2002 ISUZU AXIOM cruise control

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

0B±7 MAINTENANCE AND LUBRICATION
Automatic Transmission Fluid
Replacement
Under harsh operating conditions, such as constant
driving in heavy city traffic during hot weather, or in hilly or
mountainous terrain, change the transmission fluid and
service the sump filter after every 20,000 miles (32,000
km) of operation.
More over, the remaining life percentage of ATF can be
estimated by using TECH±II as an auxiliary tool to judge
the right time for ATF replacement.
The remaining life percentage is calculated from ATF'S
heat history. When it is close to 0%, ATF replacement is
recommended.
Auto Cruise Control Inspection
Check to see if the clearance between cruise link and
accelerator link is normal. Also check that the connected
properly.
Accelerator Linkage Inspection
Inspect for interference, binding, and damaged or
missing parts. Check accelerator pedal for smooth
operation and even pedal effort. Replace parts as
needed.

6E±3
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
DTC P0135 HO2S Heater Circuit
Bank 1 Sensor 1 6E±179. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0137 HO2S Circuit Low Voltage
Bank 1 Sensor 2 6E±182. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0138 HO2S Circuit High Voltage
Bank 1 Sensor 2 6E±185. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0140 HO2S Circuit Insufficient Activity
Bank 1 Sensor 2 6E±188. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0141 HO2S Heater Circuit
Bank 1 Sensor 2 6E±191. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0151 HO2S Circuit Low Voltage
Bank 2 Sensor 1 6E±194. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0152 HO2S Circuit High Voltage
Bank 2 Sensor 1 6E±197. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0153 HO2S Slow Response
Bank 2 Sensor 1 6E±200. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0154 HO2S Circuit Insufficient Activity
Bank 2 Sensor 1 6E±204. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0155 HO2S Heater Circuit Open
Bank 2 Sensor 1 6E±207. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0157 HO2S Circuit Low Voltage
Bank 2 Sensor 2 6E±210. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0158 HO2S Circuit High Voltage
Bank 2 Sensor 2 6E±213. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0160 HO2S Circuit Insufficient Activity
Bank 2 Sensor 2 6E±216. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0161 HO2S Heater Circuit
Bank 2 Sensor 2 6E±219. . . . . . . . . . . . . . . . . . . . . . . .
DTC P0171 Fuel Trim System Lean Bank 1 6E±222.
DTC P0172 Fuel Trim System Rich Bank 1 6E±226.
DTC P0174 Fuel Trim System Lean Bank 2 6E±230.
DTC P0175 Fuel Trim System Rich Bank 2 6E±234.
DTC P0201 Injector 1 Control Circuit 6E±238. . . . . .
DTC P0202 Injector 2 Control Circuit 6E±241. . . . . .
DTC P0203 Injector 3 Control Circuit 6E±244. . . . . .
DTC P0204 Injector 4 Control Circuit 6E±247. . . . . .
DTC P0205 Injector 5 Control Circuit 6E±250. . . . . .
DTC P0206 Injector 6 Control Circuit 6E±253. . . . . .
DTC P0300 Engine Misfire Detected 6E±256. . . . . . .
DTC P0301 Cylinder Misfire Detected 6E±260. . . . . .
DTC P0302 Cylinder Misfire Detected 6E±262. . . . . .
DTC P0303 Cylinder Misfire Detected 6E±264. . . . . .
DTC P0304 Cylinder Misfire Detected 6E±266. . . . . .
DTC P0305 Cylinder Misfire Detected 6E±268. . . . . .
DTC P0306 Cylinder Misfire Detected 6E±270. . . . . .
DTC P0325 ION Sensing Module/ION
Sensing Knock Intensity Circuit Fault 6E±272. . . . . .
DTC P0336 58X Reference Signal Circuit 6E±275. .
DTC P0337 CKP Sensor Circuit Low
Frequency 6E±278. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0351 Ignition 1 Control Circuit 6E±281. . . . . . .
DTC P0352 Ignition 2 Control Circuit 6E±284. . . . . . .
DTC P0353 Ignition 3 Control Circuit 6E±287. . . . . . .
DTC P0354 Ignition 4 Control Circuit 6E±290. . . . . . .
DTC P0355 Ignition 5 Control Circuit 6E±293. . . . . . . DTC P0356 Ignition 6 Control Circuit 6E±296. . . . . . .
DTC P0401 EGR Flow Insufficient 6E±299. . . . . . . . .
DTC P0402 EGR Pintle Crank Error 6E±302. . . . . . .
DTC P0404 EGR Open Stuck 6E±304. . . . . . . . . . . . .
DTC P0405 EGR Low Voltage 6E±306. . . . . . . . . . . .
DTC P0406 EGR High Voltage 6E±309. . . . . . . . . . .
DTC P0420 TWC System Low Efficiency
Bank 1 6E±312. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0430 TWC System Low Efficiency
Bank 2 6E±315. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0440 EVAP System 6E±318. . . . . . . . . . . . . . . .
DTC P0442 EVAP System Small Leak
Detected 6E±321. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0444 EVAP Purge Control Circuit
Open 6E±324. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0445 EVAP Purge Control Circuit
Short 6E±326. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0446 EVAP Canister Vent Control
Malfunction 6E±328. . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0447 EVAP Vent Solenoid Circuit
Open 6E±331. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0448 EVAP Vent solenoid Circuit
Short 6E±333. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0452 Fuel Tank Pressure Sensor
(Vapor Pressure Sensor) Low Voltage 6E±335. . . . .
DTC P0453 Fuel Tank Pressure Sensor
(Vapor Pressure Sensor) High Voltage 6E±338. . . . .
DTC P0456 EVAP Very Small Leak 6E±341. . . . . . .
DTC P0461 Fuel Level Sensor Performance 6E±344
DTC P0462 Fuel Level Sensor Circuit±Low
Voltage 6E±346. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0463 Fuel Level Sensor Circuit±High
Voltage 6E±349. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0462 Fuel Level Sensor Noisy Signal 6E±351
DTC P0502 VSS Circuit Low Input 6E±353. . . . . . . . .
DTC P0506 Idle Air Control System Low
RPM 6E±356. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0507 Idle Air Control System High
RPM 6E±359. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0562 System Voltage Low 6E±362. . . . . . . . . .
DTC P0563 System Voltage High 6E±364. . . . . . . . .
DTC P0565 Cruise Main Switch Circuit Error 6E±366
DTC P0566 Cruise Cancel Switch Circuit
Error 6E±368. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0567 Cruise Resume Switch Circuit
Error 6E±370. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0568 Cruise Set Switch Circuit Error 6E±372.
DTC P0571 No Brake Switch Signal 6E±374. . . . . . .
DTC P0601 PCM Memory 6E±376. . . . . . . . . . . . . . . .
DTC P0602 PCM Programming Error 6E±378. . . . . .
DTC P0604 PCM RAM Error 6E±380. . . . . . . . . . . . . .
DTC P0606 PCM Internal Performance 6E±382. . . .
DTC P1106 MAP Sensor Circuit Intermittent
High Voltage 6E±384. . . . . . . . . . . . . . . . . . . . . . . . . . .

6E±19
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
PCM Pinout Table, 80-Way Red Connector ± Row ªS1 ~ 20º
060RY00069
PINPIN FunctionWire ColorIGN ONENG RUNRefer To
S1PCM GroundBLK/PNK0.0V0.0VChassis Electrical
S2Bank 1 HO2S 1 Heater
GroundBLK/ORN0.0V0.0VGeneral Description and
Operation, Catalyst Monitor
HO2S
S3Not UsedÐÐÐÐ
S4Not UsedÐÐÐÐ
S55Volt Referenceª2º (CKP
Sensor)WHT5.0V5.0VAppropriate Sensor (CKP
Sensor, AP2 Sensor)
S6Auto Cruise Switch CancelGRY/GRN0.0V0.0VChassis Electrical
S7Purge Duty Solenoid ValveRED/BLUB+B+EVAP Emission Control
System
S8M.I.D0.5 GRNÐÐÐ
S9Not UsedÐÐÐÐ
S10Shift High (Band Apply)BRN/YELB+B+4L30E T/Mission
S11Malfunction Indicator
(Check Engine) LampWHT/GRN0.0VB+Chassis Electrical
S12Not UsedÐÐÐÐ
S13ION Sensing ModuleRED/WHT1.555V1.555VGeneral Description and
Operation, ION Sensing
Module
S14Bank 2 HO2S 1 GroundBLU0.0V0.0VÐ
S15Bank 2 HO2S 2 GroundORN0.0V0.0VÐ
S16Bank 2 HO2S 2 LowBLU0.0V0.1VGeneral Description and
Operation, Catalyst Monitor
HO2S
S17Bank 1 HO2S 1 GroundWHT0.0V0.0VÐ
S18Bank 1 HO2S 1 LowWHT/BLU0.0V0.1VGeneral Description and
Operation, Catalyst Monitor
HO2S

6E±21
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
PCM Pinout Table, 80-Way Red Connector ± Row ªS21 ~ 40º
060RY00049
PINPIN FunctionWire ColorIGN ONENG RUNRefer To
S21AudioYEL/GRNÐÐChassis Electrical
S22Transmission Output
Speed SensorBLU/YEL0.0V0.0V4L30E T/Mission
S23PCM GroundBLK0.0V0.0VChassis Electrical
S24Bank 1 HO2S 2 GroundRED0.0V0.0VÐ
S25Not UsedÐÐÐÐ
S26EGR Control HighBLU/REDB+B+General Description and
Operation, EGR Control
S27VSS InputBLK/YEL0.0V0.1V (at rest)Chassis Electrical
S28Injector Cylinder #6GRN/YELB+B+General Description and
Operation, Fuel Injector
S29Winter SwitchVIO/GRNB+B+4L30E T/Mission
S30Auto Cruise Main SwitchWHT/RED0.0V0.0VChassis Electrical
S31Shift SolenoidGRN0.0V0.0V4L30E T/Mission
S32Ignition FeedRED/GRNB+B+Chassis Electrical
S33TCC SolenoidBRN/WHT0.0V0.0VT/Mission
S34Not UsedÐÐÐÐ
S35ION Sensing ModuleRED/GRN1.555V1.555VGeneral Description and
Operation, ION Sensing
Module
S365Volt Reference (AP
Sensor 1)BLK5.0V5.0VAP Sensor
S375Volt Reference (Vapor
Pressure {Fuel Tank
Pressure} Sensor/MAP
Sensor/EGR Position
Sensor)GRY/RED5.0V5.0V(Fuel Tank Pressure
Sensor/MAP Sensor/EGR
Position Sensor) Sensor
S385Volt Reference (TP
Sensor 1)RED5.0V5.0VTP Sensor

6E±25
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
PCM Pinout Table, 80-Way Red Connector ± Row ªS61 ~ 80º
060RY00051
PINPIN FunctionWire ColorIGN ONENG RUNRefer To
S61Intake Air Temperature
(IAT) Sensor GroundYEL/GRN0.0V0.0VGeneral Description and
Operation, IAT
S62ION Sensing ModuleRED1.555V1.555VGeneral Description and
Operation, ION Sensing
Module
S63Bank 1 HO2S 2 HighWHT0.3V0.1±0.9VGeneral Description and
Operation, Catalyst Monitor
HO2S
S64Bank 2 HO2S 1 HighPNK0.3V0.1±0.9VGeneral Description and
Operation, Catalyst Monitor
HO2S
S65Bank 2 HO2S 2 HighGRN0.3V0.1±0.9VGeneral Description and
Operation, Catalyst Monitor
HO2S
S66Transmission Fluid
Temperature SensorRED/BLK0.5±4.9V
(depends on
temperature)0.5±4.9V
(depends on
temperature)4L30E T/Mission
S67Exhaust Gas Recirculation
(EGR) Position SignalGRY/RED0.6V0.6VGeneral Description and
Operation, EGR Control
S68Accelerator Position (AP)
Sensor 1WHT0.41±0.45V0.41±0.45VOn-Vehicle Service
S69Throttle Valve DC
Motor(+: FWD)GRNDuty CycleDuty CycleGeneral Description and
Operation, ETC
S70Not UsedÐÐÐÐ
S71Not UsedÐÐÐÐ
S72Ignition FeedRED/GRNB+B+Chassis Electrical
S73Auto Cruise Main LampGRN/WHTB+B+Chassis Electrical
S74Variable Intake ManifoldYEL/BLK0.0VB+ (rpm
3600 over)General Description
S75Canister Purge Cut
Solenoid ValveRED/WHT6.0V Tank
empty5.7V Tank
emptyGeneral Description and
Operation, EVAP
S76Throttle Position (TP) 1
Sensor SignalBLU0.5±0.8V0.5±0.8V (at
idle)General Description and
Operation, TPS

6E±35
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Inspect all wires in the engine compartment for proper
connections, burned or chafed spots, pinched wires,
contact with sharp edges or contact with hot exhaust
manifolds or pipes.
Basic Knowledge of Tools Required
NOTE: Lack of basic knowledge of this powertrain when
performing diagnostic procedures could result in an
incorrect diagnosis or damage to powertrain
components. Do not attempt to diagnose a powertrain
problem without this basic knowledge.
A basic understanding of hand tools is necessary to effec-
tively use this section of the Service Manual.
Serial Data Communications
Class 2 Serial Data Communications
Government regulations require that all vehicle
manufacturers establish a common communication
system. This vehicle utilizes the ªClass 2º communication
system. Each bit of information can have one of two
lengths: long or short. This allows vehicle wiring to be
reduced by transmitting and receiving multiple signals
over a single wire. The messages carried on Class 2 data
streams are also prioritized. If two messages attempt to
establish communications on the data line at the same
time, only the message with higher priority will continue.
The device with the lower priority message must wait.
The most significant result of this regulation is that it
provides Scan tool manufacturers with the capability to
access data from any make or model vehicle that is sold.
The data displayed on other Scan tools will appear the
same, with some exceptions. Some Scan tools will only
be able to display certain vehicle parameters as values
that are a coded representation of the true or actual value.
On this vehicle the Scan tool displays the actual values for
vehicle parameters. It will not be necessary to perform
any conversions from coded values to actual values.
On-Board Diagnostic (OBD II)
On-Board Diagnostic Tests
A diagnostic test is a series of steps, the result of which is
a pass or fail reported to the diagnostic executive. When
a diagnostic test reports a pass result, the diagnostic
executive records the following data:

The diagnostic test has been completed since the last
ignition cycle.

The diagnostic test has passed during the current
ignition cycle.

The fault identified by the diagnostic test is not
currently active.
When a diagnostic test reports a fail result, the diagnostic
executive records the following data:

The diagnostic test has been completed since the last
ignition cycle.

The fault identified by the diagnostic test is currently
active.

The fault has been active during this ignition cycle.

The operating conditions at the time of the failure.Remember, a fuel trim DTC may be triggered by a list of
vehicle faults. Make use of all information available (other
DTCs stored, rich or lean condition, etc.) when
diagnosing a fuel trim fault.
Comprehensive Component Monitor
Diagnostic Operation
Comprehensive component monitoring diagnostics are
required to monitor emissions-related input and output
powertrain components. The
CARB OBD II
Comprehensive Component Monitoring List Of
Components Intended To illuminate MIL
is a list of
components, features or functions that could fall under
this requirement.
Input Components:
Input components are monitored for circuit continuity and
out-of-range values. This includes rationality checking.
Rationality checking refers to indicating a fault when the
signal from a sensor does not seem reasonable, i.e.
Throttle Position (TP) sensor that indicates high throttle
position at low engine loads or MAP voltage. Input
components may include, but are not limited to the
following sensors:

Vehicle Speed Sensor (VSS)

Crankshaft Position (CKP) sensor

Throttle Position (TP) sensor

Engine Coolant Temperature (ECT) sensor

Manifold Absolute Pressure (MAP) sensor

Mass Air Flow (MAF) sensor
In addition to the circuit continuity and rationality check,
the ECT sensor is monitored for its ability to achieve a
steady state temperature to enable closed loop fuel
control.
Output Components:
Output components are diagnosed for proper response to
control module commands. Components where
functional monitoring is not feasible will be monitored for
circuit continuity and out-of-range values if applicable.
Output components to be monitored include, but are not
limited to, the following circuits:

Control module controlled EVAP Canister Purge
Valve

Electronic Transmission controls

A/C relays

VSS output

MIL control

Cruise control inhibit
Refer to PCM and Sensors in General Descriptions.
Passive and Active Diagnostic Tests
A passive test is a diagnostic test which simply monitors a
vehicle system or component. Conversely, an active test,
actually takes some sort of action when performing
diagnostic functions, often in response to a failed passive
test. For example, the EGR diagnostic active test will
force the EGR valve open during closed throttle decel
and/or force the EGR valve closed during a steady state.
Either action should result in a change in manifold
pressure.

6E±44
6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Not Run Since Code Cleared
This option will display up to DTCs that have not run since
the DTCs were last cleared. Since any displayed DTCs
have not run, their condition (passing or failing) is
unknown.
Test Failed Since Code Cleared
This selection will display all active and history DTCs that
have reported a test failure since the last time DTCs were
cleared. DTCs that last failed more than 40 warm-up
cycles before this option is selected will not be displayed.
Miscellaneous Test
This test consists of eight menus-Lights, Relays, EVAP,
Fuel System, Instruments, EGR Control, Variable Intake
Manifold Solenoid, and Injector Balance Tests.
In these tests, Tech 2 sends operating signals to the
systems to confirm their operations thereby to judge the
normality of electric circuits.
To judge intermittent trouble,
1. Confirm DTC freeze frame data, and match the
freeze frame data as test conditions with the data list
displayed by Miscellaneous Test.
2. Confirm DTC setting conditions, and match the
setting conditions as test conditions with the data list
displayed by Miscellaneous Test.
3. Refer to the latest Service Bulletin.
Check to see if the Latest software is released or not.
Down load the LATEST PROGRAMMED
SOFTWARE to the replacement PCM.
Lamps Test
This test is conducted check MIL, Up Shift Lamp, Low
Fuel Lamp, Reduced Power Lamp and Cruise Control
Lamp for its working.
Tech2 must be used for this test.
Test Procedure:
1. Connect Tech 2 to the vehicle DLC.
2. Run the Engine at idle.
3. Select F3: Miscellaneous Test in the Application
Menu.
060R100078
4. Select F0:Lamps Test in the Miscellaneous Test.
060RY00080
5. Select F0:Malfunction Indicator Lamp.
060RY00091
6. PushºOnº soft key.
7. Make sure Lamp illuminates.
8. If lamp illuminates, the Lamp is operating correctly.