charging ISUZU AXIOM 2002 Service Repair Manual

SECTION TABLE OF CONTENTS
GENERAL INFORMATION
0AGeneral Information
0BMaintenance and Lubrication
WORKSHOP MANUAL
HEATING, VENTILATION AND AIR
CONDITIONING
1AHVAC System
STEERING
2APower-Assisted System
AXIOM
(UPR/S)SUSPENSION
3CFront Suspension
3DRear Suspension
3EWheel and Tire System
3FIntelligent Suspension System
DRIVELINE/AXLE
4A1Differential (Front)
4A2Differential (Rear)
4B1Driveline Control System
4B2Driveline Control System (TOD)
4CDrive Shaft System
4D2Transfer Case (TOD)
FOREWORD
This manual includes special notes, impor tant points, service data,
precautions, etc. That are needed for the maintenance, adjustments,
service, removal and installation of vehicle components.
All information, illustrations and specifications contained in this manual
are based on the latest product information available at the time of
publication.
All rights are reserved to make changes at any time without notice.
Arrangement of the material is shown in the table of contents on the
right-hand side of this page. A black spot on the first page of each
section can be seen on the edge of the book below each section title.
These point to a more detailed table of contents preceding each
section.BRAKE
5ABrake Control System
5BAnti-Lock Brake System
5CPower-Assisted Brake System
5D1Parking Brake System (4´4 model)
5D2Parking Brake System (4´2 model)
ENGINE
6AEngine Mechanical
6BEngine Cooling
6CEngine Fuel
6D1Engine Electrical
6D2Ignition System
6D3Starting and Charging System
6EDriveability and Emissions
6FEngine Exhaust
6GEngine Lubrication
6HEngine Speed Control System
6JInduction
TRANSMISSION
7AAutomatic Transmission
7A1Transmission Control System
BODY AND ACCESSORIES
8ALighting System
8BWiper/Washer System
This manual applies to 2002 models.8CEnter tainment
8DWiring System
8EMeter and Gauge
8FBody Structure
8GSeats
8HSecurity and Locks
8ISun Roof/Convertible Top
8JExterior/Interior Trim
RESTRAINTS
9ASeat Belt System
9JSupplemental Restraint System (Air Bag System)
9J1Restraint Control System
CONTROL SYSTEM
10ACruise Control System

1A±24
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Diagnosis
Air Conditioning Cycle Diagnosis
ConditionPossible causeCorrection
No cooling or insufficient cooling.Magnetic clutch does not run.Refer to ªMagnetic Clutch Diagnosisº
in this section.
Compressor is not rotating properly.
Drive belt is loose or broken.Adjust the drive belt to the specified
tension or replace the drive belt.
Compressor is not rotating properly.
Magnetic clutch face is not clean and
slips.Clean the magnetic clutch face or
replace.
Compressor is not rotating properly.
Incorrect clearance between
magnetic drive plate and pulley.Adjust the clearance. Refer to
Compressor in this section.
Compressor is not rotating properly.
Compressor oil leaks from the shaft
seal or shell.Replace the compressor
Compressor is not rotating properly.
Compressor is seized.Replace the compressor
Insufficient or excessive charge of
refrigerant.Discharge and recover the
refrigerant. Recharge to the
specified amount.
Leaks in the refrigerant system.Check the refrigerant system for
leaks and repair as necessary.
Discharge and recover the
refrigerant. Recharge to the
specified amount.
Condenser is clogged or insufficient
radiation.Clean the condenser or replace as
necessary.
Temperature control link unit of the
heat unit is defective.Repair the link unit.
Unsteady operation due to a foreign
substance in the expansion valve.Replace the expansion valve.
Poor operation of the electronic
thermostat.Check the electronic thermostat and
replace as necessary.
Insufficient velocity of cooling air.Evaporator clogged or frosted.Check the evaporator core and
replace or clean the core.
Air leaking from the cooling unit or air
duct.Check the evaporator and duct
connection, then repair as
necessary.
Blower motor does not rotate
properly.Refer to Fan Control Lever (Fan
Switch) Diagnosis in this section.
*For the execution of the charging and discharging
operation in the table above, refer to
Recovery,
Recycling, Evacuating and Charging in this section.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±25
Checking The Refrigerant System With Manifold Gauge
Since Refrigerant-134a (HFC-134a) is used in the air
conditioning system in this vehicle, be sure to use
manifold gauges, charging hoses and other air
conditioning service tools for HFC-134a when
checking the refrigerant system.
Conditions:

Run the engine at idle

Air conditioning switch is ªONº

Run the blower motor at ªHIGHº position (5 positions)

Temperature control set to ªMAX COLDº (65
F)

Air source selector at ªCIRCº

Open the engine hood

Close all the doors
Normal Pressure:

At ambient temperature: approx. 25±30
C
(77±86
F).

At low-pressure side: approx. 147.1±294.2 kPa
(21.3±42.7 psi).

At high-pressure side: approx. 1372.9±1863.3 kPa
(199.1±270.2 psi).
Refer to the table on the refrigerant pressure-temperature
relationship.
HFC-134a Pressure-Temperature Relationship
PressureTemperature
(kPa)(psi)(
C)(
F)
365.3±20±4.4
679.7±155
10415±1014
14721±523
19628032
25537541
314451050
392571559
471682068
569822577
677983086
78511 43595
91213240104
10591544511 3
121617650122

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±31
Air Conditioning System
Individual Inspection
Triple Pressure Switch (V6, A/T)
1. Disconnect the connector and check for continuity
between pressure switch side connector terminals (1)
and (2).
2. Reconnect the connector to activate the A/C switch,
and check to see if there is continuity between the
chassis side connector terminals (3) and (4) and the
fan operates.
875RY00010
Condenser Fan
1. Disconnect the condenser fan connector.
2. Connect the battery positive terminal to the
condenser fan side connector terminal No.C-16-1
and negative to the No.C-16-2.
3. Check that condenser fan is rotating correctly.
875R200002
General Repair Procedure
Precautions For Replacement or Repair of
Air Conditioning Parts
There are certain procedures, practices and precautions
that should be followed when servicing air conditioning
systems:

Keep your work area clean.

Always wear safety goggles and protective gloves
when working on refrigerant systems.

Beware of the danger of carbon monoxide fumes
caused by running the engine.

Beware of discharged refrigerant in enclosed or
improperly ventilated garages.

Always disconnect the negative battery cable and
discharge and recover the refrigerant whenever
repairing the air conditioning system.

When discharging and recovering the refrigerant, do
not allow refrigerant to discharge too fast; it will draw
compressor oil out of the system.

Keep moisture and contaminants out of the system.
When disconnecting or removing any lines or parts,
use plugs or caps to close the fittings immediately.
Never remove the caps or plugs until the lines or parts
are reconnected or installed.

When disconnecting or reconnecting the lines, use
two wrenches to support the line fitting, to prevent
from twisting or other damage.

Always install new O-rings whenever a connection is
disassembled.

Before connecting any hoses or lines, apply new
specified compressor oil to the O-rings.

When removing and replacing any parts which
require discharging the refrigerant circuit, the
operations described in this section must be
performed in the following sequence:
1. Use the J-39500 (ACR
4: HFC-134a Refrigerant
Recovery / Recycling / Recharging / System) or
equivalent to thoroughly discharge and recover the
refrigerant.
2. Remove and replace the defective part.
3. After evacuation, charge the air conditioning
system and check for leaks.

1A±34
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
3. If the leak is still present, discharge and recover the
refrigerant from the system.
4. Replace the O-rings.

O-rings cannot be reused. Always replace with new
ones.

Be sure to apply the specified compressor oil to the
new O-rings.
5. Retighten the refrigerant line fitting to the specified
torque.

Use two wrenches to prevent twisting and damage
to the line.
6. Evacuate, charge and retest the system.
Leaks In The Hose
If the compressor inlet or outlet hose is leaking, the entire
hose must be replaced. The refrigerant hose must not be
cut or spliced for repair.
1. Locate the leak.
2. Discharge and recover the refrigerant.
3. Remove the hose assembly.

Cap the open connections at once.
4. Connect the new hose assembly.

Use two wrenches to prevent twisting or damage to
the hose fitting.

Tighten the hose fitting to the specified torque.
5. Evacuate, charge and test the system.
Compressor Leaks
If leaks are located around the compressor shaft seal or
shell, replace or repair the compressor.
Recovery, Recycling, Evacuation and
Charging of HFC-134a
Air conditioning systems contain HFC-134a. This is a
chemical mixture which requires special handling
procedures to avoid personal injury.

Always wear safety goggles and protective gloves.

Always work in a well-ventilated area. Do not weld or
steam clean on or near any vehicle-installed air
conditioning lines or components.

If HFC-134a should come in contact with any part of
the body, flush the exposed area with cold water and
immediately seek medical help.

If it is necessary to transport or carry any container of
HFC-134a in a vehicle, do not carry it in the
passenger compartment.

If it is necessary to fill a small HFC-134a container
from a large one, never fill the container completely.
Space should always be allowed above the liquid for
expansion.

HFC-134a and R-12 should never be mixed as their
compositions are not the same.

HFC-134a PAG oil tends to absorb moisture more
quickly than R-12 mineral oil and, therefore, should
be handled more carefully.

Keep HFC-134a containers stored below 40
C
(104
F).WARNING:

SHOULD HFC-134A CONTACT YOUR EYE(S),
CONSULT A DOCTOR IMMEDIATELY.

DO NOT RUB THE AFFECTED EYE(S). INSTEAD,
SPLASH QUANTITIES OF FRESH COLD WATER
OVER THE AFFECTED AREA TO GRADUALLY
RAISE THE TEMPERATURE OF THE
REFRIGERANT ABOVE THE FREEZING POINT.

OBTAIN PROPER MEDICAL TREATMENT AS
SOON AS POSSIBLE. SHOULD THE HFC-134A
TOUCH THE SKIN, THE INJURY MUST BE
TREATED THE SAME AS SKIN WHICH HAS BEEN
FROSTBITTEN OR FROZEN.
Refrigerant Recovery
The refrigerant must be discharged and recovered by
using the J-39500 (ACR4:HFC-134a Refrigerant
Recovery/Recycling/Recharging/System) or equivalent
before removing or mounting air conditioning parts.
1. Connect the high and low charging hoses of the
ACR
4(or equivalent) as shown below.
901R100022
Legend
(1) Low Side
(2) High Side
2. Recover the refrigerant by following the
Manufacturer's Instructions.
3. When a part is removed, put a cap or a plug on the
connecting portion so that dust, dirt or moisture
cannot get into it.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±35
Refrigerant Recycling
Recycle the refrigerant recovered by J-39500
(ACR4:HFC-134a Refrigerant Recovery / Recycling /
Recharging / System) or equivalent.
For the details of the actual operation, follow the steps in
the ACR
4(or equivalent) Manufacturer's Instructions.
Evacuation of The Refrigerant System
901R100023
Legend
(1) Low Side
(2) High Side
NOTE: Explained below is a method using a vacuum
pump. Refer to the ACR4(or equivalent) manufacturer's
instructions when evacuating the system with a ACR4(or
equivalent).
Air and moisture in the refrigerant will cause problems in
the air conditioning system. Therefore, before charging
the refrigerant, be sure to evacuate air and moisture thor-
oughly from the system.
1. Connect the gauge manifold.

High-pressure valve (HI) Ð Discharge-side.

Low-pressure valve (LOW) Ð Suction-side.
2. Discharge and recover the refrigerant.
3. Connect the center hose of the gauge manifold set to
the vacuum pump inlet.
4. Operate the vacuum pump, open shutoff valve and
then open both hand valves.
5. When the low-pressure gauge indicates
approximately 750 mmHg (30 inHg), continue the
evacuation for 5 minutes or more.
6. Close both hand valves and stop the vacuum pump.
7. Check to ensure that the pressure does not change
after 10 minutes or more.

If the pressure changes, check the system for
leaks.

If leaks occur, retighten the refrigerant line
connections and repeat the evacuation steps.8. If no leaks are found, again operate the vacuum pump
for 20 minutes or more. After confirming that the
gauge manifold pressure is at 750 mmHg (30 inHg),
close both hand valves.
9. Close positive shutoff valve. Stop the vacuum pump
and disconnect the center hose from the vacuum
pump.
Charging The Refrigerant System
There are various methods of charging refrigerant into the
air conditioning system.
These include using J-39500 (ACR
4:HFC-134a
Refrigerant Recovery/Recycling/Recharging/System) or
equivalent and direct charging with a weight scale
charging station.
Charging Procedure

ACR
4(or equivalent) Method
For the charging of refrigerant recovered by ACR4(or
equivalent), follow the manufacturer's instruction.
901R100022
Legend
(1) Low Side
(2) High Side

Direct charging with a weight scale charging
station method
1. Make sure the evacuation process is correctly
completed.
2. Connect the center hose of the manifold gauge to the
weight scale.

1A±36
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
3. Connect the low pressure charging hose of the
manifold gauge to the low pressure side service valve
of the vehicle.
4. Connect the high pressure charging hose of the
manifold gauge to the high pressure side service
valve of the vehicle.
901R100021
Legend
(1) Low Side
(2) High Side
(3) Refrigerant Container
(4) Weight Scale
5. Place the refrigerant container(3) up right on a weight
scale(4).
Note the total weight before charging the refrigerant.
a. Open the refrigerant container valve.
b. Open the low side vale on the manifold gauge set.
Refer to the manufacturer's instructions for a
weight scale charging station.
901RS144
6. Perform a system leak test:

Charge the system with approximately 200 g
(0.44 lbs) of HFC-134a.

Make sure the high pressure valve of the manifold
gauge is closed.

Check to ensure that the degree of pressure does
not change.

Check for refrigerant leaks by using a HFC-134a
leak detector.

If a leak occurs, recover the refrigerant. Repair the
leak and start all over again from the first step of
evacuation.
7. If no leaks are found, continue charging refrigerant to
the air conditioning system.

Charge the refrigerant until the scale reading
decreases by the amount of the charge specified.
Specified amount: 700 g (1.54 lbs)

If charging the system becomes difficult:
1. Run the engine at idle and close all the vehicle
doors.
2. Turn A/C switch ªONº.
3. Set the fan switch to its highest position.
4. Set the air source selector lever to ªCIRCº.
5. Slowly open the low side valve on the manifold
gauge set.
WARNING: BE ABSOLUTELY SURE NOT TO OPEN
THE HIGH PRESSURE VALVE OF THE MANIFOLD
GAUGE. SHOULD THE HIGH PRESSURE VALVE BE
OPENED, THE HIGH PRESSURE REFRIGERANT
WOULD FLOW BACKWARD, AND THIS MAY CAUSE
THE REFRIGERANT CONTAINER TO BURST.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±37
8. When finished with the refrigerant charging, close the
low pressure valve of the manifold gauge and
container valve.
9. Check for refrigerant leaks.
Checking The A/C System
1. Run the engine and close all the vehicle doors.
2. Turn A/C switch ªONº, set the fan switch to its highest
position.
3. Set the air source switch to ªCIRCº, set the
temperature switch to the full cool position.
4. Check the high and low pressure of the manifold
gauge.

Immediately after charging refrigerant, both high
and low pressures might be slightly high, but they
settle down to the pressure guidelines shown
below:

The ambient temperature should be between
25±30
C (77±86
F).

The pressure guideline for the high-pressure side is
approximately 1372.9±1863.3 kPa (199.1±270.2
psi).

The pressure guideline for the low-pressure side is
approximately 147.1±294.2 kPa (21.3±42.7 psi).

If an abnormal pressure is found, refer to
Checking
The Refrigerant System With Manifold Gauge in
this section.
5. Put your hand in front of the air outlet and move the
temperature switch of the control panel to different
positions. Check if the outlet temperature changes as
selected by the control switch.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±59
Compressor Oil
Oil Specification

The HFC-134a system requires a synthetic (PAG)
compressor oil whereas the R-12 system requires a
mineral compressor oil. The two oils must never be
mixed.

Compressor (PAG) oil varies according to
compressor model. Be sure to use oil specified for the
model of compressor.

Always use HFC-134a Vane Rotary Type
Compressor Oil (AIPDN Part No.2-90188-301-0)
Handling of Oil

The oil should be free from moisture, dust, metal
powder, etc.

Do not mix with other oil.

The water content in the oil increases when exposed
to the air. After use, seal oil from air immediately.
(HFC-134a Vane Rotary Compressor Oil absorbs
moisture very easily.)

The compressor oil must be stored in steel
containers, not in plastic containers.
Compressor Oil Check
The oil used to lubricate the compressor is circulating with
the refrigerant.
Whenever replacing any component of the system or a
large amount of gas leakage occurs, add oil to maintain
the original amount of oil.
Oil Capacity
Capacity total in system: 150cc (5.0 fl.oz)
Compressor (Service parts) charging amount:
150 cc (5.0 fl.oz)
Checking and Adjusting Oil Quantity
for Used Compressor
1. Perform oil return operation. Refer to Oil Return
Operation in this section.
2. Discharge and recover refrigerant and remove the
compressor.
3. Drain the compressor oil and measure the extracted
oil with a measuring cylinder.
4. If the amount of oil drained is much less than 90 cc
(3.0 fl. oz.), some refrigerant may have leaked out.
Conduct a leak tests on the connections of each
system, and if necessary, repair or replace faulty
parts.
5. Check the compressor oil contamination. (Refer to
Contamination of Compressor Oil in this section.)
6. Adjust the oil level following the next procedure
below.(Charging Amount)
(Collected Amount)
more than 90cc (3.0
fl.oz)same as collected
amount
less than 90 cc (3.0 fl.oz)90cc (3.0 fl.oz)
7. Install the compressor, then evacuate, charge and
perform the oil return operation.
8. Check system operation.
When it is impossible to preform oil return operation,
the compressor oil should be checked in the
following order:
1. Discharge and recover refrigerant and remove the
compressor.
2. Drain the compressor oil and measure the extracted
oil with a measuring cylinder.
3. Check the oil for contamination.
4. If more than 90 cc (3.0 fl. oz.) of oil is extracted from
the compressor, supply the same amount of oil to the
compressor to be installed.
5. If the amount of oil extracted is less than 90 cc (3.0 fl.
oz.), recheck the compressor oil in the following
order.
6. Supply 90 cc (3.0 fl. oz.) of oil to the compressor and
install it onto the vehicle.
7. Evacuate and recharge with the proper amount of
refrigerant.
8. Perform the oil return operation.
9. Remove the compressor and recheck the amount of
oil.
10. Adjust the compressor oil, if necessary.
(Collected Amount)
(Charging Amount)
more than 90 cc (3.0
fl.oz)same as collected
amount
less than 90 cc (3.0 fl.oz)90 cc (3.0 fl.oz)

4B2±109
DRIVE LINE CONTROL SYSTEM (TOD)
StepActionYe sNo
1Do the indicator lamps show the correct status?
Go to Step 2
Examine the
trouble based on
ªTrouble
Diagnosis
Depending on the
Status of TOD
Indicatorº.
2Is any of the trouble codes 28(P1760), 32(P1761) and 33(P1762)
recorded?Examine the
trouble based on
ªDiagnosis from
Trouble Codesº.
Go to Step 3
3Turn on the starter switch.
Is the battery voltage observed between terminals 14 and 47?
Go to Step 4Go to Step 5
4When the TOD Switch is selected to the 2H position, are the front
axle gears correctly disengaged (and when the left front tire is
jacked up and turned, is the front propeller shaft standstill)?The phenomenon
is not
reproduced.
Refer to
ªTrouble
intermittently
observedº
.
The shift on the
fly system is
failed (refer to
Section 4B1 and
4C
).
5Does the battery voltage maintain the correct level?
Repair the battery
circuit.
Go to
Step 6
Repair the battery
and charging
system.
Go to
Step 6
6Check that all the parts are mounted.
Is this step complete?
Verify the repair.Go to Step 6