1998 ISUZU TROOPER height

5C – 6 POWER ASSISTED BRAKE SYSTEM
Condition Possible Cause Correction
Brake Drag1. Master cylinder pistons not returning 1. Adjust stop light switch and vacuum
correctly. booster operating rod. If necessary,
rebuild.
2. Restricted brake pipes or hoses. 2. Check for soft hoses or damaged pipes,
and replace with new hoses and new
double-walled steel brake piping.
3. Parking brake maladjusted. 3. Adjust.
4. Parking brake lining clearance 4. Adjust.
insufficient.
5. Brake pedal free play insufficient. 5. Adjust brake pedal height or power
cylinder operating rod.
6. Piston in master cylinder sticking. 6. Replace.
7. Piston in disc brake caliper sticking. 7. Replace piston seals.
8. Brake pads sticking in caliper. 8. Clean.
9. Return spring weakened. 9. Replace.
10. Parking brake binding. 10. Overhaul parking brakes and correct.
11. Front hub bearing preload incorrect. 11. Adjust or replace.
12. Parking brake shoes not returning. 12. Correct or replace brake back plate and
brake shoe as necessary.
13. Obstructions in hydraulic circuit. 13. Clean.
14. Rotor warped excessively. 14. Grind or replace.
15. Rear brake drum distorted. 15. Grind or replace.
16. Parking cable sticking. 16. Clean or replace.
Grabbing or1. Malfunctioning vacuum booster. 1. Check operation and correct as
Uneven necessary.
Braking Action 2. Binding brake pedal mechanism. 2. Check and lubricate, if necessary.
(All conditions3. Corroded caliper assembly. 3. Clean and lubricate.
listed under
“Pulls”)
Brake Noisy1. Brake pads worn. 1. Replace.
2. Brake pads hardened. 2. Replace.
3. Brake pads in poor contact with rotor. 3. Correct.
4. Brake disc(s) warped, worn or 4. Grind or replace.
damaged.
5. Disc brake anti-squeak shims fatigued. 5. Replace.
6. Front hub bearings loose or preload is 6. Adjust or replace.
incorrect.
7. Brake disc rusted. 7. Grind or replace.
Poor Brake1. Master cylinder faulty. 1. Correct or replace.
Action2. Vacuum booster faulty. 2. Correct or replace.
3. Level of brake fluid in reservoir too 3. Replenish and bleed.
low.
4. Air in hydraulic circuit. 4. Bleed.
5. Disc brake caliper faulty. 5. Clean or replace.
6. Water or oil on brake pads. 6. Clean or replace.
7. Brake pads in poor contact with rotor. 7. Correct.
8. Brake pads worn. 8. Replace.
9. Brake disc rusted. 9. Grind or replace.
10. Check valve in vacuum hose faulty. 10. Correct or replace.

5C – 8 POWER ASSISTED BRAKE SYSTEM
SERVICE STANDARD
HYDRAULIC BRAKE FLUID DOT 3 grade
BRAKE PEDAL
Pedal Free Play mm (in) 6 to 10 (0.23 to 0.39)
Pedal Height (LHD / RHD) mm (in) 208 to 218 (8.19 to 8.58) / 211 to 221 (8.31 to 8.70)
Stop Light Switch Clearance mm (in) 0 to 0.2 (0 to 0.008)
FRONT DISC BRAKE
Pad Thickness Minimum Limit mm (in) 1.0 (0.039)
Disc (Rotor) Maximum Runout mm (in) 0.13 (0.005)
Disc (Rotor) Maximum Parallelism mm (in) 0.010 (0.0004)
Disc (Rotor) Minimum Wear
Dimensions (Thickness) mm (in) 24.60 (0.969)
Disc (Rotor) Minimum Refinish
Dimensions (Thickness) mm (in) 24.97 (0.983)
REAR DISC BRAKE
Pad Thickness Minimum Limit mm (in) 1.0 (0.039)
Disc (Rotor) Maximum Runout mm (in) 0.13 (0.005)
Disc (Rotor) Maximum Parallelism mm (in) 0.010 (0.0004)
Disc (Rotor) Minimum Wear
Dimensions (Thickness) mm (in) 16.60 (0.654)
Disc (Rotor) Minimum Refinish
Dimensions (Thickness) mm (in) 16.97 (0.668)

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 follows:
Adjust Brake Pedal
1. Measure the brake pedal height after making sure
the pedal is fully returned by the pedal return
spring.
Pedal height (L2) must be measured after starting
the engine and revving it several times.
Pedal Free Play (L1) mm (in)
6 – 10 (0.23 – 0.39)
Pedal Height (L2) mm (in)
LHD RHD
208 – 218 211 – 221
(8.19 – 8.58) (8.31 – 8.70)
NOTE:
Pedal free play (L1) must be measured after turning
off the engine and stepping on the brake pedal firmly
five times or more.
2. If the measured value is not within the above
range, adjust the brake pedal as follows:
a) Disconnect the stop light switch connector.
b) Loosen the stop light switch lock nut.
c) Rotate the stop light switch so that it moves
away from the brake pedal.
d) Loosen the lock nut on the push rod.
e) Adjust the brake pedal to the specified height
by rotating the push rod in the appropriate
direction.
f) Tighten the lock nut to the specified torque.
Lock Nut Torque N·m (kg·m/lb·ft)
20 (2.0 / 15)
g) Adjust the stop light switch to the specified
clearance (between switch housing and brake
pedal) by rotating the switch housing.
Clearance mm (in)
0 – 0.2 (0 – 0.008)
NOTE:
While adjusting the installation of the stoplight
switch, make sure that the threaded part of the
stoplight switch does not push the brake pedal.
h) Tighten the stop light switch lock nut.
i) Connect the stop light switch connector.
Switch
Floor panel
(L3)
(A)
(L2)(L1)
Lock nut
(A)

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 fully.
NOTE:
Pedal height (L3) must be 100 mm (3.9 in)/85 mm (3.5
in) (LHD/RHD) or more when about 50 kg (110.25 lb)
of stepping force is applied.
2. If the measured value is lower than the above
range, air existing in the hydrauic system is
suspected and perform bleeding procedure.
FRONT AND REAR DISC BRAKE PADS
INSPECTION
Check the outer pad by looking at each caliper from
above. Check the thickness on the inner pad by
looking down through the inspection hole in the top of
the caliper. Whenever the pad is worn to about the
thickness of the pad base, the pad should be removed
for further measurements. The pad should be
replaced anytime the pad thickness (t) is worn to
within 1.0 mm (0.039 in) of the pad itself.
The disc pads have a wear indicator that makes a
noise when the pad wears to where replacement is
required.
Minimum Limit mm (in)
1.0 (0.039)
SERVICING THE FRONT BRAKE ROTOR
In the manufacturing of the front 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.
t

5C – 46 POWER ASSISTED BRAKE SYSTEM
3. Yoke Clevis
2. Vacuum Booster
•Refer to Vacuum Booster Assembly in this
section.
1. Master Cylinder
1) Refer to Master Cylinder Assembly in this Section.
2) After installation, perform brake pedal check and
adjustment. Refer to Checking Brake Pedal Height
/ Travel in this section.

6A±27
ENGINE MECHANICAL
Exhaust Manifold RH
Removal
1. Disconnect battery ground cable.
2. Remove torsion bar. Refer to removal procedure in
Front Suspension section.
3. Remove exhaust front pipe three stud nuts and two
nuts then disconnect exhaust front pipe.
150RW061
Legend
(1) Exhaust Front Pipe RH
(2) O
2 Sensor (for IGM)
4. Remove heat protector two fixing bolts then the heat
protector.
5. Remove exhaust gas recirculation (EGR) pipe fixing
bolt and nut from exhaust manifold, remove a nut
from EGR valve and a bolt from rear side of cylinder
head for bracket of EGR pipe then remove the EGR
pipe.
056RW001
Legend
(1) Exhaust Gas Recirculation (EGR) Valve
(2) EGR Pipe
6. Remove exhaust manifold eight fixing nuts then the
exhaust manifold.
Installation
1. Install exhaust manifold and tighten bolts to the
specified torque.
Torque : 57 N´m (5.8 Kg´m/42 lb ft)
2. Install the EGR pipe, tighten bolt and nut on exhaust
manifold to specified torque.
Torque : 28 N´m (2.9 Kg´m/21 lb ft)
Tighten nut to EGR valve to the specified torque.
Torque : 44 N´m (4.5 Kg´m/33 lb ft)
Tighten the bolt for EGR pipe bracket to specified
torque.
Torque : 25 N´m (2.5 Kg´m/18 lb ft)
3. Install heat protector
4. Install exhaust front pipe and tighten three stud nuts
and two nuts to the specified torque.
Torque:
Stud nuts: 67 N´m (6.8 Kg´m/49 lb ft)
Nuts: 43 N´m (4.4 Kg´m/32 lb ft)
5. Install the torsion bar and readjust the vehicle height.
Refer to installation and vehicle height adjustment
procedure for Front Suspension.

6A±53
ENGINE MECHANICAL
2. Remove camshaft bracket fixing bolt (5), camshaft
bracket (6), then camshaft exhaust (7), and intake
side (8).
3. Remove tappet with shim (11).
4. Use the 5±8840±2446±0 valve spring compressor
and 5±8840±2547±0 valve spring compressor
adapter to remove the split collar (12), valve spring
with upper seat (13) and valve (14).
014RW042
5. Remove spark plug (1).
CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use a motorized wire brush on any
gasket sealing surface.
Inspection and Repair
1. Cylinder head gasket and mating surfaces for leaks,
corrosion and blow±by. If the gasket has failed,
determine the cause.
± Insufficient torque on head bolts.
± Improper installation
± Loose or warped cylinder head
± Missing dowel pins
± Warped case surface
2. Cylinder head for cracks, especially between valve
seats and in the exhaust ports.3. Cylinder head deck for corrosion, sand particles in
head and porosity.
CAUTION:

Do not attempt to weld the cylinder head. Replace
it.

Do not reuse cylinder head bolts.
4. Cylinder head deck, common chamber and exhaust
manifold mating surfaces for flatness. These
surfaces may be reconditioned by milling. If the
surfaces are ªout of flatº by more than specification,
the surface should be ground to within specifications.
Replace the head if it requires machining beyond the
repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362 in)011RW019
5. Water jacket sealing plugs seating surfaces.
Reassembly
1. Install Spark plug and tighten all the spark plugs to
specified torque.
Torque: 18 N´m (1.8 Kg´m/13 lb ft)
2. Tighten sub gear setting bolt.
1. Use 5±8840±2443±0 gear spring lever to turn sub
gear to right direction until the M5 bolt aligns with
the hole between camshaft driven gear and sub
gear.

6A±57
ENGINE MECHANICAL
5. Use 5±8840±2446±0 valve spring compressor and
5±8840±2547±0 valve spring compressor adapter to
remove split collar.
014RW042
6. Remove valve spring.
7. Remove valve.
8. Remove oil controller and spring lower seat.
9. Remove the valve guide using the 5±8840±2442±0
valve guide replacer.
Inspection and Repair
Valve Spring
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is evident.
1. Measure the free height of the springs. The springs
must be replaced if the free height is below the
specified limit.
Standard : 44.6 mm (1.7559 in)
Limit : 43.6 mm (1.7165 in)
014RS004
2. Measure the valve spring squareness with a steel
square and replace the valve springs if the measured
value exceeds the specified limit.
Limit : 2 mm (0.0787 in)
014RS005
3. Using a spring tester to compress the springs to the
installed height, measure the compressed spring
tension, and replace the springs if the measured
tension is below the specified limit.
At installed height: 35.0 mm (1.38 in)
Standard: 196 N (44 lb)
Limit: Less than 181 N (41 lb)
014RS006
Valve Guide
CAUTION: Take care not to damage the valve seat
contact surface, when removing carbon adhering to
the valve head. Carefully inspect the valve stem for
scratchs or abnormal wear. If these conditions are
present, the valve and the valve guide must be
replaced as a set.