1995 ISUZU TROOPER Workshop Manual

HYDRAULIC BRAKES 5A-17
ON-VEHICLE SERVICE
FLUID RESERVOIR TANK
2
T 4
3 1
Removal steps
1. Electrical connector 2. Retainer
3. Fluid reservoir
4. 0-ring
Installation steps
To install, follow the removal steps in the reverse order.
Fig. 5A-16
1••1 REMOVAL
NOTE:
Before removing fluid reservoir, remove brake fluid
from fluid reservoir.
1. Electrical connector
2. Retainer (Fig. 5A-17)
Fig. 5A-17
3. Fluid reservoir
• The fluid level sensor is built into the fluid
reservoir (Except rear wheel anti lock model). It
cannot be removed for servicing.
4. 0-ring
1••1 INSTALLATION
To install, follow the removal steps in the reverse
order, noting the
following points;
4. 0-ring (Fig. 5A-18)
• 0-ring must be set onto the fluid reservoir,
before
installing fluid reservoir.
Fluid reservoir
0-ring
Fig. 5A-18

SA-18 HYDRAULIC BRAKES
MASTER CYLINDER ASSEMBL V
6
2
Removal steps
1.
Electrical connector
2. Brake pipes
3. 2 attaching nuts
4. Combination valve/P&B
valve and bracket
5. Master cylinder
6.
Spacer and 2gaskets
Installation steps
To
install, follow the removal steps in the reverse order.
5
4
Fig. 5A-19
1••1 REMOVAL
\i7 CAUTION:
'V When removing master cylinder from vacuum
booster, be sure
to get rid of the internal negative
pressure
of the vacuum booster (by, for instance,
disconnecting vacuum hose) in advance.
If any negative pressure remains in the vacuum
booster, the piston
may possibly come out when
the master cylinder is being removed, letting the
brake fluid run out.
While removing master cylinder, further, do
not
hold the piston as it can be easily pulled out.
Outside surface of the piston is the surface on
which seals are to slide. Care should be taken to
keep the surface free of cuts and dents.
1.
Electrical connector
2. Brake pipes
• After disconnecting the brake pipe, cap or tape
the openings
of the brake pipe to prevent the
entry of foreign matter.
3. 2
attaching nuts
4. Combination valve/P & B valve and bracket
5. Master cylinder
6. Spacer and 2 gaskets
1••1 INSTALLATION
6. Spacer and 2 gaskets
5. Master cylinder
• When replacing the master cylinder or vacuum
booster
or both, always measure the vacuum
booster push rod protrusion and adjust
it as
necessary. (Refer to "Vacuum Booster
Assembly" in Section 5A 1.)
4. Combination valve/P & B valve and bracket
3. 2 attaching nuts
• Tighten the attaching nuts to the specified
torque.
~~~ Torque N·m (lb·in) 13 (113)
2. Brake pipes
• Tighten the brake pipe to the specified torque.
1~1 Torque Master cylinder side 12 (1041b·in)
N·m (lb·ft) Others
16 (12)
1. Electrical connector
•

HYDRAULIC BRAKES SA-19
UNIT REPAIR
MASTER CYLINDER
• The master cylinder is not repairable and must
be replaced as complete assembly if found
defective.
INSPECTION
Excessive brake pedal travel, malfunction or dragging
brake suggests
that the master cylinder is defective. In
such cases perform the following visual check.
IL•I Visual check
Make parts replacement as required if wear, distortion,
nicks, cuts, corrosion,
or other abnormal conditions
are
found through the following parts inspection;
• Master cylinder body
• Fluid reservoir
• 0-ring
rfil FUNCTIONAL INSPECTION OF MASTER
l..!aJ CYLINDER PISTON (Fig. SA-20)
Push the primary piston with your fingers to check that
it travels smoothly. If the motion is questionable,
replace
the master cylinder as a complete assembly.
Primary piston
Fig. 5A-20
["j"1i"l FUNCTIONAL INSPECTION OF MASTER
I..!:::..J CYLINDER (Fig. 5A-21 and 5A-22)
Inspect the master cylinder for function as follows. If
any abnormal function is found, replace with a new
one.
1®.1 Primary piston holder: J-39242
(including master cylinder attachment and
master
cylinder plug)
• Install
the primary piston holder onto the
master
cylinder with the spacer (2 bolts) with its
adjusting
bolt screwed in up to the "0" line (Fig.
5A-21)
Master cylinder Primary piston holder
Fig. 5A-21
1®.1 Radiator cap tester: J-24460-01
•
Connect master cylinder attachment with the
end
of radiator cap tester, and apply air
pressure
with the cap tester. Make sure there is
no rise in pressure and
that with the adjusting
bolt further screwed in 5 mm (align the
adjusting
bolt to the "5" line). There should be a
pressure increase
of 0.5kg/cm2 or more (Fig.
5A-22).
\f7 NOTE:
VI When checking the front (or primary) side, be sure
to mount master cylinder plug in the rear (or
secondary) port.
~ "0" line "5" line
Apply air
No pressure Pressure
pressure
to rise. increase of
the front and 0.5 kg/cm2 or
rear ports more
Remarks Checks port Checks air
into the atmos-
tightness
of the
pheric pressure pressure
chamber chamber

SA-20 HYDRAULIC BRAKES
Fig. SA-22
\f/NOTE:
Master cy I i nder plug
J-24460..()1
VI • Do not use an air compressor, as the air from
compressor is mixed with compressor oil.
•
When installing the master cylinder onto the
vacuum booster,
always adjust vacuum
booster push rod. (Refer
to section SA 1 "Brake
Booster System".)
• After the master cylinder is installed onto the
vehicle, check for leakage, pedal travel and
pedal free play.
•

HYDRAULIC BRAKES 5A-21
MAIN DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
Brake pedal
Pedal
free play
Pedal
height
Parking brake
Type Brake
handle(stem) travel
Master cylinder
Type
Piston bore diameter
TORQUE SPECIFICATIONS
mm (in)
mm (in)
mm (in)
13 (1131b·in)
Fig. 5A-23 6
to 10 (0.23 to 0.39)
208 to 218
(8.19 to 8.58)
Duo-servo
6 to 7 notches
When
pulled with a force of 30 kg (66 lb)
Dual-circuit
25.4 (1.000)
4-Wheel Antilock Brake System
N·m {lb·ft}
-Brake fluid pipe line -Flexible hose
Rear Wheel Antilock Brake System
-Brake fluid pipe line -Flexible hose