2002 Isuzu Axiom UPR/S SUV Workshop Manual (P/N C8049A)

• Covers 2002 Isuzu Axiom UPR/S SUV models (4WD and 4x2) equipped with the 3.5L V6 6VE1 engine. This Isuzu workshop manual is a 2,100-page PDF.
• Engine repair procedures cover removal, cylinder-head and cylinder-block overhaul, timing-belt replacement, camshaft installation, and shim-type valve-clearance adjustment.
• The 4L30-E automatic transmission section details stall and line-pressure testing, valve-body and oil-pump overhaul, clutch-pack service, and complete transmission disassembly and reassembly.
• Torque on Demand (TOD) coverage includes transfer-case clutch-pack, chain, and sprocket repair. Axle chapters address front and rear differential setup, including rear limited-slip differential overhaul.
• ABS coverage includes EHCU actuator tests, wheel-speed-sensor diagnosis, and the Tech 2 Service Bleed procedure. Parking-brake service is separated for 4WD and 4x2 models.
• Automatic HVAC service covers manifold-gauge diagnostics, refrigerant leak testing, heater-core replacement, and compressor magnetic-clutch repair. Control-unit self-diagnosis includes sensor and actuator checks.
• Intelligent Suspension Control procedures address fault-code retrieval, G-sensor and vehicle-speed input diagnosis, front-actuator inspection, and rear-shock replacement.

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 bearing cleaning and repacking procedures, while later versions use an integrated hub unit bearing that is 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.

Service and Maintenance Overview

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.

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.

The engine-service notes warn that supporting the engine under its oil pan can damage the oil pickup. The third-clutch reassembly instructions also warn that excessive spring compression or a seat caught in the retaining-ring groove can damage the spring seat.

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. Connector-face views, pinout tables, and ground locations support circuit-level fault tracing. Exploded assembly views accompany the mechanical repair sections.

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.

Specification Highlights

You get detailed component removal and installation procedures, fluid capacities, and torque settings for standard fasteners and specialized drivetrain components. Inspection limits, alignment data, clearance specifications, and electrical test values accompany the relevant systems.

Special-tool references identify the J-42689 valve-clearance adjusting tool and J-29770-A transmission pressure gauge, among the equipment called out for engine and transmission work.

Because working on high-pressure hydraulic and automotive systems carries inherent physical risks, always rely on the complete factory procedures and proper safety gear before beginning a repair in the bay.