2002 ISUZU AXIOM brake light

5C±78
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.
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±79 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.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).

5C±113 POWER±ASSISTED BRAKE SYSTEM
NOTE: Do not over stretch the return spring.
305RS003
9. Remove upper (inner) return spring (9).
10. Remove hold-down spring and cup (3) and hold-down
pin (16).
11. Remove Trailing shoe assembly (7) with parking
brake lever (16).
12. Remove parking brake cable from parking brake lever
(11).
13. Remove retainer (14), wave washer (13), and parking
brake lever (11).
Brake Lining Inspection
Check the shoe assemblies for wear by removing brake
drum.
Replace the shoe assemblies, if lining thickness is less
than 1.0 mm (0.039 in).
The shoe assemblies have a wear indicator that makes a
noise when the linings wear to a degree where
replacement is required.
Minimum limit: 1.0 mm (0.039 in)
305RS001
Installation
1. Apply grease lightly to back place A.
305RW002
Legend
(1) Place A (3 portions for each side)
2. Install parking brake lever (11), wave washer (13),
and retainer (14).
3. Install trailing shoe assembly (7) with parking brake
lever (16).
4. Install the parking brake cable to parking brake lever
(11).
5. Install hold-down pin (16) and hold-down spring and
cup (3).
6. Install upper (inner) return spring (9).
7. Install leading shoe assembly (8) with upper (inner)
return spring (9).
NOTE: Do not over stretch the return spring.
305RS003

5C±114
POWER±ASSISTED BRAKE SYSTEM
8. Install adjuster assembly (12).
9. Install hold-down pin (15) and hold-down spring and
cups (4).
10. Install lower return spring (5).

Use brake spring tool.
11. Install auto adjuster lever (10).
12. Install upper (outer) return spring (6).

Use brake spring tool.
13. Install brake drum (2).

Adjust the brakes, refer to the
Drum Brake
Adjustment
in this section.
14. Install wheel and tire assembly (1).

Refer to
Wheels and Tires in wheel and Tire System
section.
Drum Brake Adjustment (4y2 Model)
NOTE: All brakes are self-adjusting. Brakes are adjusted
by repeated stepping on the brake pedal. (After stepping
on the pedal and releasing it, the rear auto adjuster, in the
rear brake, produces a clicking sound.
The same operation should be repeated until the sound
disappears.)
Take the following steps after overhauling the rear brake
assembly.
1. Move the parking brake handle to its fully released
position.
2. Parking cable must be loosened sufficiently. (Loosen
the adjust nut and the lock nut.)
3. Repeat stepping on the brake pedal firmly, and
releasing it until the clicking sound can no longer be
heard.
If the difference between the brake drum inside
diameter and diameter of the brake shoes is adjusted
to be 0,5 mm, the number of times for depressing the
brake pedal can be reduced.
4. Remove the drum. Measure the brake drum inside
diameter and diameter of the brake shoes.
Shoe clearance: 0.25-0.4 mm (0.0098-0.0157 in)
If incorrect, check the brake auto-adjusting system.
5. Rotate the adjust nut until all slack disappears from
the cable. Set the adjust nut.
6. Applying about 30 kg (66 lb) of force, pull the parking
brake handle to its fully set position three or four
times.
7. If the parking brake is properly adjusted, the travel
between the fully disengaged position and the fully
engaged position will be between 9 and 11 notches.
If the traveling range is not within these limits, again
repeat steps 1 through 5.
After adjusting has been done, check to see if the rear
wheel rotates smoothly without drag when turned by
hand.
Servicing The Brake Drum
Whenever the brake drums are removed, they should be
thoroughly cleaned and inspected for cracks, scores,
deep grooves and out-of-round.
Cracked, Scored or Grooved Drum
A cracked drum is unsafe and must be replaced.
Do not attempt to weld a cracked drum.
Smooth any slight scores. Heavy or extensive scoring will
cause excessive brake lining wear, and it will probably be
necessary to machine the drum braking surface.
If the brake linings are slightly worn and the drum is
grooved, the drum should be polished with fine emery
cloth but should not be machined. At this stage,
eliminating all the grooves in the drum and smoothing the
ridges on the lining would require the removal of too much
metal and lining. If left alone, the grooves and ridges
match and satisfactory service can be obtained. If brake
linings are to be replaced, a grooved drum should be
machined. Using a grooved drum with new linings will
create inefficient braking performance and cause the
linings to wear quicker.
Out-Of-Round Drum
An out-of-round drum makes accurate brake shoe
adjustment impossible and is likely to cause excessive
wear to other parts of the brake mechanism due to its
eccentric action. An out-of-round drum can also cause
severe and irregular tire tread wear as well as a pulsing
brake pedal. When the braking surface of a brake drum
exceeds the specification limit of 0.15 mm (0.006 in) in
out-of-round, the drum should be machined to true up the
braking surface. Out-of-round can be accurately
measured with an inside micrometer fitted with proper
extension rods. When measuring a drum for out-of-round
and wear, take measurements at the open and closed
edges of machines surfaces and at right angles to each
other.
Maximum out-of-round: 0.15 mm (0.006 in)
420RS034

5D1±1
PARKING BRAKE SYSTEM (4x4 Model)
AXIOM
BRAKES
PARKING BRAKE SYSTEM (4y4 Model)
CONTENTS
Service Precaution 5D1±1. . . . . . . . . . . . . . . . . . . . . .
General Description 5D1±1. . . . . . . . . . . . . . . . . . . . .
Operation 5D1±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever and Front Cable 5D1±3. . . . . .
Parking Brake Lever Assembly and
Associated Parts 5D1±3. . . . . . . . . . . . . . . . . . . . . .
Removal 5D1±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5D1±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Rear Cable 5D1±4. . . . . . . . . . . . . . . .
Parking Brake Rear Cable and Associated
Parts 5D1±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5D1±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5D1±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 5D1±6. . . . . . . . . . . . . . . . . .
Parking Brake Adjustment 5D1±6. . . . . . . . . . . . . . . .
Main Data and Specifications 5D1±7. . . . . . . . . . . . .
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
fasteners joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fasteners.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.
General Description
Pulling up the parking brake lever by hand will set the
parking brake. By means of a ratchet type lock, the lever
can be held in that position until it is released. The position
of the lever is transmitted through cable/lever systems to
the rear wheels. These parts are designed to obtain
sufficient braking force even when parking on slopes.
When the parking brake is set, or when the ignition SW is
in theªONº position, the brake warning light illuminates.
The rear wheel parking brake is a duo±servo brake
(mechanical inside expansion type) built in the rear disc
brake. Parking brake adjustment is made through the
adjusting hole (bored through back plate). Parking brake
lever stroke should be adjusted to 6±8 notches. Refer to
Parking Brake Adjustment in this section.

5D1±6
PARKING BRAKE SYSTEM (4x4 Model)
Inspection and Repair
Parking Brake Lining Inspection
Check the shoe assemblies for wear by removing the
brake drum.
Replace the shoe assemblies if the lining thickness is less
than 1.0 mm (0.039 in).
Minimum limit: 1.0 m (0.039 in)
308RS004
Parking Brake Rotor (Drum) Inspection
Refer to ªRear Disc Brakesº in Power-Assisted Brake
System
section for inspection procedure of the rotor
(drum).
Parking Brake Adjustment
1. Prior to lever stroke adjustment, adjust rear brake
shoe/rotor (drum) gap. Perform this procedure with
loosening the adjust nut of the hand brake lever.
2. Remove the adjusting hole plug (rubber) and turn the
shoe adjusting screw downward with a small
screwdriver so that shoes will expand until they get
into close touch with the rotor. (Turn down the
adjusting screw notch by notch until the rotor does not
turn.)
3. Turn the adjusting screw in the opposite direction
(upward) until the rotor can be turned lightly. Standard
number of notches to turn upward: 7 or 8 notches
Turn the rotor and make sure that there is no brake
dragging.
4. After the rear brake shoe/rotor (drum) gap has been
adjusted, perform parking brake cable adjustment.
5. Turn the adjusting nut so that the parking brake lever
travels 6±8 notches when pulled up with a force of 30
kg (66 lb).
6. Make sure there is no brake dragging. Then tighten
the cable lock nut
Torque : 13 N´m (113 lb in)7. When poor braking effect possibly resulting from
insufficient break±in is felt, or just after replacement
of parking brake shoe, be sure to conduct break±in as
follows:
8. Forward 50 km/h (30 mph) y 400 m (About 30
seconds) with a lever pull force of 15 kg (33 lb).
9. Backward 10 km/h (6 mph) y 50 m (About 18
seconds) with a lever pull force of 15 kg (33 lb).
NOTE: Break±in procedures must be performed under
safe conditions and traffic rules.

If braking effect still remains poor after the above
break±in, wait for some time until parking brake shoe
cools down and repeat the procedures 8. and 9. noted
above.

On completion of break±in, inspect parking brake
lever stroke, and if the lever does not come within the
specified number of notches when pulled up,
readjust.

Excessive break±in may cause premature wear of
the parking brake lining.

PARKING BRAKE SYSTEM (4X2 Model)
5D2±1
AXIOM
BRAKES
PARKING BRAKE SYSTEM (4y2 Model)
CONTENTS
Service Precaution 5D2±1. . . . . . . . . . . . . . . . . . . . . .
General Description 5D2±1. . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever 5D2±2. . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever Assembly and
Associated Parts 5D2±2. . . . . . . . . . . . . . . . . . . . . .
Removal 5D2±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5D2±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Rear Cable 5D2±3. . . . . . . . . . . . . . . .
Parking Brake Rear Cable and Associated
Parts 5D2±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5D2±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5D2±4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Adjustment 5D2±4. . . . . . . . . . . . . . . .
Main Data and Specifications 5D2±5. . . . . . . . . . . . .
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.
General Description
Pulling up the parking brake lever by hand will set the
parking brake. By means of a ratchet type lock, the lever
can be held in that position until it is released. The position
of the lever is transmitted through cable/lever systems to
the rear wheels. These parts are designed to obtain
sufficient braking force even when parking on slopes.
When the parking brake is set, or when the ignition SW is
in theªONº position, the brake warning light illuminates.
The rear wheel parking brake is a leading/trailing brake
(mechanical inside expansion type). Parking brake
adjustment is made through the adjusting hole (bored
through back plate). Parking brake lever stroke should be
adjusted to 6 notches. Refer to
Parking Brake Adjustment
in this section.

ENGINE ELECTRICAL (6VE1 3.5L)6D1±3
Battery Charging
Observe the following safety precautions when charging
the battery:
1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during charging
procedure.
Battery charging should be discontinued or the rate of
charge reduced if the battery feels hot to the touch.
Battery charging should be discontinued or the rate of
charge reduced if the battery begins to gas or spew
electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue dot
or ring, it may be necessary to jiggle or tilt the battery.
4. Battery temperature can have a great effect on
battery charging capacity.
5. The sealed battery used on this vehicle may be either
quick charged or slow charged in the same manner as
other batteries.
Whichever method you decide to use, be sure that
you completely charge the battery. Never partially
charge the battery.
Jump Starting
Jump Starting with an Auxiliary (Booster)
Battery
CAUTION: Never push or tow the vehicle in an
attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.
Treat both the discharged battery and the booster
battery with great care when using jumper cables.
Carefully follow the jump starting procedure, being
careful at all times to avoid sparking.
WARNING: FAILURE TO CAREFULLY FOLLOW THE
JUMP STARTING PROCEDURE COULD RESULT IN
THE FOLLOWING:
1. Serous personal injury, particularly to your eyes.
2. Property damage from a battery explosion, battery
acid, or an electrical fire.
3. Damage to the electronic components of one or both
vehicles particularly.
Never expose the battery to an open flame or electrical
spark. Gas generated by the battery may catch fire or
explode.
Remove any rings, watches, or other jewelry before
working around the battery. Protect your eyes by wearing
an approved set of goggles.
Never allow battery fluid to come in contact with your eyes
or skin.Never allow battery fluid to come in contact with fabrics or
painted surfaces.
Battery fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes, skin,
fabric, or a painted surface, immediately and thoroughly
rinse the affected area with clean tap water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any other
metal surface of the vehicle. This will protect against a
short circuit.
Always keep batteries out of reach of young children.
Jump Starting Procedure
1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission, place the selector level in the ªPARKº
position.
If the vehicle is equipped with a manual transmission,
place the shift lever in the ªNEUTRALº position.
Turn ªOFFº the ignition.
Turn ªOFFº all lights and any other accessory
requiring electrical power.
2. Look at the built±in hydrometer.
If the indication area of the built±in hydrometer is
completely clear, do not try to jump start.
3. Attach the end of one jumper cable to the positive
terminal of the booster battery.
Attach the other end of the same cable to the positive
terminal of the discharged battery.
Do not allow the vehicles to touch each other. This will
cause a ground connection, effectively neutralizing
the charging procedure.
Be sure that the booster battery has a 12 volt rating.
4. Attach one end of the remaining cable to the negative
terminal of the booster battery.
Attach the other end of the same cable to a solid
engine ground (such as the air conditioning
compressor bracket or the generator mounting
bracket) of the vehicle with the discharged battery.
The ground connection must be at least 450 mm (18
in.) from the battery of the vehicle whose battery is
being charged.
WARNING: NEVER ATTACH THE END OF THE
JUMPER CABLE DIRECTLY TO THE NEGATIVE
TERMINAL OF THE DEAD BATTERY.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical accessories
have been turned ªOFFº.
6. Start the engine of the vehicle with the dead battery.