2002-2004 Isuzu Axiom Service & Repair Manual

SECTION TABLE OF CONTENTS GENERAL INFORMATION 0A General Information 0B Maintenance and Lubrication WORKSHOP MANUAL HEATING, VENTILATION AND AIR CONDITIONING 1A HVAC System STEERING 2A Power-Assisted System AXIOM (UPR/S) SUSPENSION 3C Front Suspension 3D Rear Suspension 3E Wheel and Tire System 3F Intelligent Suspension System DRIVELINE/AXLE 4A1 Differential (Front) 4A2 Differential (Rear) 4B1 Driveline Control System 4B2 Driveline Control System (TOD) 4C Drive Shaft System 4D2 Transfer Case (TOD) FOREWORD This manual includes special notes, important 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 5A Brake Control System 5B Anti-Lock Brake System 5C Power-Assisted Brake System 5D1 Parking Brake System (4×4 model) 5D2 Parking Brake System (4×2 model) ENGINE 6A Engine Mechanical 6B Engine Cooling 6C Engine Fuel 6D1 Engine Electrical 6D2 Ignition System 6D3 Starting and Charging System 6E Driveability and Emissions 6F Engine Exhaust 6G Engine Lubrication 6H Engine Speed Control System 6J Induction TRANSMISSION 7A Automatic Transmission 7A1 Transmission Control System BODY AND ACCESSORIES 8A Lighting System 8B Wiper/Washer System 8C Entertainment 8D Wiring System 8E Meter and Gauge 8F Body Structure 8G Seats 8H Security and Locks 8I Sun Roof/Convertible Top 8J Exterior/Interior Trim RESTRAINTS 9A Seat Belt System 9J Supplemental Restraint System (Air Bag System) 9J1 Restraint Control System CONTROL SYSTEM 10A Cruise Control System

0A–1 GENERAL INFORMATION AXIOM GENERAL INFORMATION CONTENTS General Information 0A . . . . . . . . . . . . . . . . . . . . . Maintenance and Lubrication 0B . . . . . . . . . . . . . General Information CONTENTS General Repair Instruction 0A–1 . . . . . . . . . . . . . . . . Illustration Arrows 0A–2 . . . . . . . . . . . . . . . . . . . . . . . Identification 0A–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theft Prevention Standard 0A–5 . . . . . . . . . . . . . . . . Lifting Instructions 0A–9 . . . . . . . . . . . . . . . . . . . . . . . Standard Bolts Torque Specifications 0A–11 . . . . . . Abbreviations Charts 0A–12 . . . . . . . . . . . . . . . . . . . . Service Parts Identification Plate 0A–13 . . . . . . . . . . General Repair Instruction 1. If a floor jack is used, the following precautions are recommended. Park vehicle on level ground, “block” front or rear wheels, set jack against the recommended lifting points (see “Lifting Instructions” in this section), raise vehicle and support with chassis stands and then perform the service operations. 2. Before performing service operations, disconnect ground cable from the battery to reduce the chance of cable damage and burning due to short circuiting. 3. Use a cover on body, seats and floor to protect them against damage and contamination. 4. Brake fluid and anti–freeze solution must be handled with reasonable care, as they can cause paint damage. 5. The use of proper tools and recommended essential and available tools, where specified, is important for efficient and reliable performance of service repairs. 6. Use genuine Isuzu parts. 7. Used cotter pins, plastic clips, gaskets, O–rings, oil seals, lock washers and self–locking nuts should be discarded and new ones should be installed, as normal function of the parts cannot be maintained if these parts are reused. 8. To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping fixing bolts and nuts separate is very important, as they vary in hardness and design depending on position of installation. 9. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air, and make certain they are free from restrictions. 10. Lubricate rotating and sliding faces of the parts with oil or grease before installation. 11.When necessary, use a sealer on gaskets to prevent leakage. 12. Carefully observe all specifications for bolt and nut torques. 13. When removing or replacing parts that require refrigerant to be discharged from the air conditioning system, be sure to use the Vehicle Refrigerant Recovery and Recycling Equipment (VRRRE) to recover and recycle Refrigerant–134a. 14. When a service operation is completed, make a final check to be sure the service has been done properly and the problem has been corrected. 15. SUPPLEMENTAL RESTRAINT SYSTEM The vehicle is equipped with a Supplemental Restraint System (SRS) – Air Bags. This system is not to be serviced without consulting the appropriate service information. Consult Section 9J “SRS System” if work is to be done on the front of the vehicle such as bumper, sheet metal, seats, wiring, steering wheel or column. Also review SRS system information if any arc welding is to be done on the vehicle. The SRS system equipped vehicle can be identified by: 1. “AIR BAG” warning light on the instrument cluster. 2. A Code “K” or “M” for fifth digit of Vehicle Identification Number.

0A–2 GENERAL INFORMATION Illustration Arrows Arrows are designed for specific purposes to aid your understanding of technical illustrations. Arrow Type Application Front of vehicle Up Side Task Related View Detail View Angle Dimension (1:2) Sectioning (1:3) Arrow Type Application B Ambient/Clean air flow B Cool air flow B Gas other than ambient air B Hot air flow B Ambient air mixed with another gas B Can indicate temperature change Motion or direction Lubrication point oil or fluid Lubrication point grease Lubrication point jelly

0A–3 GENERAL INFORMATION Identification Vehicle Identification Number (VIN) This is the legal identification of the vehicle. it is located on the left bottom of the windshield. It can be easily seen through the windshield from outside the vehicle. 710RW003

0A–4 GENERAL INFORMATION Engine Serial Number The gasoline engine serial number is stamped on the left rear lower area of the cylinder block above the starter. 240R200014 Automatic : Stamped on the identification plate, located on the left side of the transmission above the mode switch. 240R200013

0A–5 GENERAL INFORMATION Theft Prevention Standard The 11 major components listed below will be marked with 17 digit VIN at the stage of production. In addition its service parts will be marked with manufacturer’s trade mark, “R” mark and “DOT” mark. Reference COMPONENT INDICATION Figure No. COMPONENT PRODUCTION SERVICE PARTS 0A-10 ENGINE 1– 6VE1 VIN plate 0A-11 TRANSMISSION 2– Automatic transmission VIN plate 0A-11 BODY 3– Engine hood 4– Front door 5– Rear door 6– Fender 7– Rear Quarter panel 8– Front bumper 9– Back door left side 10– Back door right side 11– Rear bumper VIN label Anti Theft Stamping/Plate/Label STAMPING/PLATE LABEL PRODUCTION SERVICE PARTS

0A–6 GENERAL INFORMATION Anti Theft Stamping/Label/Plate Location The stamping, label and plate locations are indicated by arrows in the illustration below. NOTE: 1. VIN plate locations for production. 2. Stamping locations for service parts. Engine 901RW195 Automatic Transmission 240R200012

0A–7 GENERAL INFORMATION Body 604R200007

0A–8 GENERAL INFORMATION Body Label Instructions Do not peel off the masking tape until completion of paint work when replacing these parts, as the tape is affixed on the label attached to service parts for body of the anti–theft component. NOTE: Be sure to pull off the masking tape after paint work has been completed. Do not attempt to remove this label for any reason. 901RW083 Precautions in pulling off the masking tape 1. Use only your finger nail or a similar blunt instrument to peel off the masking tape. Use of a sharp object will damage the underlying anti–theft label. 2. Be careful not to damage the paint around the label. 901RW084

0A–9 GENERAL INFORMATION Lifting Instructions CAUTION: B If a lifting device other than the original jack is used, it is most important that the device be applied only to the correct lifting points. Raising the vehicle from any other point may result in serious damage. B When jacking or lifting a vehicle at the frame side rail or other prescribed lift points, be certain that lift pads do not contact the catalytic converter, brake pipes or cables, or fuel lines. Such contact may result in damage or unsatisfactory vehicle performance. Lifting Points and Supportable Point Locations C00RX002 Lifting Point: Front B When using a floor jack, lift on the Convex portion of the skid plate. 545RS001

2002-2004 Isuzu Axiom Service & Repair Manual

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