from Trouble Codesº and ªTrouble Diagnosis
Depending on The Status of TOD Indicatorº. The troubles
that can be recognized as abnormal phenomena of the
vehicle by the driver are examined by the procedure
ªDiagnosis from symptomº.
Self-diagnosis
The control unit has a function of self-diagnosis. If a
trouble occurs in the course of system startup, the control
unit blinks the CHECK lamp and saves the trouble code.
C07RW021
NOTE: If an intermittent fault occurs, the control unit
stops blinking upon removal of the fault. The trouble code
is saved to the control unit.

DRIVE LINE CONTROL SYSTEM (TOD) 4B2±16
How to Clear The Trouble Code
The trouble codes saved to the control unit can be deleted
by the following procedure if the starter switch is being in
the OFF position.
1. Short-circuit terminal 8 of the self-diagnostic
connector to GND (terminal 4 or 5).
2. Turn on the starter switch while maintaining the state
of step1, and stop short-circuiting terminal 8 to GND
within five seconds.
826R200011
3. If the conditions shown in steps 1 and 2 are met, the
trouble codes saved to the control unit are cleared.
(After the codes are completely deleted, the code 12
that indicates the normal condition is continuously
displayed.)
Precautions on Diagnosis
Replacement of Control Unit
The control unit itself rarely fails. In most cases, the
harnesses have failed (i.e. short-circuit) to cause
secondary troubles. Other cases include that the cause
has been unknown due to intermittent occurrence of
troubles and the troubles are removed accidentally along
with replacement of control unit, resulting in misjudgment
of cause. Therefore, before replacing the control unit,
check the connector joints and whether the unspecified
current flows in the control unit due to short-circuit
between harnesses.
Trouble Intermittently Observed
Troubles intermittently observed are mostly attributable
to temporary imperfect connection of harnesses and
connectors.
When such troubles are found, check the associated
circuit according to the following procedure.
1. Check whether improper connectors are plugged in
or connector terminals are completely engaged.
2. Check whether the terminals are deformed or
damaged. If yes, remove the deformation or damage
and connect the terminals securely.3. It is likely that wires in the harness are falsely broken.
Therefore, in examination of failed harness circuit,
shake the harness for check to such extent that the
harness will not be damaged.
Test Run of Failed TOD Vehicle
If the TOD indicator lamps experienced faulty operation
even once in the past, the failed portion can be identified
by use of the procedure ªDiagnosis from Trouble Codesº
or ªTrouble Diagnosis Depending on the Status of TOD
Indicatorº. If the troubles that are only recognized as
abnormal phenomena of the vehicle by the driver are
observed, conduct the test run in the following procedure
to reproduce the faulty phenomena and diagnose the fault
for each phenomenon.
1. Start the engine, and check that the TOD indicator
lamps are turned on for about two seconds for initial
check; the CHECK lamp goes off; and the TOD
indicator lamps display the specified drive mode. (If
the CHECK lamp starts blinking, read the trouble
codes and identify the failed portion.)
2. While keeping the vehicle standstill, operate the TOD
switch to change the modes: 2H mode"TOD
mode"4L mode"TOD mode"2H mode. Check
that the TOD indicator lamps correctly display the
status whenever the mode is changed. If the
transition status is displayed during the shift
operation, run the vehicle a little to complete shifting.
3. Slowly start the vehicle in the TOD mode, and add the
power to accelerate to at least 40 km/h (25 mph)and
maintain the speed for about two minutes. Apply the
brake to completely stop the vehicle. Repeat this test
pattern at least three times.
4. Turn the steering to the right end (or left end) in the
TOD mode, and slowly start the vehicle and make a
circle five times. Next, conduct the same test in the 2H
mode.
5. Slowly start the vehicle in the TOD mode, and
accelerate to at least 40 km/h (25 mph). Keep the
established speed, carefully change the mode in the
sequence ªTOD mode"2H mode "TOD modeº
while checking that the shift is complete in each mode
change. After the test, apply the brake to completely
stop the vehicle.
6. Slowly start the vehicle in the TOD mode, and
accelerate to at least 40 km/h (25 mph). Apply the
brake strongly so that the ABS works, and completely
stop the vehicle.
7. Slowly start the vehicle in the 4L mode, and
accelerate to at least 20 km/h (13 mph). Apply the
brake to completely stop the vehicle.
If the CHECK lamp starts blinking during the test run, read
the trouble codes and give appropriate maintenance
according to the diagnostic procedure. If the TOD
indicator lamps are lit abnormally during the run, check
the lighting condition and give appropriate maintenance
according to the diagnostic procedure. Even if the
phenomena are not observed, try to reproduce the
abnormal state reported by the customer to the possible
extent.