Isuzu Axiom UPR/S Workshop Manual (2002)

The Isuzu workshop manual covers 2002 Axiom UPR/S models (4WD and 4x2) equipped with the 6VE1 engine.

PDF Search, Wiring Detail, and Page Count

Search and circuit labels: The main text is searchable, and the opening contents page links to the manual’s sections. There are no embedded PDF bookmarks. Labels within diagram images are not searchable; small wiring labels need zooming for comfortable reading.

The ZIP contains one printable English-language PDF with 2,100 pages, including the combined title, foreword, and main contents page.

Engine, Drivetrain, and Vehicle-System Coverage

These selected workshop topics give a preview of the manual’s coverage. Further sections include headlight adjustment and rear wiper-motor replacement.

• Engine repair: Step-by-step engine removal, cylinder-head and cylinder-block overhaul, timing-belt replacement, camshaft installation, and shim-type valve-clearance adjustment.

• 4L30-E automatic transmission: Stall and line-pressure testing, valve-body and oil-pump overhaul, clutch-pack service, and complete transmission disassembly and reassembly.

• TOD transfer case and axles: Torque on Demand clutch-pack, chain, and sprocket repair; front and rear differential setup, including rear limited-slip differential overhaul.

• ABS and parking brakes: EHCU actuator tests, wheel-speed-sensor diagnosis, Tech 2 Service Bleed, and separate parking-brake procedures for 4WD and 4x2 models.

• Automatic HVAC: Manifold-gauge diagnostics, refrigerant leak testing, heater-core replacement, compressor magnetic-clutch repair, and control-unit self-diagnosis with sensor and actuator checks.

• Intelligent Suspension Control: Fault-code retrieval, G-sensor and vehicle-speed input diagnosis, front-actuator inspection, and rear-shock replacement.

• Electrical fault tracing: Connector-face views, pinout tables, ground locations, and system-specific wiring diagrams support circuit-level diagnosis.

This manual suits experienced technicians who can interpret wiring diagrams and use scan tools, pressure gauges, and the specified special tools.

Production Changes and Chassis Service

The manual separates rear-suspension, drive-shaft, and power-assisted brake procedures around the July 31/August 1, 2001 production changeover. The front-wheel-bearing distinction matters: earlier versions have cleaning and repacking procedures, while later versions use an integrated hub unit bearing serviced as an assembly rather than dismantled.

Power steering repair goes beyond fluid checks, with hydraulic performance testing, flushing and bleeding, steering-unit removal and installation, pump overhaul, and steering-column inspection. Front-suspension work includes torsion-bar adjustment, control-arm and ball-joint service, and alignment checks.

Maintenance, Fuel, and Engine Diagnosis

Maintenance schedules distinguish normal use from severe-duty operation. Engine-cooling procedures cover water-pump and thermostat service, radiator inspection, and cooling-system draining and refilling.

Fuel-system coverage includes in-tank pump service, pump-flow testing, and fuel-line quick-connector handling.

The Driveability and Emissions chapter supplies OBD II diagnostic charts, Tech 2 scan-data definitions, injector-balance testing, and fuel-pressure checks. It also addresses Electric Throttle Control (ETC) and reduced-power faults, ION Sensing Module diagnosis, and EGR/EVAP testing.

The engine-service notes warn that supporting the engine under its oil pan can damage the oil pickup.

Transmission and TOD Fault Diagnosis

For shift complaints, the separate transmission-control chapter explains Normal, Power, Winter, and backup modes. Fault charts address the mode switch, pressure-control solenoid, torque-converter clutch, and transmission component slipping. These electronic fault charts complement the mechanical and hydraulic tests when narrowing down a shift complaint.

Line-pressure testing calls for the J-29770-A transmission pressure gauge. The third-clutch reassembly instructions warn that excessive spring compression or a seat caught in the retaining-ring groove can damage the spring seat.

TOD diagnosis adds control-unit pin checks, Tech 2 fault-code routines, and troubleshooting based on indicator behavior and driving symptoms.

Wiring, Body Repair, and Restraints

Wiring references include the seven-part PCM Wiring Diagram, plus Air Conditioning, ABS, Intelligent Suspension, T.O.D., and SRS–Air Bag circuit diagrams. Exploded assembly views accompany the mechanical repair sections.

Starting and charging coverage includes starter disassembly and inspection, generator overhaul, on-vehicle electrical checks, and generator bench testing.

Body repair material covers frame and body dimensions, door and window-regulator removal, and glass replacement. Security and Locks adds keyless-entry ID-code registration.

The restraint chapters cover SRS disabling and enabling, Sensing and Diagnostic Module (SDM) diagnosis, SRS coil-assembly service, and post-accident inspections.

Standard-fastener and component-specific torque tables, fluid capacities, inspection limits, alignment data, clearance specifications, and electrical test values accompany the relevant procedures.

Brake, refrigerant, and SRS work requires the complete factory safety procedures and the specified service equipment.

Selected Cold Valve-Clearance Specifications

For the 6VE1, the valve-adjustment section lists cold intake clearance of 0.23–0.33 mm and cold exhaust clearance of 0.25–0.35 mm.

The valve-service pages pair these ranges with shim-selection guidance and the J-42689 valve-clearance adjusting tool for shim replacement. Illustrations identify the cam, shim, and tappet.