ISUZU AXIOM 2002 Service Repair Manual

8F±45 BODY STRUCTURE
14. Remove the window regulator.

Remove the 6 fixing bolts and pull the regulator out
from the lower hole of the door panel.
651R200003
15. Remove the glass run.

Pull the glass run from the door frame.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Check to see that the window regulator operates
smoothly and the glass opens and closes properly.
2. Install the waterproof sheet tightly against the door
panel.
3. Tighten the window regulator assembly fixing bolts to
the specified torque.
Torque : 6 N´m (52 lb in)

8F±46BODY STRUCTURE
Tailgate
Parts Location
681R200006
Legend
(1) Tailgate Assembly
(2) Tailgate Stay Assembly
(3) Rear Roof Trim Cover
(4) Tailgate Upper Cover Assembly
(5) Tailgate Hinge
(6) High Mount Stoplight
(7) Dove Tail
(8) Tailgate Lock Assembly
(9) Vent Grill(10) Tailgate Upper Center Trim Cover
(11) Tailgate Upper Side Trim Cover
(12) Tailgate Lower Trim Cover
(13) Tailgate Pull Box
(14) Clip
(15) Rear Wiper Motor Assembly
(16) Tailgate Panel Assembly
(17) Outside Handle
(18) Clip

8F±47 BODY STRUCTURE
Removal
1. Disconnect the battery ground cable.
2. Remove the rear roof trim cover.

Pry the six clip positions free from the body panel.
3. Remove the tailgate upper center trim cover.

Pry the four clip positions (1) free from the tailgate.
4. Remove the tailgate pull box.

Pry the tailgate pull box from the tailgate assembly.
5. Remove the three clips.
6. Remove the tailgate lower trim cover.

Pry the thirteen clip positions (1) free from the
tailgate.
7. Remove the tailgate upper side trim cover.

Pry the three clip positions (1) free from the tail gate
(RH/LH).
681R200007
8. Disconnect the high mount stoplight and rear
defogger and tailgate lock harness connectors.
9. Pull out the washer hose.
10. Remove the tailgate hinges (RH/LH).

Remove the two bolts.
11. Remove the tailgate stay assembly (RH/LH).

Remove the two bolts.
12. Remove the tailgate assembly.

Remove the tailgate assembly may require two
people.

Carefully remove the tailgate assembly not to
damage the hinge.
13. Remove the tailgate upper cover assemblies
(RH/LH).
14. Remove the dove tails (RH/LH).
15. Remove the vent grills (RH/LH).
16. Remove the high mount stoplight.
17. Remove the rear wiper arm.

Refer to
Rear Wiper Arm/Blade in Wiper/Washer
System section.
18. Remove the rear wiper motor assembly.19. Remove the tailgate lock assembly and outside
handle.

Refer to
Tailgate Lock in Security And Locks
section.
20. Remove the license plate garnish (1).

Remove the four screws (3) and the clip (2).
803R200010
21. Remove the license plate light.
22. Remove the tailgate harness.

8F±48BODY STRUCTURE
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. When installing the hinge to the body, exercise
special care not to damage the body paint surface.
2. Align the tailgate fitting to the body.

Check the roof and tailgate (1).
Clearance: 10.7 mm (0.42 in)
Height (step): ±2 mm (0.08 in)

Check the tailgate fitting to the rear quarter panel
(2), (4).
Clearance: 5.0 mm (0.196 in)
Height (step): Flush

Check the tailgate fitting to the rear bumper.
Clearance: 6.5 mm (0.26 in)
Adjust clearance with tailgate hinges. Adjust height
(step) by tapping on the tailgate lightly with a rubber
hammer.
610R200011

8F±49 BODY STRUCTURE
Spare Tire Hanger
Parts Location
530R200002
Legend
(1) Spare Tire Hanger Assembly Fixing Bolt
(2) End Cross Member
(3) Rear Suspension ´ Cross Member
(4) Spare Tire Support
(5) Spare Tire Support Fixing Bolt(6) Spare Tire Stopper Rubber (RH)
(7) Spare Tire Stopper Rubber (Front)
(8) Stopper Rubber Fixing Clip
(9) Spare Tire
(10) Spare Tire Stopper Rubber (LH)
(11) Spare Tire Hanger Assembly

8F±50BODY STRUCTURE
Removal
1. Open the hatch gate and tail gate.
2. Remove the spare tire (3).

Put the spare tire handle (1) to the center of upper
side of rear bumper (2) and turn counterclockwise.
Put spare tire down.
530R200001
3. Remove the spare tire support.

Remove the four bolts that are fixed to frame cross
member.
4. Remove the spare tire hanger assembly.

Remove the two fixing bolts.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Install the spare tire firmly.
2. Tighten the spare tire support fixing bolts to the
specified torque.
Torque : 40 N´m (4.1 kg´m)
3. Tighten the spare tire hanger fixing bolts to the
specified torque.
Torque : 19 N´m (1.9 kg´m)

8F±51 BODY STRUCTURE
Windshield
Parts Location
607R200003
Legend
(1) Windshield Wiper Arm
(2) Windshield Upper Molding
(3) Windshield(4) Windshield Side Molding
(5) Windshield Support
(6) Front Cowl Cover
(7) Hood Rear Seal
Removal
1. Disconnect the battery ground cable.
2. Remove the front pillar trim cover.

Turn up the finisher and pry the trim cover clips free
from the body panel.
3. Remove the sunvisors and sunvisor holders.

Refer to
Headlining in Exterior/Interior Trim section.
4. Remove the interior mirror.

Refer to
Interior Mirror Assembly in Exterior/Interior
Trim section.
5. Remove the windshield wiper arm.

Refer to
Windshield Wiper Arm/Blade in
Wiper/Washer System section.
6. Remove the windshield side molding.

Pull the molding out from drip rail.
7. Remove the front cowl cover.

8F±52BODY STRUCTURE
8. Remove the windshield support.
9. Remove the upper moulding.
10. Remove the windshield.

Use a knife to cut through part of the adhesive
caulking material.

Secure one end of a piece of steel piano wire (0.02
inches in diameter) to a piece of wood that can
serve as a handle.

Use a pair of needle nose pliers to insert the other
end of the piano wire through the adhesive caulking
material at the edge of the windshield glass.

Secure the other end of the piano wire to another
piece of wood.

With the aid of an assistant, carefully move the
piano wire with a sawing motion to cut through the
adhesive caulking material around the entire
circumference of the windshield glass.

Attach some cloth tape (1) on the body for
protecting the painting surface.
607RW012

Clean the remaining adhesive caulking material
from the area of the body which holds the
windshield.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Clean the bonding surfaces of both the windshield
and body panel with a soft rag and white gasoline.
2. Install the spacer.

Attach spacers in six locations as shown in the
figure.

Always use new spacer.
607R200001
3. Install the windshield upper molding.

Peel off the tear-away paper from the windshield
upper molding, and start applying it with one end of
the glass and cut away the surplus at the other end
of the glass for length adjustment.

Always use new upper molding.
4. Temporary install the windshield support.
5. Apply the primer to the windshield and body panel.

Apply the primer (3) (Sun star # 435-40 or
equivalent) to the windshield side bonding surface
as shown in the figure.

Apply the primer (Sun star # 435-95 or equivalent)
to the body side bonding surface.
NOTE: Apply an adhesive 3 minutes or more but within
24 hours after the application of primer. If more than 24
hours have passed, reapply primer.
Primer should be handled as following:
1. Use the primer manufactured 3 months or less
ago and having been kept in an refrigerator.
2. Wipe off primer-stains on positions other than
requires application.

8F±53 BODY STRUCTURE
3. Stir the primer for a minute or more before use.
607RW003
Legend
(1) Adhesive
(2) Sealing Dam(3) Primer Coating Area
(4) Windshield
(5) Upper Molding
6. Apply the adhesive (1) to the windshield.

After drying primer completely, apply a sealing
adhesive (Sun star # 555 or equivalent) along the
edge of the glass so that the sealing adhesive has a
20 mm (0.79 in) junction at middle of the base of the
glass.
607RW015

8F±54BODY STRUCTURE
NOTE: Apply an adhesive 3 minutes or more but within
24 hours after the application of primer. If more than 24
hours have passed, reapply primer.
Adhesive should be handled as follows:
1. Use the adhesive manufactured 3 months or less
ago.
2. Wipe off adhesive-stains on positions other than
requires application.
7. Install the windshield.

Set the windshield with sealing adhesive applied to
entire circumference in the body panel. Specifically,
adjust windshield support with the upper molding
making contact with the body panel, press the
glass, and tighten the windshield support.
NOTE: Affix the glass within 5 minutes of application.
607RS017
8. Install the front cowl cover.
9. Install side molding.

Use alcohol wipe or equivalent cleaner with soft
cloth to wipe away any excess adhesive.

Cure the bonding at a temperature of 20
C ± 30
C
(68
F ± 86
F) for 24 hours.

Check the windshield for any signs of water leak.
607RX010
10. Install windshield wiper arm.