sensor ISUZU AXIOM 2002 Service Repair Manual

4D2±3 TRANSFER CASE (TOD)
Removal and Installation of Tfansfer Case Assembly
F07R200001
Legend
(1) Transfer Protector
(2) Front Propeller Shaft Assembly
(3) Speedometer Sensor Harness Connector
(4) Rear Propeller Shaft Assembly(5) Center Exhaust Pipe
(6) Transfer Case Bolt
(7) Transfer Case Assembly
(8) Transfer Case Harness Connector

4D2±4
TRANSFER CASE (TOD)
Removal
1. Disconnect the battery ground cable.
2. Remove the transfer protector.
3. Disconnect the rear propeller shaft assembly from the
transfer case.
4. Disconnect the front propeller shaft assembly from
the transfer case.
5. Remove the center exhaust pipe.
6. Disconnect the speedometer sensor harness
connector from the speedometer sensor, and remove
the harness clamp from the connector bracket of the
transfer case.
7. Disconnect the engine harness connector from the
transfer harness connector.
8. Support the transfer case with a transmission jack.
9. Remove the transfer bolts.
10. Remove the transfer case assembly.
Installation
1. Apply grease (Besco L2 or its equivalent) to the input
shaft spline.
260RY00011
2. Install the transfer case assembly to the transmission
assembly.
3. Install the transfer bolts to the specified torque (Refer
to
next page).
Torque: 46 N´m (34 lb ft)
4. Connect the engine harness connector to the transfer
harness connector.
5. Install the breather hose up to bottom of the transfer
case breather and clip them firmly.
6. Securely insert the breather hose into the cutout
portion of the transfer case.
260R200001

4D2±5 TRANSFER CASE (TOD)
7. Install the speedometer harness clamp to the
connector bracket of the transfer case, and then
connect the harness connector to the speedometer
sensor.
261R200008
8. Install the center exhaust pipe.
Torque: 43 N´m (32 lb ft)
9. Connect the front and rear propeller shaft assembly
to the transfer case.
Torque: 63 N´m (46 lb ft)
10. Install the transfer protector.
Torque: 37 N´m (27 lb ft)
11. Connect the battery ground cable.

4D2±9 TRANSFER CASE (TOD)
Unit Repair
Disassembly and Reassembly of Major Components
266R200002
Legend
(1) Front Companion Flange, Oil Seal, Washer,
and End Nut
(2) 4H and 4L Switch
(3) Harness Assembly
(4) Harness Bracket
(5) Shift Motor Assembly
(6) Rear Companion Flange, Oil Seal, Washer and
End Nut(7) Speedometer Sensor and Driven Gear
(8) Plate and Bracket
(9) Connector Bracket
(10) Breather Hose
(11) Transfer Case Assembly
(12) Transfer Cover Assembly

4D2±10
TRANSFER CASE (TOD)
Disassembly
1. Remove the drain plug from the transfer case and
drain the oil.
2. Remove the speedometer sensor and driven gear.
3. Remove the front and rear speed sensor of the
harness assembly from the transfer cover assembly.
NOTE: Use care to prevent damage to speed sensor
when removing speed sensor.
4. Disconnect the clutch solenoid coil, 4H and 4L switch
harness connector.

Remove the harness bracket from the transfer
cover.
261RY00009
5. Remove the connector bracket from the transfer
case.

Remove the harness assembly and shift motor
harness connector from the connector bracket.
261RY00010
6. Remove the 4H and 4L switch from the transfer case.
7. Remove the shift motor assembly from the transfer
cover.
8. Using the flange holder J±8614±11, remove the end
nut.
Remove the washers, oil seals, front and rear
companion flange.
262RY00012
9. Remove the transfer cover retaining bolts and the
transfer cover assembly from the transfer case
assembly.
NOTE: When removing the transfer cover assembly, use
care to prevent damage to oil seal.
10. Remove the breather hose from the transfer case.
Reassembly
1. Apply recommended liquid gasket (LOCTITE 598 or
its equivalent) uniformly to the transfer case and
cover fitting surface.
261RY00011

4D2±12
TRANSFER CASE (TOD)
6. Apply recommended liquid gasket (LOCTITE 598 or
its equivalent) to the transfer cover and shift motor
assembly fitting surface.
261R200003
7. Install the shift motor assembly to the transfer cover
assembly.
Torque: 10 N´m (87 lb in)
8. Install the 4H and 4L switch.
Torque: 24 N´m (17 lb ft)
9. Install the harness assembly and shift motor harness
connector to the connector bracket.
10. Install the front and rear speed sensors to the transfer
cover.
Torque: 5 N´m (43 lb in)
11. Connect the harness assembly connector to the
clutch solenoid coil harness connector and 4H and 4L
switch.

Fix the harness with harness bracket.
261RY00009
12. Install the driven gear and speedometer sensor to the
transfer case.
Torque: 25 N´m (19 lb ft)
261RY00034
13. Remove the filler plug and fill the transfer case with
ATF DEXRON)±II or III.
14. Wind the sealing tape around the filler plug thread and
tighten the plug to the specified torque.
Torque: 25 N´m (19 lb ft)
261RY00026
15. Install the breather hose to the transfer case.

5A±1
BRAKE CONTROL SYSTEM
AXIOM
BRAKES
CONTENTS
Brake Control System 5A±1. . . . . . . . . . . . . . . . . . . .
Anti±lock Brake System 5B±1. . . . . . . . . . . . . . . . . .
Power±assisted Brake System 5C±1. . . . . . . . . . . .
Parking Brakes (4x4 Model) 5D1±1. . . . . . . . . . . . . .
Parking Brakes (4x2 Model) 5D2±1. . . . . . . . . . . . . .
Brake Control System
CONTENTS
Service Precaution 5A±2. . . . . . . . . . . . . . . . . . . . . .
General Description 5A±3. . . . . . . . . . . . . . . . . . . . .
Functional Description 5A±4. . . . . . . . . . . . . . . . .
System Components 5A±10. . . . . . . . . . . . . . . . . . .
Electronic Hydraulic Control Unit (EHCU) 5A±10.
ABS Warning Light 5A±10. . . . . . . . . . . . . . . . . . . .
Wheel Speed Sensor 5A±10. . . . . . . . . . . . . . . . . .
G-Sensor 5A±10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal and Anti-lock Braking 5A±10. . . . . . . . . . .
Brake Pedal Travel 5A±10. . . . . . . . . . . . . . . . . . . .
Acronyms and Abbreviations 5A±11. . . . . . . . . . . .
General Diagnosis 5A±11. . . . . . . . . . . . . . . . . . . . . . .
General Information 5A±11. . . . . . . . . . . . . . . . . . . .
ABS Service Precautions 5A±11. . . . . . . . . . . . . . .
Computer System Service Precautions 5A±11. . .
General Service Precautions 5A±11. . . . . . . . . . . .
Note on Intermittents 5A±11. . . . . . . . . . . . . . . . . . .
Test Driving ABS Complaint Vehicles 5A±12. . . . .
ªABSº Warning Light 5A±12. . . . . . . . . . . . . . . . . . .
Normal Operation 5A±12. . . . . . . . . . . . . . . . . . . . .
Tech 2 Scan Tool 5A±13. . . . . . . . . . . . . . . . . . . . . .
DATA LIST 5A±16. . . . . . . . . . . . . . . . . . . . . . . . . . .
ACTUATOR TEST 5A±17. . . . . . . . . . . . . . . . . . . . .
Tech 2 Service Bleed 5A±21. . . . . . . . . . . . . . . . . .
Basic Diagnostic Flow Chart 5A±22. . . . . . . . . . . .
Basic Inspection Procedure 5A±23. . . . . . . . . . . . .
EHCU Connector Pin-out Checks 5A±24. . . . . . . . .
Circuit Diagram 5A±25. . . . . . . . . . . . . . . . . . . . . . .
Connector List 5A±28. . . . . . . . . . . . . . . . . . . . . . . .
Part Location 5A±29. . . . . . . . . . . . . . . . . . . . . . . . .
Symptom Diagnosis 5A±30. . . . . . . . . . . . . . . . . . . . .
Chart A-1 ABS Works Frequently But
Vehicle Does Not Decelerate 5A±30. . . . . . . . . . .
Chart TA-1 ABS Works Frequently But
Vehicle Does Not Decelerate
(Use TECH 2) 5A±31. . . . . . . . . . . . . . . . . . . . . . . .
Chart A-2 Uneven Braking Occurs While
ABS Works 5A±31. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart TA-2 Uneven Braking Occurs While
ABS Works (Use TECH 2) 5A±31. . . . . . . . . . . . . Chart A-3, TA-3 The Wheels Are Locked 5A±32.
Chart A-4 Brake Pedal Feed Is Abnormal 5A±32.
Chart A-5, TA-5 Braking Sound
(From EHCU) Is Heard While Not Braking 5A±33
Diagnostic Trouble Codes 5A±34. . . . . . . . . . . . . . . .
Diagnosis By ªABSº Warning Light
Illumination Pattern 5A±36. . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Codes (DTCs) 5A±37. . . . . . .
Chart B-1 With the key in the ON position
(Before starting the engine). Warning light
(W/L) is not activated. 5A±39. . . . . . . . . . . . . . . . .
Chart B-2 CPU Error (DTC 14 (Flash out) /
C0271, C0272, C0273, C0284 (Serial
communications)) 5A±39. . . . . . . . . . . . . . . . . . . . .
Chart B-3 Low or High Ignition Voltage
(DTC 15 (Flash out) / C0277, 0278 (Serial
communications)) 5A±40. . . . . . . . . . . . . . . . . . . . .
Chart B-4 Excessive Dump Time (DTC 17
(Flash out) / C0269 (Serial
communications)) 5A±40. . . . . . . . . . . . . . . . . . . . .
Chart B-5 Excessive Isolation Time
(DTC 18 (Flash out) / C0274
(Serial communications)) 5A±40. . . . . . . . . . . . . . .
Chart B-6 G-Sensor Output Failure
(DTC 21 (Flash out) / C0276
(Serial communications)) 5A±41. . . . . . . . . . . . . . .
Chart B-7 Brake Switch Failure
(DTC 22 (Flash out) / C0281
(Serial communications)) 5A±41. . . . . . . . . . . . . . .
Chart B-8 2WD Controller in 4WD Vehicle
Controller (DTC 13 (Flash out) / C0285
(Serial communications)), 4WD State Input
Signal Failure (DTC 24 (Flash out) / C0282
(Serial communications)) 5A±42. . . . . . . . . . . . . . .
Chart B-9 Pump Motor Failure
(DTC 32 (Flash out) / C0267, C0268
(Serial communications)) 5A±42. . . . . . . . . . . . . . .
Chart B-10 EHCU Valve Relay Failure
(DTC 35 (Flash out) / C0265, C0266
(Serial communications)) 5A±43. . . . . . . . . . . . . . .
Chart B-11 FL Isolation Solenoid Coil Failure
(DTC 41 (Flash out) / C0245, C0247
(Serial communications)) 5A±43. . . . . . . . . . . . . . .
Chart B-12 FL Dump Solenoid Coil Failure
(DTC 42 (Flash out) / C0246, C0248
(Serial communications)) 5A±43. . . . . . . . . . . . . . .

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.

5A±3
BRAKE CONTROL SYSTEM
General Description
The Anti-lock Brake System (ABS) works on all four
wheels. A combination of wheel speed sensor and
Electronic Hydraulic Control Unit (EHCU) can determine
when a wheel is about to stop turning and adjust brake
pressure to maintain best braking.
This system helps the driver maintain greater control of
the vehicle under heavy braking conditions.
NOTE: The Electronic Hydraulic Control Unit (EHCU)
comprises the Hydraulic Unit (H/U) and the coil Integrated
Module.
C05RW004
Legend
(1) Electronic Line
(2) Hydraulic Line
(3) Hydraulic Unit (H/U)(4) Coil Integrated Module
(5) Front Wheel Speed Sensor
(6) Rear Wheel Speed Sensor
(7) Proportioning and Bypass (P&B) Valve

5A±6BRAKE CONTROL SYSTEM
Pressure Isolation (Pressure Maintain)
The electro-hydraulic control unit is activated when the
brakes are applied.
If the information from the wheel speed sensors indicates
excessive wheel deceleration (imminent lockup), the first
step in the anti-lock sequence is to isolate the brake
pressure being applied by the brake pedal.
The microprocessor in the coil integrated module sends a
voltage to the coil to energize and close the isolation
valve. This prevents any additional fluid pressure applied
by the brake pedal from reaching the wheel. With the
isolation valves closed, unnecessary increase in the
brake pressure is prevented.
C05RW011
Legend
(1) Brake
(2) Master Cylinder