2002 ISUZU AXIOM intel

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

FRONT SUSPENSION3C±1
AXIOM
SUSPENSION
CONTENTS
Front Suspension 3C±1. . . . . . . . . . . . . . . . . . . . . . .
Rear Suspension 3D±1. . . . . . . . . . . . . . . . . . . . . . . .
Wheel and Tire System 3E±1. . . . . . . . . . . . . . . . . . Intelligent Suspension Control 3F±1. . . . . . . . . . . .
FRONT SUSPENSION
CONTENTS
Service Precaution 3C±1. . . . . . . . . . . . . . . . . . . . . .
General Description 3C±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 3C±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shock Absorber 3C±5. . . . . . . . . . . . . . . . . . . . . . . . .
Shock Absorber and Associated Parts 3C±5. . . .
Removal 3C±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3C±5. . . . . . . . . . . . . . . . . .
Installation 3C±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer Bar 3C±6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer Bar and Associated Parts 3C±6. . . . . .
Removal 3C±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3C±6. . . . . . . . . . . . . . . . . .
Installation 3C±6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torsion Bar 3C±7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torsion Bar and Associated Parts 3C±7. . . . . . . .
Removal 3C±7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3C±8. . . . . . . . . . . . . . . . . .
Installation 3C±8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knuckle 3C±10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knuckle and Associated Parts 3C±10. . . . . . . . . . .
Removal 3C±10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3C±11. . . . . . . . . . . . . . . . . .
Installation 3C±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper Control Arm 3C±13. . . . . . . . . . . . . . . . . . . . . .
Upper Control Arm and Associated Parts 3C±13.
Removal 3C±13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3C±14. . . . . . . . . . . . . . . . . .
Installation 3C±14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Control Arm 3C±16. . . . . . . . . . . . . . . . . . . . . .
Lower Control Arm and Associated Parts 3C±16.
Removal 3C±16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3C±17. . . . . . . . . . . . . . . . . .
Installation 3C±18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Ball Joint 3C±19. . . . . . . . . . . . . . . . . . . . . . . . .
Upper Ball Joint and Associated Parts 3C±19. . . .
Removal 3C±19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3C±20. . . . . . . . . . . . . . . . . .
Installation 3C±20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Ball Joint 3C±21. . . . . . . . . . . . . . . . . . . . . . . . .
Lower Ball Joint and Associated Parts 3C±21. . . .
Removal 3C±21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3C±22. . . . . . . . . . . . . . . . . .
Installation 3C±22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 3C±23. . . . . . . . . . . . .
Special Tools 3C±25. . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

FRONT SUSPENSION3C±5
Shock Absorber
Shock Absorber and Associated Parts
450R200001
Legend
(1) Nut
(2) Rubber Bushing and Washer
(3) Bolt and Nut
(4) Shock Absorber(5) Rubber Bushing and Washer
(6) Actuator Bracket
(7) Actuator
(8) Screw
Removal
1. Raise the vehicle and support it with suitable safety
stands.
2. Remove wheel and tire assembly. Refer to
Wheel
Replacement in this section.
3. Remove bolt and nut.
4. Remove ISC Actuator and Bracket. Refer to
Intelligent Suspension.
5. Remove nut.
6. Remove rubber bushing and washer.
7. Remove shock absorber.
8. Remove rubber bushing and washer.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts :
Shock absorber

Rubber bushing
Installation
1. Install rubber bushing and washer.
2. Install shock absorber.
3. Install rubber bushing and washer.
4. Install nut, then tighten it to the specified torque.
Torque: 20 N´m (14 lb ft)
5. Install ISC Actuator and Bracket. Refer to
Intelligent
Suspension.
6. Install bolt and nut, then tighten to the specified
torque.
Torque: 93 N´m (69 lb ft)

3D±6REAR SUSPENSION
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts:

Coil spring

Insulator
Installation
1. Install coil spring and make sure that the coil spring is
installed in the proper position. Paint mark(1) should
be downward.
460RW001
2. Fit the end of the coil spring to the coil spring seat and
mount the coil spring on the rear axle case.
460RW004
3. Install the insulator on the coil spring. Jack up the axle
case gently with the top of the coil spring set to the
spring seat on the frame side.
460RW013
4. Install shock absorber and make sure that installed in
the proper position. (Refer to
Intelligent Suspension)
Tighten the nut lightly, then retighten it to the specified
torque after the vehicle is at curb height.
NOTE: When mounting shock absorber, be sure not to
use grease on bushings or any other nearby part.
Torque: 78 N´m (58 lb ft)
5. Install stabilizer bar.
Torque: 31 N´m (23 lb ft)
6. Install upper link with rubber plate and tighten fixing
bolt.
Torque: 137 N´m (101 lb ft)
7. Install breather hose.
8. Connect brake hose and bleed the brake system.
Refer to
Bleeding the Brake Hydraulic System in
Brake section.

REAR SUSPENSION3D±7
Shock Absorber
Shock Absorber and Associated Parts
461R200001
Legend
(1) Nut, Bush and Washer(2) Shock Absorber
(3) Nut and Washer
Removal
1. Remove shock absorber fixing nut, bush and washer
(upper side).
2. Remove shock absorber fixing nut and washer (lower
side).
3. Remove shock absorber.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts:

Shock absorber

Rubber bushing
NOTE: When mounting rubber bushings, be sure not to
use grease on bushings or any other nearby part.
Installation
1. Install shock absorber. When mounting shock
absorber, make sure to be installed in the proper
position and not to use grease on bushings or any
other nearby part. (Refer to
Intelligent Suspension)
2. Install nut and washer (lower side), then tighten the
nut lightly. Retighten to the bolt and nut specified
torque after the vehicle is at curb height.
Torque: 78 N´m (58 lb ft)
3. Install nut, bush and washer (upper side), then tighten
the nut lightly. Retighten to the nut specified torque
after the vehicle is at curb height.
Torque: 20 N´m (14 lb ft)

INTELLIGENT SUSPENSION3F±1
AXIOM
SUSPENSION
INTELLIGENT SUSPENSION CONTROL
CONTENTS
Service Precaution 3F±2. . . . . . . . . . . . . . . . . . . . . .
General Description 3F±2. . . . . . . . . . . . . . . . . . . . .
PIN ASSIGNMENT TABLE 3F±4. . . . . . . . . . . . .
System Components 3F±4. . . . . . . . . . . . . . . . . . .
Control Unit 3F±4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuator 3F±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustable Damping Force Shock Absorber 3F±4
Warning Lamp 3F±4. . . . . . . . . . . . . . . . . . . . . . . .
Vertical G-Sensor 3F±5. . . . . . . . . . . . . . . . . . . . . .
Lateral G-Sensor 3F±5. . . . . . . . . . . . . . . . . . . . . .
Acronyms and Abbreviations 3F±5. . . . . . . . . . . .
General Diagnosis 3F±5. . . . . . . . . . . . . . . . . . . . . . .
General Information 3F±5. . . . . . . . . . . . . . . . . . . .
Service Precautions 3F±5. . . . . . . . . . . . . . . . . . .
Computer System Service Precautions 3F±5. . .
General Service Precautions 3F±5. . . . . . . . . . . .
Parts Handling 3F±5. . . . . . . . . . . . . . . . . . . . . . . .
FLASHING CODES 3F±6. . . . . . . . . . . . . . . . . . . .
CLEAR DTC 3F±7. . . . . . . . . . . . . . . . . . . . . . . . . .
INTERMITTENT CONDITIONS 3F±8. . . . . . . . .
BULB CHECK 3F±8. . . . . . . . . . . . . . . . . . . . . . . . .
DTC CHECK 3F±8. . . . . . . . . . . . . . . . . . . . . . . . . .
Connector List 3F±14. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC)
Identification 3F±16. . . . . . . . . . . . . . . . . . . . . . . . .
DTC2 Actuator Coil Over Current 3F±17. . . . . . . . . .
Circuit Description 3F±17. . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids 3F±17. . . . . . . . . . . . . . . . . . . . . . . .
DTC3 Actuator Coil/Position Sensor Open
Circuit or Short 3F±19. . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 3F±19. . . . . . . . . . . . . . . . . . . . . Diagnostic Aids 3F±19. . . . . . . . . . . . . . . . . . . . . . . .
DTC4 G-Sensor Open Circuit or Short 3F±22. . . . .
Circuit Description 3F±22. . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids 3F±22. . . . . . . . . . . . . . . . . . . . . . . .
DTC5 Vehicle Speed Sensor Open Circuit
or Short 3F±23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 3F±23. . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids 3F±23. . . . . . . . . . . . . . . . . . . . . . . .
DTC6 Stop Lamp Switch Open Circuit
or Short 3F±25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 3F±25. . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids 3F±25. . . . . . . . . . . . . . . . . . . . . . . .
DTC7 Engine Speed Signal Open Circuit
or Short 3F±27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Description 3F±27. . . . . . . . . . . . . . . . . . . . .
Diagnostic Aids 3F±27. . . . . . . . . . . . . . . . . . . . . . . .
DTC9 Control Unit Abnormality 3F±28. . . . . . . . . . . .
Control Unit 3F±32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 3F±33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3F±33. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Actuator 3F±34. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 3F±35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3F±35. . . . . . . . . . . . . . . . . . . .
Installation 3F±35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Shock Absorber 3F±36. . . . . . . . . . . . . . . . . . . .
Removal 3F±37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3F±37. . . . . . . . . . . . . . . . . . . .
Installation 3F±37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3F±2INTELLIGENT SUSPENSION
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
Intellignet suspension control uses a microcomputer as a
control unit to judge running conditions including engine
revolution from Powertrain Control Module, vehicle speed
from vehicle speed sensor, a brake switch signal, and
vertical and lateral G-sensor signal, then sets optimum
damping force so that best running stability can be
achieved.

INTELLIGENT SUSPENSION3F±3
826R200007