2002 ISUZU AXIOM seats

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

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, ªblockº front or rear
wheels, set jack against the recommended lifting
points (see ªLifting Instructionsº 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 ªSRS
Systemº 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. ªAIR BAGº warning light on the instrument
cluster.
2. A Code ªKº or ªMº for fifth digit of Vehicle
Identification Number.

3E±12WHEEL AND TIRE SYSTEM
Tire
Tire Replacement
When replacement is necessary, the original metric tire
size should be used. Most metric tire sizes do not have
exact corresponding alphanumeric tire sizes. It is
recommended that new tires be installed in pairs on the
same axle. If necessary to replace only one tire, it should
be paired with tire having the most tread, to equalize
braking traction.
CAUTION: Do not mix different types of tires such
as radial, bias and bias-belted tires except in
emergencies, because vehicle handling may be
seriously affected and may result in loss of control.
Tire Dismounting
Remove valve cap on valve step and deflate the tire. Then
use a tire changing machine to mount or dismount tires.
Follow the equipment manufacturer's instruction. Do not
use hand tools or tire lever alone to change tires as they
may damage the tire beads or wheel rim.
Tire Mounting
Rim bead seats should be cleaned with a wire brush or
coarse steel wool to remove lubricants, and light rust.
Before mounting a tire, the bead area should be well
lubricated with an approved tire lubricant.
After mounting, inflate the tire to 196kPa (28 psi) so that
beads are completely seated. Inflate the air to specified
pressure and install valve cap to the stem.
WARNING: NEVER STAND OVER TIRE WHEN
INFLATING. BEAD MAY BREAK WHEN BEAD SNAPS
OVER RIM'S SAFETY HUMP AND CAUSE SERIOUS
PERSONAL INJURY.
NEVER EXCEED 240 KPA (35 PSI) PRESSURE WHEN
INFLATING. IF 240 KPA (35 PSI) PRESSURE WILL
NOT SEAT BEADS, DEFLATE, RE-LUBRICATE AND
RE-INFLATE. OVER INFLATION MAY CAUSE THE
BEAD TO BREAK AND CAUSE SERIOUS PERSONAL
INJURY.
Tire Repair
There are many different materials on the market used to
repair tires.
Manufacturers have published detailed instructions on
how and when to repair tires. These instructions can be
obtained from the tire manufacturer if they are not
included with the repair kit.
Wheel Inspection
Damaged wheels and wheels with excessive run-out
must be replaced.
Wheel run out at rim (Base on hub Bore):
Aluminum
1± Vertical play: Less than 0.55 mm (0.022 in)
2± Horizontal play: Less than 0.55 mm (0.022 in)
480RS012
General Balance Procedure
Deposits of mud, etc. must be cleaned from the inside of
the rim.
The tire should be inspected for the following: match
mount paint marks, bent rims, bulges, irregular tire wear,
proper wheel size and inflation pressure. Then balance
according to the equipment manufacturer's
recommendations.
There are two types of wheel and tire balance.
Static balance is the equal distribution of weight around
the wheel.
Assemblies that are statically unbalanced cause a
bouncing action called tramp. This condition will
eventually cause uneven tire wear.

DIFFERENTIAL (REAR)4A2±21
4. Assemble the differential case into the housing (less
pinion). Install bearing caps and finger tight bolts.
Mount a dial indicator with a magnetic base to the
housing and indicate on the flange or head of screw.
Force the differential assembly as far as possible in
the dirction towards the indicator.
With force still applied, set indicator at zero(0).
NOTE: Dial indicator set should be capable of a minimum
travel of 5.08 mm (0.2 in).
425RS107
5. Force the differetial assembly as far as it will go in the
opposite direction. Repeat these steps until the same
reading is obtained.
6. RECORD THE READING OF THE INDICATOR.
This amount, in shims, will be included in the final
assembly shim stack to establish side bearing
preload and ring gear and pinion backlash.
7. After marking sure the readings are correct, remove
the indicator and differetial assembly from the
housing.
Pinion Installation

The bearing cups should have been installed in Pinion
Depth Adjustment in this section.
1. Place the shim(1) and inner oil slinger(2) on the pinion
gear, then install the pinion inner bearing(3) using
installer J±42828.
425RW023

Drive the bearing until the bearing cone seats on the
pinion shims.
2. Install a new collapsible spacer.

Lubracate the pinion bearings with axle lublicant.
3. Install pinion to the axle housing.
4. Install outer pinion bearing onto the pinion.

Hold the pinion forward from inside the case while
driving the bearing onto the pinion.
5. Install oil seal slinger.
6. Install pinion oil seal using installer J±37263.
7. Install the pinion flange to the pinion by tapping it with
a rawhide hammer until a few threads show through
the pinion flange.
8. Install pinion washer and a new nut while holding the
pinion flange with flange holder J±8614±01.

Tighten the nut until the pinion end play is just taken
up. Rotate the pinion while tightening the nut to seat
the bearings.
Torque:217-678 N´m (160-500 lb ft)
Once there is no end play in the pinion, the preload
torque should be checked.

Remove flange holder J±8614±01. Using an
inch-pound torque wrench, check the pinion
preload by rotating the pinion with the wrench.

4C±5 DRIVE SHAFT SYSTEM
Reassembly
1. Install wheel pin.

Place hub on a wood workbench or a block of wood
approx. 6º by 6º to protect the wheel stud ends and
threads.

Install wheel stud, using a hammer.
NOTE: Be sure wheel stud is started squarely and seats
completely.
411RS005
2. Align scribe marks(1) and attach the hub to disc then
tighten the bolts to the specified torque.
Torque: 103 N´m (76 lb ft)
411RS003
3. Install inner bearing.
Install the outer race by driving it into the hub by using
installer J±36829 and grip J±8092.
411RS023
4. Install outer bearing.
Install the outer race by driving it into the hub by using
installer J±36828 and grip J-8092.
901RW056

4C±10
DRIVE SHAFT SYSTEM
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.

Hub

Hub bearing, oil seal

Knuckle spindle

Disc

Caliper

Shift on the fly system parts (Cap, Hub flange, Shim,
Snap ring)

ABS sensor ring
For inspection and servicing of disc caliper and related
parts, refer to
Disc Brakes in Brake section.
Reassembly
1. Install wheel pin.

Place the hub on a wood workbench or a block of
wood approx. 6º by 6º to protect the wheel stud
ends and threads.

Insert a wheel stud using a hammer.
NOTE: Be sure the wheel stud is started squarely and
seats completely.
411RS005
2. Align scribe marks(1) and attach the hub to the disc,
then tighten the bolts to the specified torque.
Torque: 103 N´m (76 lb ft)
411RS003
3. Install inner bearing.
Install the outer race by driving it into the hub by using
insatller J±36829 and grip J±8092.
901RW055

4C±48
DRIVE SHAFT SYSTEM
Reassembly
1. Install wheel pin.
411RS005

Place hub on a wood workbench or a block of wood
approx. 6º by 6º to protect the wheel stud ends and
threads.

Install wheel stud, using a hammer.
NOTE: Be sure wheel stud is started squarely and seats
completely.
2. Install the hub unit bearing to the knuckle.
Tighten the bolts to the specified torque.
Hub unit bearing bolt
Torque: 103+10 N´m (10.5 + 1 kg´m)
If there is rust on the bearing and knuckle contact
surfaces, use sandpaper to remove it before installation.
3. Install the ABS sensor connector.
4. Install the disc rotor.
5. Install the brake caliper to the bracket.
Refer to
Front disc caliper assembly in Section 5C of this
Manual.

4C±51 DRIVE SHAFT SYSTEM
Reassembly
1. Install the wheel pin.

Place hub on a wood workbench or a block of wood
approx. 6º by 6º to protect the wheel stud ends and
threads.

Install the wheel stud, using a hammer.
NOTE: Be sure wheel stud is started squarely and seats
completely.
411RS005
2. Install the ABS rotor sensor to the hub unit bearing.
Tighten the bolts to the specified torque.
ABS rotor sensor bolt
Torque: 18.7+5 N´m (1.9+0.5 kg´m)
3. Install the hub unit bearing to the knuckle. Tighten the
bolts to the specified torque.
Hub unit bearing bolt
Torque: 103+10 N´m (10.5+1 kg´m)
If there is rust on the bearing and knuckle contact
surfaces, use sandpaper to remove it before installation.
Take care not to push the front drive shaft and oil seal out
of position.
4. Hand tighten the front drive shaft nuts.
Use new nuts.
5. Install the disc rotor.
6. Install the brake caliper to the bracket.
Refer to
Front disc caliper assembly in Section 5C of this
Manual.7. Tighten the front drive shaft nuts to the specified
torque.
Front drive shaft nut
Torque: 245+19.6 N´m (25+2 kg´m)
411R200005
8. Caulk the front drive shaft nuts.
The caulking must be free of cracks.
411R200006