hood open ISUZU AXIOM 2002 Service Repair Manual

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

1A±60
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Checking and Adjusting for
Compressor Replacement
150 cc (5.0 fl.oz.) of oil is charged in compressor (service
parts). So it is necessary to drain the proper amount of oil
from the new compressor.
1. Perform oil return operation.
2. Discharge and recover the refrigerant and remove the
compressor.
3. Drain the compressor oil and measure the extracted
oil.
4. Check the compressor oil for contamination.
5. Adjust the oil level as required.
(Amount of oil drained
from used compressor)
(Draining amount of oil
from new compressor)
less than 90 cc (3.0 fl.oz)Same as drained
amount
more than 90 cc (3.0
fl.oz)90 cc (3.0 fl.oz)
6. Evacuate, charge and perform the oil return
operation.
7. Check the system operation.
Contamination of Compressor Oil
Unlike engine oil, no cleaning agent is added to the
compressor oil. Even if the compressor runs for a long
period of time (approximately one season), the oil never
becomes contaminated as long as there is nothing wrong
with the compressor or its method of use.
Inspect the extracted oil for any of the following
conditions:

The capacity of the oil has increased.

The oil has changed to red.

Foreign substances, metal powder, etc., are present
in the oil.
If any of these conditions exists, the compressor oil
is contaminated. Whenever contaminated
compressor oil is discovered, the receiver/drier must
be replaced.
Oil Return Operation
There is close affinity between the oil and the refrigerant.
During normal operation, part of the oil recirculates with
the refrigerant in the system. When checking the amount
of oil in the system, or replacing any component of the
system, the compressor must be run in advance for oil
return operation. The procedure is as follows:
1. Open all the doors and the engine hood.
2. Start the engine and air conditioning switch to ªONº
and set the fan control knob at its highest position.
3. Run the compressor for more than 20 minutes
between 800 and 1,000 rpm in order to operate the
system.
4. Stop the engine.
Replacement of Component Parts
When replacing the system component parts, supply the
following amount of oil to the component parts to be
installed.
(Component parts to be
installed)
(Amount of Oil)
Evaporator 50 cc (1.7 fl. oz.)
Condenser30 cc (1.0 fl. oz.)
Receiver/dryer30 cc (1.0 fl. oz.)
Refrigerant line (one
piece)10 cc (0.3 fl. oz.)

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).

POWER±ASSISTED STEERING SYSTEM2A±43
7. When installing the steering column cover, be sure to
wire (through each harness) as illustrated so that the
harnesses starter switch, combination switch and
SRS coil may not catch wiring.
825RW017
Legend
(1) Steering Column Cover
(2) Starter Switch Harness
(3) Combination Switch Harness
(4) Inflator Module Harness
8. Install steering wheel by aligning the setting marks
made during removal.
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.
9. Tighten the steering wheel fixing nut to the specified
torque.
Torque: 34 N´m (25 lb ft)
10. Support inflator module and carefully connect the
SRS connector and horn lead, then install inflator
module.
NOTE: Pass the lead wire through the tabs on the plastic
cover (wire protector) of inflator to prevent lead wire from
being pinched.
11. Tighten fixing bolts to specified torque.
Torque: 9 N´m (78 lb in)
12. Install driver knee bolster (reinforcement).
13. Install instrument panel lower cover, then install the
engine hood opening lever.
14. Connect the yellow 2-way SRS connector located
under the steering column.
15. Connect the battery ground cable.
System Inspection
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.

POWER±ASSISTED STEERING SYSTEM2A±45
5. Remove the engine hood opening lever, then remove
instrument panel lower cover.
6. Remove driver knee bolster (reinforcement).
7. Loosen the inflator module fixing bolt from behind the
steering wheel assembly using a TORX) driver or
equivalent until the inflator module can be released
from steering assembly.
827RW070
8. Disconnect the yellow 2-way SRS connector and
horn lead located behind the inflator module.
9. Remove inflator module.
WARNING: T H E I N F L AT O R M O D U L E S H O U L D
ALWAYS BE CARRIED WITH THE TRIM COVER
AWAY FROM YOUR BODY AND SHOULD ALWAYS
BE LAID ON A FLAT SURFACE WITH THE
URETHANE SIDE UP. THIS IS NECESSARY
BECAUSE FREE SPACE IS PROVIDED TO ALLOW
THE AIR CUSHION TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY MAY RESULT.
827RW072
10. Apply a setting mark (1) across the steering wheel
and shaft so parts can be reassembled in their original
position. Move the front wheels to the straight ahead
position, then use steering wheel remover J±29752
to remove the steering wheel.
430RW021
430RX005
11. Remove steering column cover.
12. Disconnect the wiring harness connectors located
under the steering column.

POWER±ASSISTED STEERING SYSTEM2A±49
13. Install steering wheel and align the setting marks
made when removing.
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.
14. Tighten the steering wheel fixing nut to the specified
torque.
Torque: 34 N´m (25 lb ft)
15. Support the module and carefully connect the module
connector and horn lead, then install inflator module.
NOTE: Pass the lead wire through the tabs on the plastic
cover (wire protector) of inflator to prevent lead wire from
being pinched.
16. Tighten bolts to specified torque.
Torque: 9 N´m (78 lb in)
17. Install driver knee bolster (reinforcement).
18. Install instrument panel lower cover.
19. Install the engine hood opening lever.
20. Connect the yellow 2-way SRS connector and horn
lead located under the steering column.
21. Connect the battery ground cable.
System Inspection
Turn the ignition switch ªONº and observe if the warning
lamp flashes 7 times. If the warning lamp does not
operate correctly, refer to
Restraints section.

5C±18
POWER±ASSISTED BRAKE SYSTEM
Brake Pedal and Associated Parts
310RY00006
Legend
(1) Brake Pedal Bracket Assembly
(2) Fulcrum Pin and Nut
(3) Connector
(4) Snap Pin
(5) Return Spring(6) Peadl Assembly
(7) Push Rod Pin
(8) Lower Cover
(9) Bolts and Nut
(10) Driver Knee Bolster
Removal
1. Disconnect the battery ª±º terminal cable, and wait at
least 5 minutes.
2. Disconnect the yellow 3 way SRS connector located
under the steering column.
3. Remove the engine hood opening lever.
4. Remove lower cover (8).
5. Remove driver knee bolster (10).
6. Disconnect the stop light switch connector (3).
Disconnect the anti-theft control module connector.
Refer to
Body and Accessories section in this
Manual.
7. Remove snap pin (4) and push rod pin (7).
8. Remove the steering column shaft fixing bolt and nut
(9) on the steering wheel side, and lower the steering
column shaft.
9. Remove the brake pedal bracket assembly (1).
10. Remove return spring (5).
11. Remove fulcrum pin and nut (2).12. Remove pedal assembly (6).
Installation
1. Apply grease to the entire circumference of the
fulcrum pin.
2. Install pedal assembly (6) and fulcrum pin and nut (2).
Tighten the nut (2) to the specified torque.
Torque: 35 N´m (26 lb ft)
3. Install the brake pedal bracket assembly (1).
Tighten the bolts and nuts soecified torque.
Torque: 15 N´m (11 lb ft)
4. Install return spring (5).
5. Adjust pedal free travel.
Refer to
Brake Pedal Adjustment in this section.
6. Tighten the steering column fixing bolt (9) (dash
panel) to the specified torque.
Torque: 20 N´m (14 lb ft)

5C±19 POWER±ASSISTED BRAKE SYSTEM
7. Tighten the steering column fixing nut (9) (Cross
Beam) to the specified torque.
Torque: 17 N´m (12 lb ft)
8. Apply grease to the entire circumference of the Push
rod pin (7).
9. Install push rod pin (7).
10. Install snap pin (4).
11. Connect the anti-theft control module connector.
Refer to
Body and Accessories section in this
manual.12. Connect the stop light switch connector (3).
13. Install driver knee bolster (10) and lower cover (8).
14. Install the engine hood opening lever.
15. Connect the yellow 3 way SRS connector located
under the steering column.
16. Connect the battery ª±º terminal cable.
Stoplight Switch
Parts Location
310RW008
Legend
(1) Connector
(2) Switch
(3) Lock Nut
Removal
1. Disconnect connector (1)
2. Remove lock nut (3).
3. Remove switch (2).
Installation
1. Adjust the stop light switch to the specified clearance
(between switch housing and brake pedal) by rotating
the switch housing.
Clearance : 0-0.2 mm (0-0.08 in)
NOTE: Do not attempt to force the push rod into position
during the stop light switch installation and adjustment
procedure.
310RY00005
2. Connect connector (1).
3. Install lock nut (3).