boot ISUZU AXIOM 2002 Service Owner's Guide

5C±98
POWER±ASSISTED BRAKE SYSTEM
Front Disc Brake Caliper
Front Disc Brake Caliper Disassembled View
302R200018
Legend
(1) Bleeder with Cap
(2) Caliper Body(3) Piston
(4) Piston Seal
(5) Dust Boot: Piston
Disassembly
1. Insert a block of wood into the caliper and force out
the piston by blowing compressed air into the caliper
at the flexible hose attachment. This procedure must
be done prior to removal of the dust boot.
Remove piston.
WARNING: D O N O T P L A C E Y O U R F I N G E R S I N
FRONT OF THE PISTON IN AN ATTEMPT TO CATCH
OR PROTECT IT WHEN APPLYING COMPRESSED
AIR. THIS COULD RESULT IN PERSONAL INJURY.
CAUTION: Use just enough air to ease the piston
out of the bore. If the piston is blown out, it may be
damaged.
302R200012

5C±99 POWER±ASSISTED BRAKE SYSTEM
2. Remove dust boot: piston.
3. Remove piston seal.
4. Remove bleeder with cap.
5. Remove caliper body.
Inspection and Repair
Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:

Rotor

Cylinder body

Cylinder bore

Piston

Guide pin, lock pin

Support bracket
NOTE: The piston seal, boot ring and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace them with new ones.
Reassembly
1. Install caliper body.
2. Install bleeder with cap and tighten the cap to the
specified torque.
Torque: 8 N´m (69 lb in)
3. Apply special rubber grease to the piston seal and
cylinder wall, then insert the piston seal into the
cylinder. The special rubber grease is included in the
repair kit.
302R200013
4. When inserting the piston into the cylinder, use finger
pressure only and do not use a mallet or other impact
tool, since damage to the cylinder wall or piston seal
can result.
Install piston.
302R200015
5. Apply special grease (approximately 1 g) to the piston
and attach the dust boot to the piston and caliper.
Insert the dust boot ring into the dust boot.
6. Install guide bolt and lock bolt dust boot.
7. Install the dust boot on the support bracket after
applying special grease (approximately 1 g) onto the
dust boot inner surface. Apply special grease onto the
lock pin and guide pin setting hole of the support
bracket.
302R200022
Legend
(1) Guide Pin
(2) Lock Pin
(3) Pin Boot
8. Install pin bolt and tighten the bolt to the specified
torque.
Torque: 45 N´m (33 lb ft)

5C±108
POWER±ASSISTED BRAKE SYSTEM
302RW017
7. Install the wheel and tire assembly, referring to
Wheels and Tires System in Section 3E.
8. Bleed brakes. Refer to
Hydraulic Brakes in this
section.
Rear Disc Brake Caliper (4y4 Model)
Rear Disc Brake Caliper Disassembled View
306RW014
Legend
(1) Guide Bolt
(2) Lock Bolt
(3) Bleeder with Cap
(4) Caliper Body(5) Piston Seal
(6) Piston
(7) Dust Boot: Piston
(8) Dust Boot Ring
(9) Dust Boot: Guide Bolt and Lock Bolt

5C±109 POWER±ASSISTED BRAKE SYSTEM
Disassembly
1. Remove guide bolt.
2. Remove lock bolt.
3. Remove dust boot; guide bolt and lock bolt.
4. Remove dust boot ring, using a small screwdriver.
302RS016
5. Insert a block of wood into the caliper and force out
the piston by blowing compressed air into the caliper
at the flexible hose attachment. This procedure must
be done prior to removal of the dust boot.
Remove piston.
WARNING: D O N O T P L A C E Y O U R F I N G E R S I N
FRONT OF THE PISTON IN AN ATTEMPT TO CATCH
OR PROTECT IT WHEN APPLYING COMPRESSED
AIR. THIS COULD RESULT IN PERSONAL INJURY.
CAUTION: Use just enough air to ease the piston
out of the bore. If the piston is blown out, it may be
damaged.
302RS017
6. Remove dust boot: piston.
7. Remove piston seal.
8. Remove bleeder with cap.
9. Remove caliper body.
Inspection and Repair
Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:

Rotor

Cylinder body

Cylinder bore

Piston

Guide bolt, lock bolt

Support bracket
NOTE: The piston dust seal and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace with new ones.
Reassembly
1. Install caliper body.
2. Install bleeder with cap and tighten the cap to the
specified torque.
Torque: 8 N´m (69 lb ft)
3. Install piston seal and apply special rubber grease to
the piston seal and cylinder wall, then insert the piston
seal into the cylinder. The special rubber grease is
included in the repair kit.
302RS018
4. When inserting the piston into the cylinder, use finger
pressure only and do not use a mallet or other impact
tool, since damage to the cylinder wall or piston seal
can result.
Install piston.

5C±110
POWER±ASSISTED BRAKE SYSTEM
302RS019
5. Apply special grease (approximately 1g) to the piston
and attach the dust boot to the piston and caliper.
Insert the dust boot ring into the dust boot.
302RS020
6. Install guide bolt and lock bolt dust boot.
7. Install the dust boot on the support bracket after
applying special grease (Approx. 1g) onto the dust
boot inner surface. Also apply special grease onto the
lock bolt and guide bolt setting hole of the support
bracket.
302RS021
8. Install lock bolt and guide bolt and tighten the bolt to
the specified torque.
Torque: 44 N´m (32 lb ft)

5C±116
POWER±ASSISTED BRAKE SYSTEM
Disassembled View
305RS006
Legend
(1) Boot
(2) Piston Assembly
(3) Piston Cup
(4) Return Spring
(5) Bleeder
(6) Wheel Cylinder
Disassembly
1. Remove boot (1) and piston assembly (2).
2. Remove piston cup (3) from piston assembly (2).
3. Remove return spring (4) and bleeder (5) from wheel
cylinder (6).
Inspection and Repair
1. Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition are found
through inspection.
Check the following parts;

Wheel cylinder body

Cylinder bore

Piston

Return spring

Bleeder
NOTE: Replace the piston cups and boots each time the
wheel cylinder is overhauled. Discard these used rubber
parts and replace with new ones.
Reassembly
1. Lubricate the cylinder bore with clean rubber grease.
305RS007
2. Install bleeder (5) to wheel cylinder (6).
Torque: 10 N´m (8 lb ft)
305RS008

5C±117 POWER±ASSISTED BRAKE SYSTEM
3. Install new piston cups (3) on each piston so that the
flared end of the cups are turned to the inboard side of
the pistons.
Attach the return spring (4) and the boot (1) to the
piston.
305RS009
4. Apply DELCO silicone lube No. 5459912 (or
equivalent) to the piston and the inner face of the
boots.
5. Install piston assembly (2) to wheel cylinder (6).

6E±560
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Electronic Ignition System
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the ignition coil connector at the ignition
coil assemblies.
3. Remove the two screws that secure the ignition coil
assemblies to the rocker cover.
060RY022
Legend
(1) Ignition Coil Connectors
(2) Bolts
(3) Ignition Coil Assemblies
4. Remove the ignition coil assemblies and the spark
plug boot from the spark plug.

Twist the ignition coil assemblies while pulling it
straight up.
5. Use the appropriate spark plug socket in order to
remove the spark plug from the engine.
Installation Procedure
NOTE: The plug must thread smoothly into the cylinder
head and be fully seated. Use a thread chaser if
necessary to clean the threads in the cylinder head.
Cross-threading or failure to fully seat the spark plug can
cause plug overheating, exhaust blow-by gases, or
thread damage. Do not overtighten the spark plugs. Over
tightening can cause aluminum threads to strip.
1. Install the spark plug in the engine. Use the
appropriate spark plug socket.
Tighten

Tighten the spark plug to 18 N´m (13 lb ft.).
2. Install the ignition coil assemblies and spark plug boot
over the spark plug.CAUTION: Ignition coil assembly #6 is different
from ignition coil assembly #1 to #5. Ignition coil
assemblies #6 is short type. Be careful it when
installing ignition coil assembly of #6.
060RY00002
Legend
(1) Long Type Ignition Coil Assemblies (#1 ~ #5)
(2) Short Type Ignition Coil Assembly (#6)
3. Install ignition coil assemblies and tighten the fixing
bolts to the specified torque.
Torque: 4 N´m (35.4 Ib in)
060RY022
Legend
(1) Ignition Coil Connectors
(2) Bolts
(3) Ignition Coil Assemblies
4. Connect the ignition coil connector at the ignition coil
assemblies.
5. Connect the negative battery cable.

6E±580
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Throttle Body Unit
The throttle body has a throttle plate to control the amount
of air delivered to the engine. The TP sensor are also
mounted on the throttle body. Vacuum ports located
behind the throttle plate provide the vacuum signals
needed by various components.
Engine coolant is directed through a coolant cavity in the
throttle body to warm the throttle valve and to prevent
icing.
025RY00005
General Description (Electronic
Ignition System)
Crankshaft Position (CKP) Sensor
The crankshaft position (CKP) sensor provides a signal
used by the powertrain control module (PCM) to calculate
the ignition sequence. The sensor initiates the 58X
reference pulses which the PCM uses to calculate RPM
and crankshaft position. Refer to
Electronic Ignition
System
section for additional information.
Electronic Ignition
The electronic ignition system controls fuel combustion
by providing a spark to ignite the compressed air/fuel
mixture at the correct time. To provide optimum engine
performance, fuel economy, and control of exhaust
emissions, the PCM controls the spark advance of the
ignition system. Electronic ignition has the following
advantages over a mechanical distributor system:

No moving parts.

Less maintenance.

Remote mounting capability.

No mechanical load on the engine.

More coil cooldown time between firing events.

Elimination of mechanical timing adjustments.

Increased available ignition coil saturation time.
0013
Ignition Coils
A separate coil-at-plug module is located at each spark
plug. The coil-at-plug module is attached to the engine
with two screws. It is installed directly to the spark plug by
an electrical contact inside a rubber boot. A three-way
connector provides 12-volt primary supply from the
15-amp ignition fuse, a ground-switching trigger line from
the PCM, and a ground.
060RY00022
Ignition Control
The ignition control (IC) spark timing is the PCM's method
of controlling the spark advance and the ignition dwell.
The IC spark advance and the ignition dwell are
calculated by the PCM using the following inputs:

Engine speed.

Crankshaft position (58X reference).

Engine coolant temperature (ECT) sensor.

Throttle position (TP) sensor.

ION sensing module.

Park/Neutral position (PRNDL input).