2002 ISUZU AXIOM air condition

5C±69 POWER±ASSISTED BRAKE SYSTEM
Condition CorrectionPossible cause
Poor Brake ActionMaster cylinder faulty.Correct or replace.
Vacuum booster faulty.Correct or replace.
Level of brake fluid in reservoir too
low.Replenish and bleed.
Air in hydraulic circuit.Bleed
Disc brake caliper faulty.Clean or replace.
Water or oil on brake pads.Clean or replace.
Brake pads in poor contact with the
rotor.Correct
Brake pads worn.Replace
Brake disc rusted.Grind or replace.
Check valve in vacuum hose faulty.Correct or replace.

5C±71 POWER±ASSISTED BRAKE SYSTEM
NOTE: Do not allow the fluid level in the reservoir to go
below the half±way mark.
12. Reconnect the brake pipe (1) to 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 (1) at 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 of
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.
330R200004
17. Bleed the air from the front wheel brake pipe
connection (2) by repeating steps 7 through 16.
Bleeding the Caliper
18. Bleed the air from each wheel in the order listed
below:

Right rear caliper or wheel cylinder

Left rear caliper or wheel cylinder

Right front caliper

Left 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 or
wheel cylinder.
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. Loosen the bleeder screw until fluid flows through the
tube.
23. Retighten the bleeder screw.24. Release the brake pedal slowly.
25. Repeat steps 21 through 24 until the air is completely
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 wheel
is bled.
Be sure to monitor reservoir fluid level.
27. Depress the brake pedal to check if you feel
ªsponginessº after the air has been removed from all
wheel cylinders and calipers.
If the pedal feels ªspongyº, the entire bleeding
procedure must be repeated.
28. After the bleeding operation is completed on the each
individual wheel, check the level of the brake fluid in
the reservoir and replenish up to the ªMAXº level as
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 hydraulic 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 the Brake
Hydraulic System
in this section.
Brake Hose Inspection
The brake hose 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.

5C±83 POWER±ASSISTED BRAKE SYSTEM
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

O±ring

Wash each part in brake fluid before beginning the
inspection procedure.

Check the inside surfaces of the master cylinder for
abrasion, corrosion, and other damage. Replace the
cylinder if necessary.

Check the return port for clogging. Clean the port with
a wire and compressed air if nesessay.

Check the piston and piston cup for abrasion,
damage, and wear. Replace the piston assembly if
any of these conditions exist.

Check the return spring. Replace the spring if it is
weak.

Check the snap ring. Replace the snap ring if it is
stretched or weak.
Reassembly
1. Wash each master cylinder internal part in brake fluid
before beginning installation.
2. Install the cylinder body.
3. Press the secondary piston assembly into the
cylinder body and hold it. Thread the pin through the
long hole of the piston to secure the piston assembly.
4. Install the primary piston assembly.
5. Install the snap ring.
6. Install the O±ring
7. Install the reserve tank and the reserve tank cap.
8. Install the spring pin.
Installation
1. Install 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 in section).
2. Install P&B valve and bracket.
3. Install 2 attaching nuts and tighten the attaching nuts
to the specified torque.
Torque: 13 N´m (113 lb in)
4. Install brake pipes and tighten the brake pipe to the
specified torque.
Master cylinder and P&B valve sides
Torque: 12 N´m (104 lb in)
Others
Torque: 16 N´m (12 lb in)
5. Connect electrical connector.

5C±88
POWER±ASSISTED BRAKE SYSTEM
Inspection and Repair
Visual Check
Make necessary parts replacement if cuts, nicks,
excessive wear, or other abnormal conditions are found
through inspection.
NOTE: The parts listed below must be replaced with new
ones whenever the master cylinder is removed.
1. Plate and seal assembly
2. Retainer
Installation
1. Install plate and seal assembly.
2. Install retainer.
3. Install vacuum booster, refer to
Vacuum Booster in
this section.
4. Install master cylinder, refer to
Master Cylinder in this
section and after installation, perform brake pedal
check and adjustment. Refer to
Brake Pedal in this
section.
Vacuum Booster Overhaul
Vacuum Booster
The vacuum booster cannot be disassembled for repair.
Replace a defective vacuum booster with a new one.

5C±99 POWER±ASSISTED BRAKE SYSTEM
2. Remove dust boot: piston.
3. Remove piston seal.
4. Remove bleeder with cap.
5. Remove caliper body.
Inspection and Repair
Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:

Rotor

Cylinder body

Cylinder bore

Piston

Guide pin, lock pin

Support bracket
NOTE: The piston seal, boot ring and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace them with new ones.
Reassembly
1. Install caliper body.
2. Install bleeder with cap and tighten the cap to the
specified torque.
Torque: 8 N´m (69 lb in)
3. Apply special rubber grease to the piston seal and
cylinder wall, then insert the piston seal into the
cylinder. The special rubber grease is included in the
repair kit.
302R200013
4. When inserting the piston into the cylinder, use finger
pressure only and do not use a mallet or other impact
tool, since damage to the cylinder wall or piston seal
can result.
Install piston.
302R200015
5. Apply special grease (approximately 1 g) to the piston
and attach the dust boot to the piston and caliper.
Insert the dust boot ring into the dust boot.
6. Install guide bolt and lock bolt dust boot.
7. Install the dust boot on the support bracket after
applying special grease (approximately 1 g) onto the
dust boot inner surface. Apply special grease onto the
lock pin and guide pin setting hole of the support
bracket.
302R200022
Legend
(1) Guide Pin
(2) Lock Pin
(3) Pin Boot
8. Install pin bolt and tighten the bolt to the specified
torque.
Torque: 45 N´m (33 lb ft)

5C±109 POWER±ASSISTED BRAKE SYSTEM
Disassembly
1. Remove guide bolt.
2. Remove lock bolt.
3. Remove dust boot; guide bolt and lock bolt.
4. Remove dust boot ring, using a small screwdriver.
302RS016
5. Insert a block of wood into the caliper and force out
the piston by blowing compressed air into the caliper
at the flexible hose attachment. This procedure must
be done prior to removal of the dust boot.
Remove piston.
WARNING: D O N O T P L A C E Y O U R F I N G E R S I N
FRONT OF THE PISTON IN AN ATTEMPT TO CATCH
OR PROTECT IT WHEN APPLYING COMPRESSED
AIR. THIS COULD RESULT IN PERSONAL INJURY.
CAUTION: Use just enough air to ease the piston
out of the bore. If the piston is blown out, it may be
damaged.
302RS017
6. Remove dust boot: piston.
7. Remove piston seal.
8. Remove bleeder with cap.
9. Remove caliper body.
Inspection and Repair
Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:

Rotor

Cylinder body

Cylinder bore

Piston

Guide bolt, lock bolt

Support bracket
NOTE: The piston dust seal and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace with new ones.
Reassembly
1. Install caliper body.
2. Install bleeder with cap and tighten the cap to the
specified torque.
Torque: 8 N´m (69 lb ft)
3. Install piston seal and apply special rubber grease to
the piston seal and cylinder wall, then insert the piston
seal into the cylinder. The special rubber grease is
included in the repair kit.
302RS018
4. When inserting the piston into the cylinder, use finger
pressure only and do not use a mallet or other impact
tool, since damage to the cylinder wall or piston seal
can result.
Install piston.

5C±116
POWER±ASSISTED BRAKE SYSTEM
Disassembled View
305RS006
Legend
(1) Boot
(2) Piston Assembly
(3) Piston Cup
(4) Return Spring
(5) Bleeder
(6) Wheel Cylinder
Disassembly
1. Remove boot (1) and piston assembly (2).
2. Remove piston cup (3) from piston assembly (2).
3. Remove return spring (4) and bleeder (5) from wheel
cylinder (6).
Inspection and Repair
1. Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition are found
through inspection.
Check the following parts;

Wheel cylinder body

Cylinder bore

Piston

Return spring

Bleeder
NOTE: Replace the piston cups and boots each time the
wheel cylinder is overhauled. Discard these used rubber
parts and replace with new ones.
Reassembly
1. Lubricate the cylinder bore with clean rubber grease.
305RS007
2. Install bleeder (5) to wheel cylinder (6).
Torque: 10 N´m (8 lb ft)
305RS008

5D1±6
PARKING BRAKE SYSTEM (4x4 Model)
Inspection and Repair
Parking Brake Lining Inspection
Check the shoe assemblies for wear by removing the
brake drum.
Replace the shoe assemblies if the lining thickness is less
than 1.0 mm (0.039 in).
Minimum limit: 1.0 m (0.039 in)
308RS004
Parking Brake Rotor (Drum) Inspection
Refer to ªRear Disc Brakesº in Power-Assisted Brake
System
section for inspection procedure of the rotor
(drum).
Parking Brake Adjustment
1. Prior to lever stroke adjustment, adjust rear brake
shoe/rotor (drum) gap. Perform this procedure with
loosening the adjust nut of the hand brake lever.
2. Remove the adjusting hole plug (rubber) and turn the
shoe adjusting screw downward with a small
screwdriver so that shoes will expand until they get
into close touch with the rotor. (Turn down the
adjusting screw notch by notch until the rotor does not
turn.)
3. Turn the adjusting screw in the opposite direction
(upward) until the rotor can be turned lightly. Standard
number of notches to turn upward: 7 or 8 notches
Turn the rotor and make sure that there is no brake
dragging.
4. After the rear brake shoe/rotor (drum) gap has been
adjusted, perform parking brake cable adjustment.
5. Turn the adjusting nut so that the parking brake lever
travels 6±8 notches when pulled up with a force of 30
kg (66 lb).
6. Make sure there is no brake dragging. Then tighten
the cable lock nut
Torque : 13 N´m (113 lb in)7. When poor braking effect possibly resulting from
insufficient break±in is felt, or just after replacement
of parking brake shoe, be sure to conduct break±in as
follows:
8. Forward 50 km/h (30 mph) y 400 m (About 30
seconds) with a lever pull force of 15 kg (33 lb).
9. Backward 10 km/h (6 mph) y 50 m (About 18
seconds) with a lever pull force of 15 kg (33 lb).
NOTE: Break±in procedures must be performed under
safe conditions and traffic rules.

If braking effect still remains poor after the above
break±in, wait for some time until parking brake shoe
cools down and repeat the procedures 8. and 9. noted
above.

On completion of break±in, inspect parking brake
lever stroke, and if the lever does not come within the
specified number of notches when pulled up,
readjust.

Excessive break±in may cause premature wear of
the parking brake lining.