ISUZU AXIOM 2002 Service Repair Manual

SECTION TABLE OF CONTENTS
GENERAL INFORMATION
0AGeneral Information
0BMaintenance and Lubrication
WORKSHOP MANUAL
HEATING, VENTILATION AND AIR
CONDITIONING
1AHVAC System
STEERING
2APower-Assisted System
AXIOM
(UPR/S)SUSPENSION
3CFront Suspension
3DRear Suspension
3EWheel and Tire System
3FIntelligent Suspension System
DRIVELINE/AXLE
4A1Differential (Front)
4A2Differential (Rear)
4B1Driveline Control System
4B2Driveline Control System (TOD)
4CDrive Shaft System
4D2Transfer Case (TOD)
FOREWORD
This manual includes special notes, impor tant points, service data,
precautions, etc. That are needed for the maintenance, adjustments,
service, removal and installation of vehicle components.
All information, illustrations and specifications contained in this manual
are based on the latest product information available at the time of
publication.
All rights are reserved to make changes at any time without notice.
Arrangement of the material is shown in the table of contents on the
right-hand side of this page. A black spot on the first page of each
section can be seen on the edge of the book below each section title.
These point to a more detailed table of contents preceding each
section.BRAKE
5ABrake Control System
5BAnti-Lock Brake System
5CPower-Assisted Brake System
5D1Parking Brake System (4´4 model)
5D2Parking Brake System (4´2 model)
ENGINE
6AEngine Mechanical
6BEngine Cooling
6CEngine Fuel
6D1Engine Electrical
6D2Ignition System
6D3Starting and Charging System
6EDriveability and Emissions
6FEngine Exhaust
6GEngine Lubrication
6HEngine Speed Control System
6JInduction
TRANSMISSION
7AAutomatic Transmission
7A1Transmission Control System
BODY AND ACCESSORIES
8ALighting System
8BWiper/Washer System
This manual applies to 2002 models.8CEnter tainment
8DWiring System
8EMeter and Gauge
8FBody Structure
8GSeats
8HSecurity and Locks
8ISun Roof/Convertible Top
8JExterior/Interior Trim
RESTRAINTS
9ASeat Belt System
9JSupplemental Restraint System (Air Bag System)
9J1Restraint Control System
CONTROL SYSTEM
10ACruise Control System

0A±1
GENERAL INFORMATION
AXIOM
GENERAL INFORMATION
CONTENTS
General Information 0A. . . . . . . . . . . . . . . . . . . . .
Maintenance and Lubrication 0B. . . . . . . . . . . . .
General Information
CONTENTS
General Repair Instruction 0A±1. . . . . . . . . . . . . . . .
Illustration Arrows 0A±2. . . . . . . . . . . . . . . . . . . . . . .
Identification 0A±3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theft Prevention Standard 0A±5. . . . . . . . . . . . . . . . Lifting Instructions 0A±9. . . . . . . . . . . . . . . . . . . . . . .
Standard Bolts Torque Specifications 0A±11. . . . . .
Abbreviations Charts 0A±12. . . . . . . . . . . . . . . . . . . .
Service Parts Identification Plate 0A±13. . . . . . . . . .
General Repair Instruction
1. If a floor jack is used, the following precautions are
recommended.
Park vehicle on level ground, ªblockº front or rear
wheels, set jack against the recommended lifting
points (see ªLifting Instructionsº in this section), raise
vehicle and support with chassis stands and then
perform the service operations.
2. Before performing service operations, disconnect
ground cable from the battery to reduce the chance of
cable damage and burning due to short circuiting.
3. Use a cover on body, seats and floor to protect them
against damage and contamination.
4. Brake fluid and anti±freeze solution must be handled
with reasonable care, as they can cause paint
damage.
5. The use of proper tools and recommended essential
and available tools, where specified, is important for
efficient and reliable performance of service repairs.
6. Use genuine Isuzu parts.
7. Used cotter pins, plastic clips, gaskets, O±rings, oil
seals, lock washers and self±locking nuts should be
discarded and new ones should be installed, as
normal function of the parts cannot be maintained if
these parts are reused.
8. To facilitate proper and smooth reassembly
operation, keep disassembled parts neatly in groups.
Keeping fixing bolts and nuts separate is very
important, as they vary in hardness and design
depending on position of installation.
9. Clean the parts before inspection or reassembly. Also
clean oil ports, etc. using compressed air, and make
certain they are free from restrictions.
10. Lubricate rotating and sliding faces of the parts with
oil or grease before installation.
11. When necessary, use a sealer on gaskets to prevent
leakage.
12. Carefully observe all specifications for bolt and nut
torques.13. When removing or replacing parts that require
refrigerant to be discharged from the air conditioning
system, be sure to use the Vehicle Refrigerant
Recovery and Recycling Equipment (VRRRE) to
recover and recycle Refrigerant±134a.
14. When a service operation is completed, make a final
check to be sure the service has been done properly
and the problem has been corrected.
15. SUPPLEMENTAL RESTRAINT SYSTEM
The vehicle is equipped with a Supplemental
Restraint System (SRS) ± Air Bags. This system is
not to be serviced without consulting the appropriate
service information. Consult Section 9J ªSRS
Systemº if work is to be done on the front of the
vehicle such as bumper, sheet metal, seats, wiring,
steering wheel or column. Also review SRS system
information if any arc welding is to be done on the
vehicle. The SRS system equipped vehicle can be
identified by:
1. ªAIR BAGº warning light on the instrument
cluster.
2. A Code ªKº or ªMº for fifth digit of Vehicle
Identification Number.

0A±2
GENERAL INFORMATION
Illustration Arrows
Arrows are designed for specific purposes to aid your understanding of technical illustrations.
Arrow Type
Application
Front of vehicle
Up Side
Task Related
View Detail
View Angle
Dimension (1:2)
Sectioning (1:3)
Arrow TypeApplication

Ambient/Clean air
flow

Cool air flow

Gas other than
ambient air

Hot air flow

Ambient air mixed
with another gas

Can indicate
temperature change
Motion or direction
Lubrication point oil or
fluid
Lubrication point grease
Lubrication point jelly

0A±3
GENERAL INFORMATION
Identification
Vehicle Identification Number (VIN)
This is the legal identification of the vehicle. it is located on
the left bottom of the windshield. It can be easily seen
through the windshield from outside the vehicle.
710RW003

0A±4
GENERAL INFORMATION
Engine Serial Number
The gasoline engine serial number is stamped on the left
rear lower area of the cylinder block above the starter.
240R200014Automatic : Stamped on the identification plate, located
on the left side of the transmission above the mode
switch.
240R200013

0A±5
GENERAL INFORMATION
Theft Prevention Standard
The 11 major components listed below will be marked
with 17 digit VIN at the stage of production. In addition its
service parts will be marked with manufacturer's trade
mark, ªRº mark and ªDOTº mark.
Reference
COMPONENTINDICATION
Figure No.COMPONENTPRODUCTIONSERVICE PARTS
0A-10ENGINE 1± 6VE1VIN plate
0A-11TRANSMISSION 2± Automatic transmissionVIN plate
0A-11BODY 3± Engine hood
4± Front door
5± Rear door
6± Fender
7± Rear Quarter panel
8± Front bumper
9± Back door left side
10± Back door right side
11± Rear bumperVIN label
Anti Theft Stamping/Plate/Label
STAMPING/PLATELABEL
PRODUCTION
SERVICE PARTS

0A±6
GENERAL INFORMATION
Anti Theft Stamping/Label/Plate Location
The stamping, label and plate locations are indicated by
arrows in the illustration below.
NOTE:
1. VIN plate locations for production.
2. Stamping locations for service parts.
Engine
901RW195
Automatic Transmission
240R200012

0A±7
GENERAL INFORMATION
Body
604R200007

0A±8
GENERAL INFORMATION
Body Label Instructions
Do not peel off the masking tape until completion of paint
work when replacing these parts, as the tape is affixed on
the label attached to service parts for body of the
anti±theft component.
NOTE: Be sure to pull off the masking tape after paint
work has been completed.
Do not attempt to remove this label for any reason.
901RW083
Precautions in pulling off the masking tape
1. Use only your finger nail or a similar blunt instrument
to peel off the masking tape. Use of a sharp object will
damage the underlying anti±theft label.
2. Be careful not to damage the paint around the label.
901RW084

0A±9
GENERAL INFORMATION
Lifting Instructions
CAUTION:

If a lifting device other than the original jack is
used, it is most important that the device be
applied only to the correct lifting points. Raising
the vehicle from any other point may result in
serious damage.
When jacking or lifting a vehicle at the frame side
rail or other prescribed lift points, be certain that
lift pads do not contact the catalytic converter,
brake pipes or cables, or fuel lines. Such contact
may result in damage or unsatisfactory vehicle
performance.
Lifting Points and Supportable Point Locations
C00RX002
Lifting Point: Front

When using a floor jack, lift on the Convex portion of
the skid plate.
545RS001