engine ISUZU AXIOM 2002 Service Service Manual

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±119
Power Transistor
1. Remove the power transistor connector (C±34) from
the evaporator assembly.
2. Check the conduction between the power transistor
side terminals.
C01R200006
MAX HI Relay
1. Remove the MAX ± HI relay connector (C±35) from
the blower assembly.
2. Check the conduction between the MAX ± HI relay
side terminals.
C01R200011
In Car Sensor
1. Turn on the ignition switch (the engine is started).
Start the air conditioner in ªAutoº.
2. Make sure that the in car sensor suctions cigarette
smokes and such.
In Car Sensor
1. Dismount the in car sensor from the automatic
heater/air conditioner control unit. Connect (+) end
and (±) end of the battery to the aspirator motor side
terminals No.I17±1 and No.I17±2, respectively, then
check if the motor runs normally.
C01R200010

POWER±ASSISTED STEERING SYSTEM2A±5
Power Steering System
There is some noise in all power steering systems. One
of the most common is a hissing sound when the steering
wheel is fully turned and the car is not moving. This noise
will be most evident when the steering wheel is operated
while the brakes are applied. There is no relationshipbetween this noise and steering performance. Do not
replace the valve unless the ªhissingº noise is extremely
objectionable. A replacement valve will also have a slight
noise, and is not always a cure for the condition.
Condition
Possible causeCorrection
Rattle or Chucking NoisePressure hose touching other parts
of vehicle.Adjust hose position. Do not bend
tubing by hand.
Tie rod ends loose.Tighten or replace tie rod end.
Loose steering unit mounting.Tighten steering unit mounting.
Poor Return of Steering Wheel to
Center
Improper front wheel alignment.Adjust front wheel alignment.
CenterWheel bearing worn.Replace front wheel bearing.
Tie rod end binding.Replace tie rod end.
Ball joint binding.Replace ball joint.
Tight or frozen steering shaft
bearing.Replace steering assembly.
Sticky or plugged steering unit valve.Flush or replace steering unit.
Entry of air in the power steering
system.Bleed the system.
Momentary Increase In Effort When
Turning Wheel Fast To Right or Left
High internal leakage.Repair steering gear.
Turning Wheel Fast To Right or LeftPower steering fluid level low.Replenish fluid.
Steering Wheel Surges or Jerks
When Turning Especially During
Insufficient pump pressure.Repair pump assembly.
When Turning Especially During
Parkin
gSticky steering unit valve.Flush or replace steering unit.Parking
Power steering fluid level low.Replenish fluid.
Excessive Wheel Kick Back or Loose
Steering
Air in system.Bleed hydraulic system.
SteeringTie rod end loose.Tighten tie rod end.
Wheel bearing worn.Replace wheel bearing.
Hard Steering or Lack or Power
Assist
Sticky steering unit valve.Flush or replace steering unit.
AssistInsufficient pump pressure.Repair pump assembly.
Excessive internal pump leakage.Repair pump assembly.
Excessive internal steering gear
leakage.Repair steering gear.
Power steering fluid level low.Replenish fluid.
Unstable Engine Idling or Stalling
When TurningPressure switch of the power
steering pump or its harness is faulty.Repair or replace.

POWER±ASSISTED STEERING SYSTEM2A±9
The hydraulic pump is vane-type design. The submerged
pump has housing and internal parts that are inside the
reservoir and operate submerged in oil. There are two
bore openings at the rear of the pump housing. The larger
opening contains the cam ring, pressure plate, thrust
plate, rotor and vane assembly, and end plate. The
smaller opening contains the pressure line union, flow
control valve and spring.
The flow control orifice is part of the pressure line union.
The pressure relief valve inside the flow control valve
limits the pump pressure.Pressure Switch
When hydraulic pressure reaches 3430 kPa (500 psi), the
pressure switch of the power steering pump closes
causing the Powertrain Control Module (PCM) to actuate
the throttle valve, which increases the engine rpm to
prevent the overload-induced engine speed slow down.
The switch opens when hydraulic pressure drops to 2940
kPa (430 psi).
Steering Column
431RY00009
WARNING: T O AV O I D D E P L O Y M E N T W H E N
TROUBLE-SHOOTING THE SRS SYSTEM, DO NOT
USE ELECTRICAL TEST EQUIPMENT, SUCH AS
BATTERY-POWERED OR A/C-POWERED
VOLT-METER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN
SPECIFIED IN THIS MANUAL. DO NOT USE A
NON-POWERED PROBE-TYPE TESTER.INSTRUCTION IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE PERSONAL
INJURY MAY RESULT.
When servicing a vehicle equipped with Supplemental
Restraint System, pay close attention to all WARNINGS
and CAUTIONS.
For detailed explanation about SRS, refer to
Restraints
section.

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.

2A±12
POWER±ASSISTED STEERING SYSTEM
4. Install all the lines and hoses. Fill the system with new
power steering fluid and bleed the system as
described in Bleeding The Power Steering System.
Operate the engine for about 15 minutes.
Remove the pump return line at the pump inlet and
plug the connection on the pump. While refilling the
reservoir, check the draining fluid for contamination.
If foreign material is still evident, replace all lines,
disassemble and clean or replace the power steering
system components. Do not re-use any drained
power steering fluid.
Steering Wheel Free Play Inspection
430R200001
1. With the tires in the straight-ahead position, check the
amount of steering wheel play by turning the wheel in
both directions until the tires begin to move.
NOTE: The wheel free play should be checked with the
engine running.
Free play: 0 ± 30 mm (0 ± 1.18 in)
2. Also check the steering wheel for play and looseness
in the mount by moving it back and forth and
sideways. When test driving, check for hard steering,
steering shimmy and tendency to pull to one side.
Front End Alignment Inspection and
Adjustment
General Description
ªFront End Alignmentº refers to the angular relationship
between the front wheels, the front suspension attaching
parts and the ground.
Proper front end alignment must be maintained in order to
insure efficient steering, good directional stability and to
prevent abnormal tire wear.
The most important factors of front end alignment are
wheel toe-in, wheel camber and axle caster.Camber:
This illustration shows view from the front of the vehicle.
480RS004Camber is the vertical tilting inward or outward of the front
wheels. When the wheels tilt outward at the top, the
camber is positive (+). When the wheels tilt inward at the
top, the camber is negative (-). The amount of tilt
measured in degrees from the vertical is called the
camber angle (1). If camber is extreme or unequal
between the wheels, improper steering and excessive tire
wear will result. Negative camber causes wear on the
inside of the tire, while positive camber causes wear to the
outside.
Caster:
This illustration shows view from the side of the vehicle.
480RS005

POWER±ASSISTED STEERING SYSTEM2A±25
Inspection and Repair
Make all necessary adjustments, repairs, and part
replacements if wear, damage, or other problems are
discovered during inspection.
Rotor
442RS002Check that the groove in the vane is free from excessive
wear and that the vane slides smoothly. When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.
Vane
442RS003
Sliding faces of the vane should be free from wear.
(Particularly the curved face at the tip that contact with the
cam should be free from wear and distortion). When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.
Cam
The inner face of the arm should have a uniform contact
pattern without a sign of step wear. When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.
Side Plate
The sliding faces of parts must be free from step wear
(more than 0.01 mm), which can be felt by the finger nail.
The parts with minor scores may be reused after lapping
the face.
Relief Valve
The sliding face of the valve must be free from burrs and
damage. The parts with minor scores may be reused after
smoothing with emery cloth (#800 or finer).
Shaft
Oil seal sliding faces must be free from a step wear which
can be felt by the finger nail. Bushing fitting face must be
free from damage and wear.
O-ring, Oil Seal, Snap Ring
Be sure to discard used parts, and always use new parts
for installation. Prior to installation, lubricate all seals and
rings with power steering fluid.
Pressure Switch
Check the switch operation as follows:
With engine idling and A/C on, turn the steering wheel
fully to the left; compressor should interrupt and engine
idle speed will increase. Shut off A/C and again turn
steering fully to the left; engine idle will increase. If system
fails to function properly, disconnect connector at the
pressure switch and repeat system check while testing
continuity across disconnected SW connector.
Reassembly
1. Install oil seal to front housing. Be sure to discard
used oil seal, and always use new parts for
installation.
CAUTION: When installing the oil seal, be careful
not to damage the oil seal contacting surface of the
housing.
2. Install shaft assembly.

2A±36
POWER±ASSISTED STEERING SYSTEM
Combination Switch
Combination Switch and Associated Parts
431R200003
Legend
(1) Steering Column Cover
(2) Steering Wheel
(3) Inflator Module(4) Combination Switch and SRS Coil Assembly
(5) Instrument Panel Lower Cover
(6) Driver Knee Bolster (reinforcement)
Removal
1. Turn the steering wheel so that the vehicle's wheels
are pointing straight ahead.
2. Turn the ignition switch to ªLOCKº.
3. Disconnect the battery ground cable, and wait at least
5 minutes.
4. Disconnect the yellow 2-way SRS connector located
under the steering column.CAUTION: T h e w heels of the vehicle must be
straight ahead and the steering column in the
ªLOCKº position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to become uncentered which will cause damage to
the coil assembly.
5. Remove the engine hood opening lever, then remove
instrument panel lower cover.
6. Remove the driver knee bolster (reinforcement).

POWER±ASSISTED STEERING SYSTEM2A±39
2. When installing the steering column cover, be sure to
route each wire harness as illustrated so that the
harnesses do not catch on any moving parts.
825RW017
Legend
(1) Steering Column Cover
(2) Starter Switch Harness
(3) Combination Switch Harness
(4) Inflator Module Harness
3. Align the setting marks made when removing then
install steering wheel.
CAUTION: Never apply force to the steering wheel
shaft using a hammer or other impact tools in an
attempt to remove the steering wheel. The steering
shaft is designed as an energy absorbing unit.
4. Tighten the steering wheel fixing nut to the specified
torque.
Torque: 34 N´m (25 lb ft)
5. Support the inflator module and carefully connect the
SRS connector and horn lead.
NOTE: Pass the lead wire through the tabs on the plastic
cover (wire protector) of inflator to prevent lead wire from
being pinched.
6. Tighten bolts to specified torque.
Torque: 9 N´m (78 lb in)
7. Install driver knee bolster (reinforcement).
8. Install instrument panel lower cover then Install the
engine hood opening lever.
9. Connect the SRS connector.
10. Connect the battery ª-º terminal cable.
11. Turn the ignition switch to the ªONº position and
observe the warning lamp. The lamp should flash 7
times. If the lamp does not operate correctly, refer to
Restraints section.

2A±40
POWER±ASSISTED STEERING SYSTEM
Lock Cylinder
Lock Cylinder and Associated Parts
431RX005
Legend
(1) Inflator Module
(2) Steering Wheel
(3) Steering Column Cover
(4) Combination Switch and SRS Coil Assembly
(5) Snap Ring(6) Cushion Rubber
(7) Lock Cylinder Assembly
(8) Instrument Panel Lower Cover
(9) Driver Knee Bolster (reinforcement)
(10) Shift Lock Cable (for A/T)
Removal
1. Turn the steering wheel so that the vehicle's wheels
are pointing straight ahead.
2. Turn the ignition switch to ªLOCKº.
3. Disconnect the battery ground cable, and wait at least
5 minutes.
4. Disconnect the yellow 2-way SRS connector located
under the steering column.CAUTION: T h e w heels of the vehicle must be
straight ahead and the steering column in the
ºLOCKº position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to become uncentered which will cause damage to
the coil assembly.
5. Remove the engine hood opening lever and steering
lower cover.
6. Remove driver knee bolster (reinforcement).