spare tire 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.

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

3E±6WHEEL AND TIRE SYSTEM
Tire Rotation
Tire rotation is recommended to equalize wear for longer
tire life.
480RS002
Legend
(1) Spare Tire
If the following conditions are noted, rotate the tires:

Front tire wear is different from rear.

Uneven wear exists across the tread of any tire.

Left and right front tire wear is unequal.

Left and right rear tire wear is unequal.
Check wheel alignment if the following conditions are
noted:

Left and right front tire wear is unequal.

Wear is uneven across the tread of any front tire.

Front tire treads have a scuffed appearance with
ªfeatherº edges on one side of the tread ribs or blocks.
Tread Wear Indicators
480RS006The original equipment tires have built-in tread wear indi-
cators(1) to show when tires need replacement. Theseindicators may appear as wide bands. When the indica-
tors appear in two or more grooves at three locations, tire
replacement is recommended.
Inflation of Tires
710RW002Tire pressure, in cold condition (after vehicle has set for
three hours or more, and driven less than one mile),
should be checked monthly or before any extended trip.
Tire pressure increases approximately 15% when the
tires become hot during driving. Tire pressure specifica-
tion is shown on the label located on the left door lock pil-
lar.
NOTE: Check the tire pressure whenever irregular wear
is found. Tire inflation greatly affects tire wear. If the
alignment check does not reveal any alignment problems,
check the condition of the shock absorbers and wheel/tire
balance.
Diagnosis List
If the following conditions are noted, rotation is required.
1. Front tire wear is different from rear.
2. Uneven wear exists across the tread of any tire.
3. Left and right front tire wear is unequal.
4. Left and right rear tire wear is unequal.
If the following conditions are noted, check the wheel
alignment.
1. Left and right front tire wear is unequal.
2. Uneven wear exists across the tread of any tire.
3. Front tire treads have scuffed appearance with
ªfeatherº edges on one side of tread ribs or blocks.
4. There is cupping, flat spotting etc.
Higher than recommended pressure can cause:
1. Hard ride.
2. Poor steering stability.
3. Rapid and uneven wear at center of the tread.
Lower than recommended pressure can cause:
1. Tire squeal on turns.
2. Hard steering.
3. Rapid and uneven wear on the edges of the tread.
4. Tire rim bruises and rupture.

5C±11 POWER±ASSISTED BRAKE SYSTEM
330RW012
17. Bleed the air from the front wheel brake pipe
connection (2) by repeating steps 7 through 16.
Bleeding the Caliper
18. Bleed the air from each wheel in the order listed
below:

Right rear caliper or wheel cylinder

Left rear caliper or wheel cylinder

Right front caliper

Left front caliper
Conduct air bleeding from the wheels in the above
order. If no brake fluid comes out, it suggests that air
is mixed in the master cylinder. In this case, bleed air
from the master cylinder in accordance with steps 7
through 17, and then bleed air from the caliper or
wheel cylinder.
19. Place the proper size box end wrench over the
bleeder screw.
20. Cover the bleeder screw with a transparent tube, and
submerge the free end of the transparent tube in a
transparent container containing brake fluid.
21. Pump the brake pedal slowly three (3) times
(once/sec), then hold it depressed.
22. Loosen the bleeder screw until fluid flows through the
tube.
23. Retighten the bleeder screw.
24. Release the brake pedal slowly.
25. Repeat steps 21 through 24 until the air is completely
removed.
It may be necessary to repeat the bleeding procedure
10 or more times for front wheels and 15 or more
times for rear wheels.
26. Go to the next wheel in the sequence after each wheel
is bled.
Be sure to monitor reservoir fluid level.
27. Depress the brake pedal to check if you feel
ªsponginessº after the air has been removed from all
wheel cylinders and calipers.
If the pedal feels ªspongyº, the entire bleeding
procedure must be repeated.28. After the bleeding operation is completed on the each
individual wheel, check the level of the brake fluid in
the reservoir and replenish up to the ªMAXº level as
necessary.
29. Attach the reservoir cap.
If the diaphragm inside the cap is deformed, reform
it and install.
30. Stop the engine.
Flushing Brake Hydraulic System
It is recommended that the entire hydraulic system be
thoroughly flushed with clean brake fluid whenever new
parts are installed in the hydraulic system. Approximately
one quart of fluid is required to flush the hydraulic system.
The system must be flushed if there is any doubt as to the
grade of fluid in the system or if fluid has been used which
contains the slightest trace of mineral oil. All rubber parts
that have been subjected to a contaminated fluid must be
replaced.
Brake Pipes and Hoses
The hydraulic brake system components are
interconnected by special steel piping and flexible hoses.
Flexible hoses are used between the frame and the front
calipers, the frame and rear axle case and the rear axle
and the rear calipers.
When the hydraulic pipes have been disconnected for
any reason, the brake system must be bled after
reconnecting the pipe. Refer to
Bleeding the Brake
Hydraulic System
in this section.
Brake Hose Inspection
The brake hose should be inspected at least twice a year.
The brake hose assembly should be checked for road
hazard, cracks and chafing of the outer cover, and for
leaks and blisters. Inspect for proper routing and
mounting of the hose. A brake hose that rubs on
suspension components will wear and eventually fail. A
light and mirror may be needed for an adequate
inspection. If any of the above conditions are observed on
the brake hose, adjust or replace the hose as necessary.
CAUTION: Never allow brake components such as
calipers to hang from the brake hoses, as damage to
the hoses may occur.

5C±71 POWER±ASSISTED BRAKE SYSTEM
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.
330R200004
17. Bleed the air from the front wheel brake pipe
connection (2) by repeating steps 7 through 16.
Bleeding the Caliper
18. Bleed the air from each wheel in the order listed
below:

Right rear caliper or wheel cylinder

Left rear caliper or wheel cylinder

Right front caliper

Left front caliper
Conduct air bleeding from the wheels in the above
order. If no brake fluid comes out, it suggests that air
is mixed in the master cylinder. In this case, bleed air
from the master cylinder in accordance with steps 7
through 17, and then bleed air from the caliper or
wheel cylinder.
19. Place the proper size box end wrench over the
bleeder screw.
20. Cover the bleeder screw with a transparent tube, and
submerge the free end of the transparent tube in a
transparent container containing brake fluid.
21. Pump the brake pedal slowly three (3) times
(once/sec), then hold it depressed.
22. Loosen the bleeder screw until fluid flows through the
tube.
23. Retighten the bleeder screw.24. Release the brake pedal slowly.
25. Repeat steps 21 through 24 until the air is completely
removed.
It may be necessary to repeat the bleeding procedure
10 or more times for front wheels and 15 or more
times for rear wheels.
26. Go to the next wheel in the sequence after each wheel
is bled.
Be sure to monitor reservoir fluid level.
27. Depress the brake pedal to check if you feel
ªsponginessº after the air has been removed from all
wheel cylinders and calipers.
If the pedal feels ªspongyº, the entire bleeding
procedure must be repeated.
28. After the bleeding operation is completed on the each
individual wheel, check the level of the brake fluid in
the reservoir and replenish up to the ªMAXº level as
necessary.
29. Attach the reservoir cap.
If the diaphragm inside the cap is deformed, reform
it and install.
30. Stop the engine.
Flushing Brake Hydraulic System
It is recommended that the entire hydraulic system be
thoroughly flushed with clean brake fluid whenever new
parts are installed in the hydraulic system. Approximately
one quart of fluid is required to flush the hydraulic system.
The system must be flushed if there is any doubt as to the
grade of fluid in the system or if fluid has been used which
contains the slightest trace of mineral oil. All rubber parts
that have been subjected to a contaminated fluid must be
replaced.
Brake Pipes and Hoses
The hydraulic brake system components are
interconnected by special steel piping and flexible hoses.
Flexible hoses are used between the frame and the front
calipers, the frame and rear axle case and the rear axle
and the rear calipers.
When the hydraulic pipes have been disconnected for
any reason, the brake system must be bled after
reconnecting the pipe. Refer to
Bleeding the Brake
Hydraulic System
in this section.
Brake Hose Inspection
The brake hose should be inspected at least twice a year.
The brake hose assembly should be checked for road
hazard, cracks and chafing of the outer cover, and for
leaks and blisters. Inspect for proper routing and
mounting of the hose. A brake hose that rubs on
suspension components will wear and eventually fail. A
light and mirror may be needed for an adequate
inspection. If any of the above conditions are observed on
the brake hose, adjust or replace the hose as necessary.
CAUTION: Never allow brake components such as
calipers to hang from the brake hoses, as damage to
the hoses may occur.

8F±1 BODY STRUCTURE
AXIOM
BODY AND ACCESSORIES
BODY STRUCTURE
CONTENTS
Service Precaution 8F±2. . . . . . . . . . . . . . . . . . . . . .
Frame 8F±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 8F±2. . . . . . . . . . . . . . . . . . . . .
Frame Dimensions 8F±3. . . . . . . . . . . . . . . . . . . .
General Description (Bumper) 8F±4. . . . . . . . . . . .
Front Bumper 8F±4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±4. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Bumper 8F±7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±7. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description (Sheet Metal) 8F±10. . . . . . . . .
Engine Hood 8F±10. . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±10. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Hood Lock 8F±13. . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±13. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Fender Panel 8F±15. . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±15. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body Mounting 8F±18. . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±18. . . . . . . . . . . . . . . . . . . . . . . .
Tightening Torque 8F±18. . . . . . . . . . . . . . . . . . . . . . .
Body Dimension 8F±19. . . . . . . . . . . . . . . . . . . . . . . .
Front Section 8F±19. . . . . . . . . . . . . . . . . . . . . . . . .
Room Section (Front Side) 8F±22. . . . . . . . . . . . . .
Room Section (Rear Side) 8F±24. . . . . . . . . . . . . .
Rear Section 8F±26. . . . . . . . . . . . . . . . . . . . . . . . . .
Side Body Section (Front side) 8F±28. . . . . . . . . .
Side Body Section (Rear side) 8F±30. . . . . . . . . .
General Description (Body) 8F±32. . . . . . . . . . . . . . .
Instrument Panel Assembly 8F±32. . . . . . . . . . . . . . .
Parts Location 8F±32. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 8F±34. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Door Assembly 8F±35. . . . . . . . . . . . . . . . . . . .
Parts Location 8F±35. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±36. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Door Assembly 8F±37. . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±37. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±38. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Window Regulator, Glass and Glass
Run 8F±39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±39. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±41. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Window Regulator, Glass and Glass
Run 8F±42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±42. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±43. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±45. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tailgate 8F±46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±46. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±48. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spare Tire Hanger 8F±49. . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±49. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±50. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±50. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windshield 8F±51. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±51. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±51. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±52. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Quarter Glass 8F±55. . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±55. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±55. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±56. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tailgate Glass 8F±57. . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Location 8F±57. . . . . . . . . . . . . . . . . . . . . . . .
Removal 8F±57. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 8F±58. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 8F±59. . . . . . . . . . . . .

8F±49 BODY STRUCTURE
Spare Tire Hanger
Parts Location
530R200002
Legend
(1) Spare Tire Hanger Assembly Fixing Bolt
(2) End Cross Member
(3) Rear Suspension ´ Cross Member
(4) Spare Tire Support
(5) Spare Tire Support Fixing Bolt(6) Spare Tire Stopper Rubber (RH)
(7) Spare Tire Stopper Rubber (Front)
(8) Stopper Rubber Fixing Clip
(9) Spare Tire
(10) Spare Tire Stopper Rubber (LH)
(11) Spare Tire Hanger Assembly

8F±50BODY STRUCTURE
Removal
1. Open the hatch gate and tail gate.
2. Remove the spare tire (3).

Put the spare tire handle (1) to the center of upper
side of rear bumper (2) and turn counterclockwise.
Put spare tire down.
530R200001
3. Remove the spare tire support.

Remove the four bolts that are fixed to frame cross
member.
4. Remove the spare tire hanger assembly.

Remove the two fixing bolts.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Install the spare tire firmly.
2. Tighten the spare tire support fixing bolts to the
specified torque.
Torque : 40 N´m (4.1 kg´m)
3. Tighten the spare tire hanger fixing bolts to the
specified torque.
Torque : 19 N´m (1.9 kg´m)