park assist 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

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.

2A±6
POWER±ASSISTED STEERING SYSTEM
Power Steering Pump
Foaming milky power steering fluid, low fluid level, and
possible low pressure can be caused by air in the fluid, or
loss of fluid due to internal pump leakage. Check for leak
and correct. Bleed the system. Extremely cold
temperatures will cause air bubbles in the system if thefluid level is low. If the fluid level is correct and the pump
still foams, remove the pump from the vehicle and check
housing for cracks. If the housing is cracked, replace the
pump housing.
Condition
Possible causeCorrection
Low Pressure Due to Steering PumpRelief valve sticking or inoperative.Replace relief valve.
Side plate not flat against cam ring.Replace side plate.
Extreme wear of cam ring.Replace cam ring.
Scored side plate or rotor.Replace side plate or rotor.
Vanes sticking in rotor slots.Repair or replace vanes and rotor.
Cracked or broken side plate.Replace side plate.
High internal leakage.Repair internal leakage.
Low Pressure Due to Steering GearScored housing bore.Replace housing.
Growling Noise In Steering PumpExcessive back pressure in hoses or
steering unit caused by restriction.Repair steering unit or pump.
Scored side plate or rotor.Replace side plate or rotor.
Worn cam ring.Replace cam ring.
Groaning Noise In Steering PumpAir in the fluid.Bleed hydraulic system.
Low fluid level.Replenish fluid.
Pump mounting loose.Tighten mounting bolt.
Rattling Noise In Steering PumpVanes sticking in rotor slots.Repair or replace vanes and rotor.
Vane improperly installed.Repair rotor and vane.
Swishing Noise In Steering PumpDamaged relief valve.Replace relief valve.
Whining Noise In Steering PumpScored side plate and vanes.Replace side plate and vanes.
Steering Column Lock System
ConditionPossible causeCorrection
Will Not UnlockDamaged lock cylinder.Replace lock cylinder.
Damaged park lock cable.Replace park lock cable.
Will Not LockLock spring broken or worn.Replace lock cylinder.
Damaged lock cylinder.Replace lock cylinder.
Ignition switch stuck.Repair or replace ignition switch.
Park lock cable damaged.Replace park lock cable.
Key Cannot be Removed in
ªOFF LOCKº
Ignition switch is not set correctly.Correct ignition switch.
ªOFF-LOCKºDamaged lock cylinder.Replace lock cylinder.
Faulty shift lock mechanism.Repair or replace the shift lock
mechanism.
Column
ConditionPossible causeCorrection
Noise in ColumnUniversal joint loose.Tighten joint.
Shaft lock snap ring not seated.Place snap ring in proper position.

POWER±ASSISTED STEERING SYSTEM2A±13
Caster (1) is the vertical tilting of the wheel axis either
forward or backward (when viewed from the side of the
vehicle). A backward tilt is positive (+) and a forward tilt is
negative (-). On the short and long arm type suspension
you cannot see a caster angle without a special
instrument, but if you look straight down from the top of
the upper control arm to the ground, the ball joints do not
line up (fore and aft) when a caster angle other than 0
degree is present. With a positive angle, the lower ball
joint would be slightly ahead (toward the front of the
vehicle) of the upper ball joint center line.
Toe-in:
This illustration shows view from the top of the vehicle.
480RS003Toe-in is the measured amount the front wheels are
turned in. The actual amount of toe-in is normally a
fraction of a degree. Toe-in is measured from the center
of the tire treads or from the inside of the tires. The
purpose of toe-in is to insure parallel rolling of the front
wheels and to offset any small deflections of the wheel
support system which occurs when the vehicle is rolling
forward. Incorrect toe-in results in excessive toe-in and
unstable steering. Toe-in is the last alignment to be set in
the front end alignment procedure.
Inspection
Before making any adjustments affecting caster, camber
or toe-in, the following front end inspection should be
made.
1. Inspect the tires for proper inflation pressure. Refer to
Main Data and Specifications in Wheel and Tire
System
section.
2. Make sure that the vehicle is unladen condition (With
no passenger or loading).
3. Make sure that the spare tire is installed at the normal
position.
4. Inspect the front wheel bearings for proper
adjustment. Refer to
Front Hub and Disc Overhaul in
Suspension
section.
5. Inspect the ball joints and tie rod ends. If excessive
looseness is noted, correct before adjusting. Refer to
Steering Linkage in this section.6. Inspect the wheel and tires for run-out. Refer to
Wheel Replacement in Wheel and Tire System
section.
7. Inspect the trim height. If not within specifications, the
correction must be made before adjusting caster.
8. Inspect the steering unit for looseness at the frame.
9. Inspect shock absorbers for leaks or any noticeable
noise. Refer to
Shock Absorber in Suspension
section.
10. Inspect the control arms or stabilizer bar attachment
for looseness. Refer to
Suspension section.
11. Inspect the front end alignment using alignment
equipment. Follow the manufacturer's instructions.
12. Park the vehicle on a level surface.
Trim Height Adjustment
Adjust the trim height (1) by means of the adjusting bolt on
the height control arms.
CAUTION: When adjusting front end alignment, be
sure to begin with trim height first, as it may change
other adjusted alignments.
450RS003
410RS001

2A±14
POWER±ASSISTED STEERING SYSTEM
1. Check and adjust the tire inflation pressures.
2. Park the vehicle on a level ground and move the front
of the vehicle up and down several times to settle the
suspension.
3. Make necessary adjustment with the adjusting bolt on
the height control arms.
Trim height: 119 + 5 mm (4.69 + 0.2 in)
Caster Adjustment
The caster angle can be adjusted by means of the caster
shims (1) installed between the chassis frame (2) and
fulcrum pins.
Caster angle: 2
30' + 1

CAUTION: Left and right side must be equal within
30'.
450RW006
450RS002
NOTE: Difference of the caster shim front/rear thickness
should be 3.6 mm (0.142 in) or less. Overall thickness of
caster shim and camber shim should be 10.8 mm
(0.425 in) or less.
Tighten the fulcrum pin bolt to the specified torque.
Torque: 152 N´m 112 ( lb ft)
Camber Adjustment
The camber angle can be adjusted by means of the
camber shims (2) installed in position between the
chassis frame (1) and fulcrum pins
Camber angle: 0
+ 30'
King pin inclination: 12
30' + 30'
CAUTION: Left and right side must be equal within
30'.
450RW007
450RS005

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. . . . . . . . . . . . . . .

5C±6
POWER±ASSISTED BRAKE SYSTEM
Diagnosis
Road Testing The Brakes
Brake Test
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake
performance cannot be made if the roadway is wet,
greasy or covered with loose dirt where all tires do not grip
the road equally. Testing will also be adversely affected if
the roadway is crowned so as to throw the weight of the
vehicle toward wheels on one side or if the roadway is so
rough that wheels tend to bounce. Test the brakes at
different vehicle speeds with both light and heavy pedal
pressure; however, avoid locking the wheels and sliding
the tires. Braking without locking the tires will stop the
vehicle in less distance than braking to a skid (which has
no brake efficiency). More tire to road friction is present
while braking without locking the tires than braking to a
skid.
The standard brake system is designed and balanced to
avoid locking the wheels except at very high deceleration
levels.
It is designed this way because the shortest stopping
distance and best control is achieved without brake
lock±up.
Because of high deceleration capability, a firmer pedal
may be felt at higher deceleration levels.
External Conditions That Affect Brake Performance
1. Tires: Tires having unequal contact and grip on the
road will cause unequal braking. Tires must be
equally inflated, identical in size, and the thread
pattern of right and left tires must be approximately
equal.
2. Vehicle Loading: A heavily loaded vehicle requires
more braking effort.
3. Wheel Alignment: Misalignment of the wheels,
particularly in regard to excessive camber and caster,
will cause the brakes to pull to one side.
Brake Fluid Leaks
With engine running at idle and the transmission in
ªNeutralº, depress the brake pedal and hold a constant
foot pressure on the pedal. If pedal gradually falls away
with the constant pressure, the hydraulic system may be
leaking.
Check the master cylinder fluid level. While a slight drop in
the reservoir level will result from normal lining wear, an
abnormally low level in reservoir indicates a leak in the
system. The hydraulic system may be leaking internally
as well as externally. Refer to
Master Cylinder Inspection.
Also, the system may appear to pass this test but still
have slight leakage. If fluid level is normal, check the
vacuum booster push rod length. If an incorrect length
push rod is found, adjust or replace the push rod. Check
the brake pedal travel and the parking brake adjustment.
When checking the fluid level, the master cylinder fluid
level may be lower than the ªMAXº mark if the front and
rear linings are worn. This is normal.
Warning Light Operation
When the ignition switch is in the START position, the
ªBRAKEº warning light should turn on and go off when the
ignition switch returns to the ON position.
The following conditions will activate the ªBRAKEº light:
1. Parking brake applied. The light should be on
whenever the parking brake is applied and the ignition
switch is on.
2. Low fluid level. A low fluid level in the master cylinder
will turn the ªBRAKEº light on.
3. During engine cranking the ªBRAKEº light should
remain on. This notifies the driver that the warning
circuit is operating properly.

5C±8
POWER±ASSISTED BRAKE SYSTEM
Condition CorrectionPossible cause
Excessive Brake Pedal TravelAir in hydraulic circuit.Bleed the hydraulic circuit.
Level of brake fluid in the reservoir
too low.Replenish brake fluid reservoir to
specified level and bleed hydraulic
circuit as necessary.
Master cylinder push rod clearance
excessive.Adjust
Leakage in hydraulic system.Correct or replace defective parts.
Brake DragMaster cylinder pistons not returning
correctly.Adjust the stop light switch and
vacuum booster push rod. If
necessary, rebuild.
Restricted brake pipes or hoses.Check for soft hoses or damaged
pipes, and replace with new hoses
and new double±walled steel brake
piping.
Parking brake maladjusted.Adjust
Parking brake lining clearance
insufficient.Adjust
Brake pedal free play insufficient.Adjust the brake pedal height or
power cylinder operating rod.
Piston in the master cylinder sticking.Replace
Piston in the disc brake caliper
sticking.Replace piston seals.
Brake pads sticking in caliper.Clean
Return spring weakened.Replace
Parking brake binding.Overhaul the parking brakes and
correct.
Front hub bearing preload incorrect.Adjust or replace.
Parking brake shoes not returning.Correct or replace the brake back
plate and brake shoe as necessary.
Obstructions in hydraulic circuit.Clean
Rotor warped excessively.Grind or replace.
Rear brake drum distorted.Grind or replace.
Parking cable sticking.Grind or replace.
Grabbing or Uneven Braking Action
(All conditions listed under ªPullsº)Malfunctioning vacuum booster.Check operation and correct as
necessary.
Binding brake pedal mechanism.Check and lubricate, if necessary.
Corroded caliper assembly.Clean and lubricate.
Brake NoisyBrake pads are worn.Replace
Brake pads are hardened.Replace
Brake pads are in poor contact with
rotor.Correct
Brake disc(s) warped, worn or
damaged.Grind or replace.
Disc brake anti±squeak shims
fatigued.Replace
Front hub bearings are loose or
preload is incorrect.Adjust or replace.
Brake disc is rusted.Grind or replace.

5C±10
POWER±ASSISTED BRAKE SYSTEM
Hydraulic Brakes
Filling Master Cylinder Reservoir
CAUTION: Use only specified brake fluid. Do not
use any fluid which contains a petroleum base. Do
not use a container which has been used for
petroleum based fluids or a container which is wet
with water. Petroleum based fluid will cause swelling
and distortion of rubber parts in the hydraulic brake
system. Water mixed with brake fluid lowers the fluid
boiling point. Keep all fluid containers capped to
prevent contamination.
Always fill the master cylinder reservoir when the en-
gine is cold.
Never allow the brake fluid to come in contact with
the painted surfaces.
The master cylinder reservoir must be kept properly
filled to ensure adequate reserve and to prevent air
and moisture from entering the hydraulic system.
However, because of expansion due to heat ab-
sorbed from the brakes and the engine, the reservoir
must not be overfilled. The brake fluid reservoir is on
the master cylinder, which is located under the hood
on the left side of the cowl. Thoroughly clean reser-
voir cap before removal to avoid getting dirt into res-
ervoir. Remove the diaphragm. Add fluid as required
to bring level to the ªMAXº mark on the reservoir
tank. Use ªDOT 3º Hydraulic Brake Fluid. If the fluid
cap diaphragm is stretched, return it to the original
position before installing.
Deterioration of Brake Fluid
Using any other brake fluid than specified or brake fluid
with mineral oil or water mixed in will drop the boiling point
of brake fluid. It may, in turn, result in vapor lock or
deteriorated rubber parts of the hydraulic system. Be sure
to change the brake fluid at specified intervals.
If the rubber parts are deteriorated, remove all the system
parts and clean them with alcohol. Prior to reassembly,
dry the cleaned parts with air to remove the alcohol.
Replace all the hoses and rubber parts of the system.
Leakage of Brake Fluid
With engine idling, set shift lever in the neutral position
and continue to depress brake pedal at a constant pedal
application force.
Should the pedal stroke become deeper gradually,
leakage from the hydraulic pressure system is possible.
Perform visual inspection for any signs of leakage.
Bleeding Brake Hydraulic System
A bleeding operation is necessary to remove air from the
hydraulic brake system whenever air is introduced into
the hydraulic system. It may be necessary to bleed the
hydraulic system at all four brakes if air has been
introduced through a low fluid level or by disconnecting
brake pipes at the master cylinder. If a brake pipe is
disconnected at one wheel, only that wheel
cylinder/caliper needs to be bled. If the pipes aredisconnected at any fitting located between the master
cylinder and brakes, then the brake system served by the
disconnected pipe must be bled.
1. For 4±Wheel Antilock Brake System (ABS) equipped
vehicle, be sure to remove the ABS main fuse 60A
located at the relay and fuse box before bleeding air. If
you attempt to bleed air without removing the main
fuse, air cannot be let out thoroughly, and this may
cause damage to the hydraulic unit. After bleeding air,
be sure to replace the ABS main fuse back to its
original position.
2. Set the parking brake completely, then start the
engine.
NOTE: The vacuum booster will be damaged if the
bleeding operation is performed with the engine off.
3. Remove the master cylinder reservoir cap.
4. Fill the master cylinder reservoir with brake fluid.
Keep the reservoir at least half full during the air
bleeding operation
5. Always use new brake fluid for replenishment.
6. When replenishing the brake fluid reservoir, carefully
pour in the brake fluid to prevent air bubbles from
entering the brake system.
When the master cylinder is replaced or overhauled,
first bleed the air from the master cylinder, then from
each wheel cylinder and caliper following the
procedures described below.
Bleeding the Master Cylinder
7. Disconnect the rear wheel brake pipe (1) from the
master cylinder.
Check the fluid level and replenish as necessary. If
replenished, leave the system for at least one minute.
8. Depress the brake pedal slowly once and hold it
depressed.
9. Completely seal the delivery port of the master
cylinder with your finger, where the pipe was
disconnected then release the brake pedal slowly.
10. Release your finger from the delivery port when the
brake pedal returns completely.
11. Repeat steps 8 through 10 until the brake fluid comes
out of the delivery port during step 8.
NOTE: Do not allow the fluid level in the reservoir to go
below the half±way mark.
12. Reconnect the brake pipe (1) to the master cylinder
and tighten the pipe.
13. Depress the brake pedal slowly once and hold it
depressed.
14. Loosen the rear wheel brake pipe (1) at the master
cylinder.
15. Retighten the brake pipe, then release the brake
pedal slowly.
16. Repeat steps 13 through 15 until no air comes out of
the port when the brake pipe is loosened
NOTE: Be very careful not to allow the brake fluid to come
in contact with painted surfaces.

5C±54
POWER±ASSISTED BRAKE SYSTEM
Brake Lining
Brake Lining and Associated Parts
305RW001
Legend
(1) Wheel and Tire Assembly
(2) Drum
(3) Hold-down Spring and Cup
(4) Hold-down Spring and Cups
(5) Lower Return Spring
(6) Upper (other) Return Spring
(7) Trailing Shoe Assembly with Parking Brake
Lever
(8) Leading Shoe Assembly with Upper (inner)
Return Spring(9) Upper (inner) Return Spring
(10) Auto Adjuster Lever
(11) Parking Brake Lever
(12) Adjuster Assembly
(13) Wave Washer
(14) Retainer
(15) Hold-down Pin
(16) Hold-down Pin
Removal
1. Raise the vehicle and support with suitable safety
stands.
2. Remove wheel and tire assembly (1).

Refer to
ªWheel and Tiresº in Wheel and Tire
System
section.
3. Remove Drum (2).

If difficulty is encountered in removing the drum:
± Mark the position of the drum to the axle.
± Make sure the parking brake is released.± Use a rubber mallet to tap gently on the outer rim of
the drum and/or around the inner drum. Be careful
to avoid damaging the drum.
4. Remove upper (other) return spring (6) and auto
adjuster lever.
5. Remove lower return spring (5).
6. Remove hold-down spring and cups (4) and
hold-down pin (15).
7. Remove adjuster assembly (12)
8. Remove leading shoe assembly (8) with upper (inner)
return spring (9).