diagram ISUZU AXIOM 2002 Service Repair Manual

1A±2
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Compressor 1A±53. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution 1A±53. . . . . . . . . . . . . . . . . . . .
General Description 1A±53. . . . . . . . . . . . . . . . . . . . . .
Diagnosis 1A±54. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnetic Clutch Assembly (DKV-14G Type) 1A±55
Parts Location View 1A±55. . . . . . . . . . . . . . . . . . . .
Removal 1A±55. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 1A±57. . . . . . . . . . . . . . . . . .
Installation 1A±57. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil 1A±59. . . . . . . . . . . . . . . . . . . . . . . . .
Oil Specification 1A±59. . . . . . . . . . . . . . . . . . . . . . .
Handling of Oil 1A±59. . . . . . . . . . . . . . . . . . . . . . . .
Compressor Oil Check 1A±59. . . . . . . . . . . . . . . . .
Checking and Adjusting Oil Quantity for
Used Compressor 1A±59. . . . . . . . . . . . . . . . . . . . .
Checking and Adjusting for Compressor
Replacement 1A±60. . . . . . . . . . . . . . . . . . . . . . . . .
Contamination of Compressor Oil 1A±60. . . . . . . .
Oil Return Operation 1A±60. . . . . . . . . . . . . . . . . . .
Replacement of Component Parts 1A±60. . . . . . .
Main Data and Specifications 1A±61. . . . . . . . . . . . .
Special Tools 1A±63. . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Air Conditioning System 1A±64. . . . . . . .
General Description 1A±64. . . . . . . . . . . . . . . . . . . . . .
Automatic Air Conditioner Parts
Configuration 1A±64. . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram 1A±65. . . . . . . . . . . . . . . . . . . . . . .
Functions and Features 1A±70. . . . . . . . . . . . . . . .
Automatic Air Conditioner Block Diagram 1A±71.
Control Panel Layout 1A±72. . . . . . . . . . . . . . . . . . .
Air Control Functions 1A±73. . . . . . . . . . . . . . . . . . .
Control Panel Switch Operation 1A±74. . . . . . . . .
Overview of Construction, Movement and
Control of Major Parts of Automatic Air
Conditioner System 1A±77. . . . . . . . . . . . . . . . . . .
Overview of Automatic Control of Automatic
Air Conditioner 1A±81. . . . . . . . . . . . . . . . . . . . . . .
Automatic Air Conditioning System 1A±82. . . . . .
Troubleshooting 1A±86. . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting, Its Overview and
Procedures 1A±86. . . . . . . . . . . . . . . . . . . . . . . . . .
Auto Air Conditioner Control Unit Power
Supply Diagnosis 1A±87. . . . . . . . . . . . . . . . . . . . . Performance and Movement checklist for
Automatic Air Conditioner Related Parts 1A±89.
Troubleshooting With Self-Diagnosis
Function 1A±91. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection By Failed Location 1A±97. . . . . . . . . . . . .
Inspection of the Sensors 1A±97. . . . . . . . . . . . . . .
Inspection of the Intake Actuator System 1A±101.
Inspection of the Mix Actuator System 1A±104. . . .
Inspection of the Mode Actuator System 1A±107. .
Inspection of the Fan Motor System 1A±110. . . . . .
Inspection of the Magnetic Clutch System 1A±115
Individual Inspection 1A±118. . . . . . . . . . . . . . . . . . .
On-Vehicle Service 1A±121. . . . . . . . . . . . . . . . . . . . . .
Power Transistor 1A±121. . . . . . . . . . . . . . . . . . . . . .
Removal 1A±121. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±121. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Heater/Air Conditioner Control
Unit 1A±121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±121. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±121. . . . . . . . . . . . . . . . . . . . . . . . . . . .
In Car Sensor 1A±122. . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±122. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±122. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient Sensor 1A±122. . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±122. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±122. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sun Sensor 1A±123. . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±123. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±123. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct Sensor 1A±123. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±123. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±123. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode Actuator 1A±124. . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±124. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±124. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mix Actuator 1A±124. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±124. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±124. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Actuator 1A±125. . . . . . . . . . . . . . . . . . . . . . . .
Removal 1A±125. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 1A±125. . . . . . . . . . . . . . . . . . . . . . . . . . . .

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±65
Circuit Diagram
D01R200010

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±71
Automatic Air Conditioner Block Diagram
F01R200004

3F±10INTELLIGENT SUSPENSION
Circuit Diagram
826R200008

4B1±2
DRIVELINE CONTROL SYSTEM
Shift On The Fly System
Outline of Shift on The Fly System
The shift on the fly system switches between 2 wheel
drive (2WD) and 4 wheel drive (4WD) electronically by the
driver turning the TOD switch on the instrument panel.
This system will control the following operations. (Shifting
between ª4Hº and ª4Lº must be performed by TOD
switch.)
1. Transmitting the torque to the front propeller shaft.
2. Connecting front wheels to, and disconnecting them
from, the front axles by axle motor actuator.
3. Indicating on instrument panel.
4. 4WD out signal to other Electronic Brake Control
Module (EBCM).
System Diagrams
412R200008

4B2±1
DRIVE LINE CONTROL SYSTEM (TOD)
AXIOM
DRIVELINE/AXLE
DRIVELINE CONTROL SYSTEM (TOD)
CONTENTS
Service Precaution 4B2±1. . . . . . . . . . . . . . . . . . . . . .
General Description 4B2±2. . . . . . . . . . . . . . . . . . . . .
Transfer Position and Drive Mode 4B2±2. . . . . . . .
TOD Control 4B2±3. . . . . . . . . . . . . . . . . . . . . . . . . .
TOD Indicator Control 4B2±3. . . . . . . . . . . . . . . . . .
Abbreviations 4B2±3. . . . . . . . . . . . . . . . . . . . . . . . .
System Components 4B2±4. . . . . . . . . . . . . . . . . . . .
Parts Location 4B2±4. . . . . . . . . . . . . . . . . . . . . . . .
Front and Rear Speed Sensors 4B2±5. . . . . . . . . .
Electromagnetic Coil 4B2±5. . . . . . . . . . . . . . . . . . .
Multi Plate Disk Clutch Pack 4B2±5. . . . . . . . . . . .
Mechanical Lock Sleeve 4B2±5. . . . . . . . . . . . . . . .
High-Low Planetary Gear Set 4B2±6. . . . . . . . . . .
4H and 4L Switch 4B2±6. . . . . . . . . . . . . . . . . . . . . .
Transfer Connector (12-pin type) 4B2±6. . . . . . . .
Transfer Connector (8-pin type) 4B2±6. . . . . . . . .
TOD Indicator Lamps
(on the instrument panel) 4B2±7. . . . . . . . . . . . . .
Check Lamp 4B2±7. . . . . . . . . . . . . . . . . . . . . . . . . .
TOD ECU 4B2±8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Low Shift Motor 4B2±9. . . . . . . . . . . . . . . . . . .
Motor Position and Encoder Position Code 4B2±10
Encode Position Plate 4B2±10. . . . . . . . . . . . . . . . . .
Shift High Range and Low Range 4B2±10. . . . . . . . Functions of TOD Switch and Indicator
Lamp 4B2±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOD Switch and Indication of Drive Mode 4B2±11.
Check Lamp 4B2±13. . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis 4B2±14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information Diagnosis 4B2±14. . . . . . . . . .
Self-diagnosis 4B2±14. . . . . . . . . . . . . . . . . . . . . . . . .
Precautions on Diagnosis 4B2±16. . . . . . . . . . . . . . .
Basic Diagnostic Flow Chart 4B2±18. . . . . . . . . . . . . .
Parts Location 4B2±19. . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram 4B2±20. . . . . . . . . . . . . . . . . . . . . . . . .
Connector List 4B2±24. . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Failed Pin 4B2±26. . . . . . . . . . . . . . . . . . . . .
Connector Pin Assignment 4B2±26. . . . . . . . . . . . . .
Reference 4B2±28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Failed TOD Control Unit Pin 4B2±30. . . . .
Tech 2 Scan Tool 4B2±32. . . . . . . . . . . . . . . . . . . . . .
Getting Started 4B2±33. . . . . . . . . . . . . . . . . . . . . . . .
Operating Procedure 4B2±33. . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Codes 4B2±35. . . . . . . . . . . . . . . .
Diagnosis from Trouble Codes 4B2±36. . . . . . . . . . . .
Trouble Diagnosis Depending on The Status
of TOD Indicator 4B2±67. . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis from Symptom 4B2±102. . . . . . . . . . . . . . . . .
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

DRIVE LINE CONTROL SYSTEM (TOD) 4B2±20
Circuit Diagram
D04R200026

5A±1
BRAKE CONTROL SYSTEM
AXIOM
BRAKES
CONTENTS
Brake Control System 5A±1. . . . . . . . . . . . . . . . . . . .
Anti±lock Brake System 5B±1. . . . . . . . . . . . . . . . . .
Power±assisted Brake System 5C±1. . . . . . . . . . . .
Parking Brakes (4x4 Model) 5D1±1. . . . . . . . . . . . . .
Parking Brakes (4x2 Model) 5D2±1. . . . . . . . . . . . . .
Brake Control System
CONTENTS
Service Precaution 5A±2. . . . . . . . . . . . . . . . . . . . . .
General Description 5A±3. . . . . . . . . . . . . . . . . . . . .
Functional Description 5A±4. . . . . . . . . . . . . . . . .
System Components 5A±10. . . . . . . . . . . . . . . . . . .
Electronic Hydraulic Control Unit (EHCU) 5A±10.
ABS Warning Light 5A±10. . . . . . . . . . . . . . . . . . . .
Wheel Speed Sensor 5A±10. . . . . . . . . . . . . . . . . .
G-Sensor 5A±10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal and Anti-lock Braking 5A±10. . . . . . . . . . .
Brake Pedal Travel 5A±10. . . . . . . . . . . . . . . . . . . .
Acronyms and Abbreviations 5A±11. . . . . . . . . . . .
General Diagnosis 5A±11. . . . . . . . . . . . . . . . . . . . . . .
General Information 5A±11. . . . . . . . . . . . . . . . . . . .
ABS Service Precautions 5A±11. . . . . . . . . . . . . . .
Computer System Service Precautions 5A±11. . .
General Service Precautions 5A±11. . . . . . . . . . . .
Note on Intermittents 5A±11. . . . . . . . . . . . . . . . . . .
Test Driving ABS Complaint Vehicles 5A±12. . . . .
ªABSº Warning Light 5A±12. . . . . . . . . . . . . . . . . . .
Normal Operation 5A±12. . . . . . . . . . . . . . . . . . . . .
Tech 2 Scan Tool 5A±13. . . . . . . . . . . . . . . . . . . . . .
DATA LIST 5A±16. . . . . . . . . . . . . . . . . . . . . . . . . . .
ACTUATOR TEST 5A±17. . . . . . . . . . . . . . . . . . . . .
Tech 2 Service Bleed 5A±21. . . . . . . . . . . . . . . . . .
Basic Diagnostic Flow Chart 5A±22. . . . . . . . . . . .
Basic Inspection Procedure 5A±23. . . . . . . . . . . . .
EHCU Connector Pin-out Checks 5A±24. . . . . . . . .
Circuit Diagram 5A±25. . . . . . . . . . . . . . . . . . . . . . .
Connector List 5A±28. . . . . . . . . . . . . . . . . . . . . . . .
Part Location 5A±29. . . . . . . . . . . . . . . . . . . . . . . . .
Symptom Diagnosis 5A±30. . . . . . . . . . . . . . . . . . . . .
Chart A-1 ABS Works Frequently But
Vehicle Does Not Decelerate 5A±30. . . . . . . . . . .
Chart TA-1 ABS Works Frequently But
Vehicle Does Not Decelerate
(Use TECH 2) 5A±31. . . . . . . . . . . . . . . . . . . . . . . .
Chart A-2 Uneven Braking Occurs While
ABS Works 5A±31. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart TA-2 Uneven Braking Occurs While
ABS Works (Use TECH 2) 5A±31. . . . . . . . . . . . . Chart A-3, TA-3 The Wheels Are Locked 5A±32.
Chart A-4 Brake Pedal Feed Is Abnormal 5A±32.
Chart A-5, TA-5 Braking Sound
(From EHCU) Is Heard While Not Braking 5A±33
Diagnostic Trouble Codes 5A±34. . . . . . . . . . . . . . . .
Diagnosis By ªABSº Warning Light
Illumination Pattern 5A±36. . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Codes (DTCs) 5A±37. . . . . . .
Chart B-1 With the key in the ON position
(Before starting the engine). Warning light
(W/L) is not activated. 5A±39. . . . . . . . . . . . . . . . .
Chart B-2 CPU Error (DTC 14 (Flash out) /
C0271, C0272, C0273, C0284 (Serial
communications)) 5A±39. . . . . . . . . . . . . . . . . . . . .
Chart B-3 Low or High Ignition Voltage
(DTC 15 (Flash out) / C0277, 0278 (Serial
communications)) 5A±40. . . . . . . . . . . . . . . . . . . . .
Chart B-4 Excessive Dump Time (DTC 17
(Flash out) / C0269 (Serial
communications)) 5A±40. . . . . . . . . . . . . . . . . . . . .
Chart B-5 Excessive Isolation Time
(DTC 18 (Flash out) / C0274
(Serial communications)) 5A±40. . . . . . . . . . . . . . .
Chart B-6 G-Sensor Output Failure
(DTC 21 (Flash out) / C0276
(Serial communications)) 5A±41. . . . . . . . . . . . . . .
Chart B-7 Brake Switch Failure
(DTC 22 (Flash out) / C0281
(Serial communications)) 5A±41. . . . . . . . . . . . . . .
Chart B-8 2WD Controller in 4WD Vehicle
Controller (DTC 13 (Flash out) / C0285
(Serial communications)), 4WD State Input
Signal Failure (DTC 24 (Flash out) / C0282
(Serial communications)) 5A±42. . . . . . . . . . . . . . .
Chart B-9 Pump Motor Failure
(DTC 32 (Flash out) / C0267, C0268
(Serial communications)) 5A±42. . . . . . . . . . . . . . .
Chart B-10 EHCU Valve Relay Failure
(DTC 35 (Flash out) / C0265, C0266
(Serial communications)) 5A±43. . . . . . . . . . . . . . .
Chart B-11 FL Isolation Solenoid Coil Failure
(DTC 41 (Flash out) / C0245, C0247
(Serial communications)) 5A±43. . . . . . . . . . . . . . .
Chart B-12 FL Dump Solenoid Coil Failure
(DTC 42 (Flash out) / C0246, C0248
(Serial communications)) 5A±43. . . . . . . . . . . . . . .

5A±25
BRAKE CONTROL SYSTEM
Circuit Diagram
D05R200004

6A±28
ENGINE MECHANICAL (6VE1 3.5L)
Installation
NOTE: For correct belt installation, the letter on the belt
must be able to be read as viewed from the front of the
vehicle.
014RW005
Legend
(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley
(4) Idle Pulley
(5) LH Bank Camshaft Drive Gear Pulley
(6) Tension Pulley
(7) Alignment Mark on Oil Pump.
(8) Alignment Mark on Timing Belt
014RW006
Legend
(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side
1. Install timing belt.
1. Align groove of crankshaft timing pulley (2) with
mark on oil pump (1).
Align the mark on the crankshaft timing pulley (3)
with alignment mark (white dotted line) on the tim-
ing belt (4).
Secure the belt with a double clip or equivalent
clip.
NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.
014RW003
Legend
(1) Alignment Mark on Oil Pump
(2) Groove on Crankshaft Timing Pulley
(3) Alignment Mark on Crankshaft Timing Pulley
(4) Alignment Mark on Timing Belt
2. Align the alignment mark on the RH bank
camshaft drive pulley (2) to the alignment mark of
the cylinder head cover RH (3).
The camshaft pulley is not 1:1 with the camshafts.
It is necessary to rotate the camshaft pulley until
the camshaft lobes are in the position as shown
in the diagram on page 6A±34.
The camshaft pulley alignment mark should also
align with alignment mark on the cylinder head
cover.
It may require up to four revolutions of the
camshaft pulley to achieve alignment of all marks.