brake rotor ISUZU AXIOM 2002 Service Repair Manual

0B±6MAINTENANCE AND LUBRICATION
Always change the oil and the oil filter as soon as possible
after driving in a dust storm.
Engine Cooling System Inspection
Inspect the coolant/anti±freeze. If the coolant is dirty or
rusty, drain, flush and refill with new coolant. Keep coolant
at the proper mixture for proper freeze protection,
corrosion inhibitor level and best engine operating
temperature. Inspect hoses and replace if cracked,
swollen or deteriorated. Tighten the hose clamps if
equipped with screw±type clamps. Clean outside of
radiator and air conditioning condenser. Wash filler cap
and neck. To help ensure proper operation, a pressure
test of both the cooling system and the cap is also
recommended.
Exhaust System Inspection
Visually inspect the exhaust pipes, muffler, heat shields
and hangers for cracks, deterioration, or damage.
Be alert to any changes in the sound of the exhaust
system or any smell of fumes. These are signs the system
may be leaking or overheating. Repair the system at
once, if these conditions exist. (See also ªEngine Exhaust
Gas Safetyº and ªThree Way Catalytic Converterº in the
Owner's manual.)
Fuel Cap, Fuel Lines, and Fuel Tank
Inspection
Inspect the fuel tank, the fuel cap and the fuel lines every
60,000 miles (96,000 km) for damage which could cause
leakage.
Inspect the fuel cap and the gasket for correct sealing and
physical damage. Replace any damaged parts.
Drive Belt Inspection
Check the serpentine belt driving for cracks, fraying,
wear, and correct tension every 30,000 miles (48,000
km). Replace as necessary.
Wheel Alignment, Balance and Tires
Operation
Uneven or abnormal tire wear, or a pull right or left on a
straight and level road may show the need for a wheel
alignment. A vibration of the steering wheel or seat at
normal highway speeds means a wheel balancing is
needed. Check tire pressure when the tires are ªcoldº
(include the spare).
Maintain pressure as shown in the tire placard, which is
located on the driver's door lock pillar.
Steering System Operation
Be alert for any changes in steering operation. An
inspection or service is needed when the steering wheel
is harder to turn or has too much free play, or if there are
unusual sounds when turning or parking.
Brake Systems Operation
Watch for the ªBRAKEº light coming on. Other signs of
possible brake trouble are such things as repeated pulling
to one side when braking, unusual sounds when braking
or between brake applications, or increased brake pedaltravel. If you note one of these conditions, repair the
system at once.
For convenience, the following should be done when
wheels are removed for rotation: Inspect lines and hoses
for proper hookup, bindings, leaks, crack, chafing etc.
Inspect disc brake pads for wear and rotors for surface
condition.
Inspect other brake parts, including parking brake drums,
linings etc., at the same time. Check parking brake
adjustment.
Inspect the brakes more often if habit or conditions
result in frequent braking.
Parking Brake and Transmission Park
Mechanism Operation
Park on a fairly steep hill and hold the vehicle with the
parking brake only. This checks holding ability. On
automatic transmission vehicles, shifting from ªPº
position to the other positions cannot be made unless the
brake pedal is depressed when the key switch is in the
ªONº position or the engine is running.
WARNING: B E F O R E C H E C K I N G T H E S TA R T E R
SAFETY SWITCH OPERATION BELOW, BE SURE TO
HAVE ENOUGH ROOM AROUND THE VEHICLE.
THEN FIRMLY APPLY BOTH THE PARKING BRAKE
AND THE REGULAR BRAKE. DO NOT USE THE
ACCELERATOR PEDAL. IF THE ENGINE STARTS,
BE READY TO TURN OFF THE KEY PROMPTLY.
TAKE THESE PRECAUTIONS BECAUSE THE
VEHICLE COULD MOVE WITHOUT WARNING AND
POSSIBLY CAUSE PERSONAL INJURY OR
PROPERTY DAMAGE.
Starter Safety Switch Operation
Check by trying to start the engine in each gear while
setting the parking brake and the foot brake. The starter
should crank only in ªPº (Park) or ªNº (Neutral).
Accelerator Linkage Lubrication
Lubricate the accelerator pedal fulcrum pin with chassis
grease.
Steering and Suspension Inspection
Inspect the front and rear suspension and steering
system for damaged, loose or missing parts or signs of
wear. Inspect power steering lines and hoses for proper
hookup, binding, leaks, cracks, chafing, etc.
Body and Chassis Lubrication
Lubricate the key lock cylinders, the hood latch, the hood
and door hinges, the door check link, the parking cable
guides, the underbody contact points, and the linkage.
Propeller Shaft Inspection and Lubrication
Check the propeller shaft flange±to±pinion bolts for
proper torque to 63 Nwm (46 lb ft) for front and rear
propeller shaft.

4C±46
DRIVE SHAFT SYSTEM
Front Hub and Disc (2WD Model)
Disassembled View
411R200011
Legend
(1) Disc Rotor
(2) Hub unit, Bearing(3) Wheel Pin
(4) Bolt
Disassembly
1. Raise the vehicle with a jack. Support the frame with
chassis stands.
2. Remove the brake caliper from the bracket. Secure
the caliper with a wire so that it does not interfere with
the work process.
Refer to
Front disc caliper assembly in Section 5C of this
Manual.
3. Remove the disk rotor
Apply penetrating oil to the bearing and disc rotor contact
surfaces if the surfaces are stuck together because of
rust.
4. Inspect the hub unit bearing. Refer to
Inspection
below.
5. Use a dial gauge to measure the bearing axial rattle.
Bearing axial rattle: 0.05 mm max
411R200002

4C±48
DRIVE SHAFT SYSTEM
Reassembly
1. Install wheel pin.
411RS005

Place hub on a wood workbench or a block of wood
approx. 6º by 6º to protect the wheel stud ends and
threads.

Install wheel stud, using a hammer.
NOTE: Be sure wheel stud is started squarely and seats
completely.
2. Install the hub unit bearing to the knuckle.
Tighten the bolts to the specified torque.
Hub unit bearing bolt
Torque: 103+10 N´m (10.5 + 1 kg´m)
If there is rust on the bearing and knuckle contact
surfaces, use sandpaper to remove it before installation.
3. Install the ABS sensor connector.
4. Install the disc rotor.
5. Install the brake caliper to the bracket.
Refer to
Front disc caliper assembly in Section 5C of this
Manual.

4C±49 DRIVE SHAFT SYSTEM
Front Hub and Disc (4WD Model)
Disassembled View
411R200010
Legend
(1) Disc Rotor
(2) Hub Unit, Bearing(3) Wheel Pin
(4) ABS Sensor Ring
(5) Bolt
Disassembly
1. Move the transfer case lever to the 2WD position.
2. Raise the vehicle with a jack. Support the frame with
chassis stands.
3. Remove the brake caliper from the bracket. Secure
the caliper with a wire that it does not interfare with the
work process.Refer to
Front disc caliper assembly in Section 5C of this
Manual.
4. Remove the disk rotor.
Apply penetrating oil to the bearing and disc rotor contact
surfaces if the surfaces are stuck together because of
rust.
5. Inspect the hub unit bearing. Refer to
inspection
below.

4C±51 DRIVE SHAFT SYSTEM
Reassembly
1. Install the wheel pin.

Place hub on a wood workbench or a block of wood
approx. 6º by 6º to protect the wheel stud ends and
threads.

Install the wheel stud, using a hammer.
NOTE: Be sure wheel stud is started squarely and seats
completely.
411RS005
2. Install the ABS rotor sensor to the hub unit bearing.
Tighten the bolts to the specified torque.
ABS rotor sensor bolt
Torque: 18.7+5 N´m (1.9+0.5 kg´m)
3. Install the hub unit bearing to the knuckle. Tighten the
bolts to the specified torque.
Hub unit bearing bolt
Torque: 103+10 N´m (10.5+1 kg´m)
If there is rust on the bearing and knuckle contact
surfaces, use sandpaper to remove it before installation.
Take care not to push the front drive shaft and oil seal out
of position.
4. Hand tighten the front drive shaft nuts.
Use new nuts.
5. Install the disc rotor.
6. Install the brake caliper to the bracket.
Refer to
Front disc caliper assembly in Section 5C of this
Manual.7. Tighten the front drive shaft nuts to the specified
torque.
Front drive shaft nut
Torque: 245+19.6 N´m (25+2 kg´m)
411R200005
8. Caulk the front drive shaft nuts.
The caulking must be free of cracks.
411R200006

5A±10BRAKE CONTROL SYSTEM
System Components
Electronic Hydraulic Control Unit (EHCU), three Wheel
Speed Sensors, Warning Light, and G-sensor.
Electronic Hydraulic Control Unit (EHCU)
The EHCU consists of ABS control circuits, fault detector,
and a fail-safe. The signal received from each sensor
activates the hydraulic unit accordingly and cancels the
ABS to return to normal braking if a malfunction occurs in
the ABS system.
The EHCU has a self-diagnosing function which can
indicate faulty circuits during diagnosis.
The EHCU is mounted on the engine compartment rear
right side. It consists of a Motor, Plunger Pump, Solenoid
Valves.
Solenoid Valves: Reduces or holds the caliper fluid
pressure for each front disc brake or both rear disc brakes
according to the signal sent from the EHCU.
Reservoir: Temporarily holds the brake fluid that returns
from the front and rear disc brake caliper so that pressure
of front disc brake caliper can be reduced smoothly.
Plunger Pump: Feeds the brake fluid held in the reservoir
to the master cylinder.
Motor: Drives the pump according to the signal from
EHCU.
Check Valve: Controls the brake fluid flow.
ABS Warning Light
821R200015Vehicles equipped with the Anti-lock Brake System have
an amber ªABSº warning light in the instrument panel.
The ªABSº warning light will illuminate if a malfunction in
the Anti-lock Brake System is detected by the Electronic
Hydraulic Control Unit (EHCU).In case of an electronic
malfunction, the EHCU will turn ªONº the ªABSº warning
light and disable the Anti-lock braking function.
The ªABSº light will turn ªONº for approximately three
seconds after the ignition switch is turned to the ªONº
position.If the ªABSº light stays ªONº after the ignition switch is
turned to the ªONº position, or comes ªONº and stays
ªONº while driving, the Anti-lock Brake System should be
inspected for a malfunction according to the diagnosis
procedure.
Wheel Speed Sensor
It consists of a sensor and a rotor. The sensor is attached
to the knuckle on the front wheels and to the rear axle
case on the rear differential.
The front sensor rotor is attached to the each brake rotor
by bolts.
The rear rotor is press-fit in the differential case.
The magnetic flux generated from electrodes magnetized
by a magnet in the sensor varies due to rotation of the
rotor, and the electromagnetic induction generates
alternating voltage in the coil. This voltage draws a ªsine
curveº with the frequency proportional to rotor speed and
it allows detection of wheel speed.
G-Sensor
The G-sensor installed inside the EHCU detects the
vehicle deceleration speed and sends a signal to the
EHCU. In 4WD operation, all four wheels may be
decelerated in almost the same phase, since all wheels
are connected mechanically.
This tendency is noticeable particularly on roads with low
friction coefficient, and the ABS control is adversely
affected.
The G-sensor judges whether the friction coefficient of
road surface is low or high, and changes the EHCU's
operating system to ensure ABS control.
Normal and Anti-lock Braking
Under normal driving conditions, the Anti-lock Brake
System functions the same as a standard power assisted
brake system. However, with the detection of wheel
lock-up, a slight bump or kick-back will be felt in the brake
pedal. This pedal ªbumpº will be followed by a series of
short pedal pulsations which occurs in rapid succession.
The brake pedal pulsation will continue until there is no
longer a need for the anti-lock function or until the vehicle
is stopped. A slight ticking or popping noise may be heard
during brake applications when the Anti-lock features is
being used.
When the Anti-lock feature is being used, the brake pedal
may rise even as the brakes are being applied. This is
also normal. Maintaining a constant force on the pedal
will provide the shortest stopping distance.
Brake Pedal Travel
Vehicles equipped with the Anti-lock Brake System may
be stopped by applying normal force to the brake pedal.
Although there is no need to push the pedal beyond the
point where it stops or holds the vehicle, by applying more
force the pedal will continue to travel toward the floor.
This extra brake pedal travel is normal.

5A±23
BRAKE CONTROL SYSTEM
Basic Inspection Procedure
1. Basic Inspection of Service Brake
StepActionYe sNo
1Is the fluid level normal?
Go to Step 2
Replenish with
fluid
Go to
Step 2
2Does fluid leak?Repair
Go to
Step 3Go to Step 3
3Is the booster functioning properly?
Go to Step 4
Repair
Go to
Step 4
4Is the pad and rotor within specs?
Go to Step 5
Repair
Go to
Step 5
5Reconnect all components. Ensure all component are properly
mounted.
Was this step finished?
FinishedGo to Step 5
2. Ground Inspection
StepActionYe sNo
1Is there good contact with the ABS ground points?
Go to Step 2
Repair
Go to
Step 2
2Reconnect all components. Ensure that all component are
properly mounted.
FinishedGo to Step 2

5A±48BRAKE CONTROL SYSTEM
Chart B-20 FL Speed Sensor Missing Signal (DTC 61 (Flash out) / C0226, C0227 (Serial
communications))
StepActionYe sNo
11. Turn the key off.
2. Disconnect coil integrated module connector.
3. Measure the FL speed sensor resistance between coil
integrated module connector (C-6) terminals 2 and 10.
Is the resistance between 2.0k and 2.8k ohms?
Go to Step 2Go to Step 3
2Is there play sensor/sensor rotor?Repair.
Go to
Step 6Go to Step 4
3Measure the FL speed sensor resistance at the sensor connector.
Is the resistance between 2.0k and 2.8k ohms?Repair harness
abnormality
between sensors
and coil
integrated
module.
Go to
Step 6
Replace sensor.
Go to
Step 6
4Damage and powdered iron sticking to sensor/sensor ring?Repair.
Go to
Step 6Go to Step 5
5Is sensor output normal? (Chart C-1-1 or TC-1)Check for faults
in harness
between speed
sensor and coil
integrated
module.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to
Step 6
Replace sensor.
Go to
Step 6
61. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
Repeat the ªBasic
diagnostic flow
chartº
Go to Step 6
NOTE: Even after repairing the faulty part the warning
light (W/L) does not go out if the vehicle is at a stop. Turn
the ignition switch to the ON position and drive the vehicle
at 12 km/h (8 mph) or higher to make sure that the
warning light goes out.

5A±49
BRAKE CONTROL SYSTEM
Chart B-21 FR Speed Sensor Missing Signal (DTC 62 (Flash out) / C0222, C0223 (Serial
communications))
StepActionYe sNo
11. Turn the key off.
2. Disconnect coil integrated module connector.
3. Measure the FR speed sensor resistance between coil
integrated module connector (C-6) terminals 3 and 11.
Is the resistance between 2.0k and 2.8k ohms?
Go to Step 2Go to Step 3
2Is there play sensor/sensor rotor?Repair.
Go to
Step 6Go to Step 4
3Measure the FR speed sensor resistance at the sensor
connector.
Is the resistance between 2.0k and 2.8k ohms?Repair harness
abnormality
between sensors
and coil
integrated
module.
Go to
Step 6
Replace sensor.
Go to
Step 6
4Damage and powered iron sticking to sensor/sensor ring?Repair.
Go to
Step 6Go to Step 5
5Is sensor output normal? (Chart C-1-2 or TC-1)Check for faults
in harness
between speed
sensor and coil
integrated
module.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to
Step 6
Replace sensor.
Go to
Step 6
61. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
Repeat the ªBasic
diagnostic flow
chartº
Go to Step 6
NOTE: Even after repairing the faulty part the warning
light (W/L) does not go out if the vehicle is at a stop. Turn
the ignition switch to the ON position and drive the vehicle
at 12 km/h (8 mph) or higher to make sure that the
warning light goes out.

5A±50BRAKE CONTROL SYSTEM
Chart B-22 Rear Speed Sensor Missing Signal (DTC 63 (Flash out) / C0236, C0237 (Serial
communications))
StepActionYe sNo
11. Turn the key off.
2. Disconnect coil integrated module connector.
3. Measure the Rear speed sensor resistance between coil
integrated module connector (C-6) terminals 4 and 12.
Is the resistance between 1.0k and 1.7k ohms?
Go to Step 2Go to Step 3
2Is there play sensor/sensor rotor?Repair.
Go to
Step 6Go to Step 4
3Measure the rear speed sensor resistance at the sensor
connector.
Is the resistance between 1.0k and 1.7k ohms?Repair harness
abnormality
between sensors
and coil
integrated
module.
Go to
Step 6
Replace sensor.
Go to
Step 6
4Damage and powered iron sticking to sensor/sensor ring?Repair.
Go to
Step 6Go to Step 5
5Is sensor output normal? (Chart C-1-3 or TC-1)Check for faults
in harness
between speed
sensor and coil
integrated
module.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU.
Go to
Step 6
Replace sensor.
Go to
Step 6
61. Reconnect all components, ensure all components are
properly mounted.
2. Clear diagnostic trouble code.
Was this step finished?
Repeat the ªBasic
diagnostic flow
chartº
Go to Step 6
NOTE: Even after repairing the faulty part the warning
light (W/L) does not go out if the vehicle is at a stop. Turn
the ignition switch to the ON position and drive the vehicle
at 12 km/h (8 mph) or higher to make sure that the
warning light goes out.