1998 ISUZU TROOPER Service Repair Manual

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Page 889 of 3573

ISUZU TROOPER 1998 Service Repair Manual POWER ASSISTED BRAKE SYSTEM 5C – 11
12. Reconnect the brake pipe 1to the master cylinder
and tighten the pipe.
13. Depress the brake pedal slowly once and hold it
depressed.
14. Loosen the rear whe

POWER ASSISTED BRAKE SYSTEM 5C – 11
12. Reconnect the brake pipe 1to the master cylinder
and tighten the pipe.
13. Depress the brake pedal slowly once and hold it
depressed.
14. Loosen the rear wheel brake pipe 1at the master
cylinder.
15. Retighten the brake pipe, then release the brake
pedal slowly.
16. Repeat steps 13 through 15 until no air comes out
from the port when the brake pipe is loosened.
NOTE:
Be very careful not to allow the brake fluid to come in
contact with painted surfaces.
17. Bleed the air from the front wheel brake pipe
connection 2by repeating steps 7 through 16.
Bleeding the Caliper
18. Bleed the air from each wheel in the order listed
below.
LHD models:
1) Right rear caliper
2) Left rear caliper
3) Load sensing proportioning valve (only for
Europe and South Africa)
4) Right front caliper
5) Left front caliper
RHD models:
1) Left rear caliper
2) Right rear caliper
3) Load sensing proportioning valve (only for
Europe and South Africa)
4) Left front caliper
5) Right front caliper
Conduct air bleeding from the wheels in the above
order. If no brake fluid comes out, it suggests that air
is mixed in the master cylinder. In this case, bleed air
from the master cylinder in accordance with Steps 7
through 17, and then bleed air from the caliper.
19. Place the proper size box end wrench over the
bleeder screw.
20. Cover the bleeder screw with a transparent tube,
and submerge the free end of the transparent tube
in a transparent container containing brake fluid.
21. Pump the brake pedal slowly three (3) times
(once/sec), then hold it depressed.
22. Loose the bleeder screw until fluid flows through
the tube.
23. Retighten the bleeder screw.
24. Release the brake pedal slowly.
25. Repeat step 21 through 24 until the air is
compeletely removed. It may be necessary to
repeat the bleeding procedure 10 or more times
for front wheels and 15 or more times for rear
wheels.
26. Go to the next wheel in the sequence after each
wheels is bled. Be sure to monitor reservoir fluid
level.

Page 890 of 3573

ISUZU TROOPER 1998 Service Repair Manual 5C – 12 POWER ASSISTED BRAKE SYSTEM
27. Depress the brake pedal to check if you feel
“sponginess” after the air has been removed from
all wheel cylinders and calipers. If the pedal feels
“spon

5C – 12 POWER ASSISTED BRAKE SYSTEM
27. Depress the brake pedal to check if you feel
“sponginess” after the air has been removed from
all wheel cylinders and calipers. If the pedal feels
“spongy”, the entire bleeding procedure must be
repeated.
28. After the bleeding operation is completed on each
individual wheel, check the level of brake fluid in
the reservoir and replenish up to the “MAX” level if
necessary.
29. Attach the reservoir cap.
•If the diaphragm inside the cap is deformed,
reform it and install.
30. Stop the engine.
FLUSHING BRAKE HYDRAULIC SYSTEM
It is recommended that the entire hydraulic system be
thoroughly flushed with clean brake fluid whenever
new parts are installed in the hydraluic system.
Approximately one quart of fluid is required to flush
the hydraulic system.
The system must be flushed if there is any doubt as to
the grade of fluid in the system or if fluid has been
used which contains the slightest trace of mineral oil.
All rubber parts that have been subjected to a
contaminated fluid must be replaced.
BRAKE PIPES AND HOSES
The hydraulic brake system components are
interconnected by special steel piping and flexible
hoses. Flexible hoses are used between the frame and
the front calipers, the frame and rear axle case and the
rear axle and the rear calipers.
When the hydraulic pipes have been disconnected for
any reason, the brake system must be bled after
reconnecting the pipe; refer to “Bleeding Brake
Hydraulic System” in this section.
BRAKE HOSE INSPECTION
The brake hoses should be inspected at least twice a
year. The brake hose assembly should be checked for
road hazard, cracks and chafing of the outer cover,
and for leaks and blisters. Inspect for proper routing
and mounting of the hose. A brake hose that rubs on
suspension components will wear and eventually fail.
A light and mirror may be needed for an adequate
inspection. If any of the above conditions are
observed on the brake hose, adjust or replace the
hose as necessary.
CAUTION:
Never allow brake components such as calipers to
hang from the brake hoses, as damage to the hoses
may occur.

Page 891 of 3573

ISUZU TROOPER 1998 Service Repair Manual POWER ASSISTED BRAKE SYSTEM 5C – 13
CHECKING BRAKE PEDAL HEIGHT
The push rod serves as the brake pedal stopper when
the pedal is fully released. Brake pedal height
adjustment should be performed as

Page 892 of 3573

ISUZU TROOPER 1998 Service Repair Manual 5C – 14 POWER ASSISTED BRAKE SYSTEM
CHECKING BRAKE PEDAL TRAVEL
1. Pedal height (L3) must be measured after starting
the engine and removing it several times to apply
vacuum to the vacuum booster fu

Page 893 of 3573

ISUZU TROOPER 1998 Service Repair Manual POWER ASSISTED BRAKE SYSTEM 5C – 15
CHECKING LATERAL RUNOUT
1. Adjust the wheel bearing correctly.
•Refer to Front Hub and Disc in Driveline / Axle
Section.
2. Attach a dial indicator to some por

Page 894 of 3573

ISUZU TROOPER 1998 Service Repair Manual 5C – 16 POWER ASSISTED BRAKE SYSTEM
PARALLELSIM
Parallelism is the measurement of the thickness of the
rotor at four or more points around the circumference
of the rotor. All measurements must be ma

5C – 16 POWER ASSISTED BRAKE SYSTEM
PARALLELSIM
Parallelism is the measurement of the thickness of the
rotor at four or more points around the circumference
of the rotor. All measurements must be made at 22 mm
(0.87 in) from the edge of the rotor.
The rotor thickness must not vary more than 0.010
mm (0.0004 in) from point to point.
Maximum Parallelism Variation mm (in)
0.010 (0.0004)
REPLACING REAR BRAKE ROTORS
When installing new brake rotors, do not refinish the
surfaces. These parts are at the correct level of surface
finish.
REFINISHING REAR BRAKE ROTORS
Accurate control of the rotor tolerances is necessary
for proper performance of the disc brakes. Machining
of the rotor should be done only with precision
equipment. All brake rotors have a minimum
thickness dimension cast into them. This dimension is
the minimum wear dimension and not a refinish
dimension. The minimum wear dimension is 16.60
mm (0.654 in). The refinish dimension is 16.97 mm
(0.668 in).
When refinishing rotors, always use sharp cutting
tools or bits. Dull or worn tools leave a poor surface
finish which will affect initial braking performance.
SERVICING THE REAR BRAKE ROTOR
In the manufacturing of the rear brake rotor, all the
tolerances regarding surface finish, parallelism and
lateral runout are held very closely. The maintenance
of these tolerances provide the surface necessary to
assure smooth brake operation.
LATERAL RUNOUT
Lateral runout is the movement of the rotor from side
to side as it rotates on the spindle. This could also be
referred to as “rotor wobble”.
This movement causes the piston to be knocked back
into its bore. This results in additional pedal travel and
a vibration during braking.
CHECKING LATERAL RUNOUT
1. Attach a dial indicator to some portion of the
suspension so that the stem contacts the rotor
face about 22 mm (0.87 in) from the rotor edge.
2. Move the rotor one complete rotation.
•The lateral runout should not exceed 0.13 mm
(0.005 in).
Maximum Runout mm (in)
0.13 (0.005)
t

Page 895 of 3573

ISUZU TROOPER 1998 Service Repair Manual POWER ASSISTED BRAKE SYSTEM 5C – 17
Vibration dampening attachments should always be
used when refinishing braking surfaces. These
attachments eliminate tool chatter and will result in
better surfa

Page 896 of 3573

ISUZU TROOPER 1998 Service Repair Manual 5C – 18 POWER ASSISTED BRAKE SYSTEM
FIXING TORQUE
Brake Hydraulic Lines N·m (kg·m/lb·ft)
12(1.2/104 lb•in)
Brake fluid pipe line
Flexible hose
16(1.6/12)16(1.6/12)
16(1.6/12)
35(3.5/26)
16(1.6/

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