2007 ISUZU KB P190 vacuum

BRAKES 5C-53
MASTER CYLINDER
REMOVAL AND INSTALLATION

MASTER CYLINDER ASSEMBLY






This illustration is based on the RHD model

RTW 75CMF000901

Removal Steps
▲ 1. Brake line
2. Nut; Master cylinder to vacuum booster
3. Master cylinder assembly

Installation Steps
3. Master cylinder assembly
▲ 2. Nut; Master cylinder to vacuum booster
▲ 1. Brake line






RTW 75CSH002701

Important Operation - Removal
1. Brake Line
Be very careful not to spill brake fluid on the painted surface.
Damage to the painted surface will result.








Important Operation - Installation
2. Nut; Master Cylinder to Vacuum Booster
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
10 – 16 (1.0 – 1.6 / 7 – 12)

1. Brake Line
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
13 – 19 (1.3 – 1.9 / 9 – 14)

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ISUZU KB P190 2007

BRAKES 5C-55
Important Operations
W hen disassembling, inspecting or reassembling the master
cylinder assembly, take care not to bring the parts into contact
with mineral oil or dust. W ash the piston cups only with brake
fluid. Do not use gasoline or other mineral-base cleaning
solvents.



7. Front Seal
Front seal remain in the vacuum booster side, when removing
master cylinder.
9. Snap Ring
Remove the snap ring from the cylinder body with pushing in
the primary and secondary pistons.
10. Stopper Bolt and Gasket
Remove the stopper bolt from the cylinder body with pushing in
the primary and secondary pistons.


RTW 75CSH002201

11. Primary Piston
12. Secondary Piston
Don’t remove the spring from the piston.



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ISUZU KB P190 2007

BRAKES 5C-59



10. Filter
11. Diaphragm
12. Cap



RTW 75CSH002501








13. Front Seal
1. Lubricate the front seal with silicon grease (0.3 ~ 0.5g).



RTW 75CSH002601







2. Lubricate the front cylinder shell of vacuum booster with
silicon grease (0.2g).


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ISUZU KB P190 2007

5C-60 BRAKES
VACUUM BOOSTER
REMOVAL AND INSTALLATION




This illustration is based on the RHD model
RTW 75CMF000501


Removal Steps
▲ 1. Brake pipe
▲ 2. Master cylinder fixing nut
▲ 3. Bracket
▲ 4. Master cylinder assembly
5. Vacuum hose
6. Snap pin
7. Vacuum booster fixing nut
8. Gasket
9. Spacer
10. Vacuum booster assembly

Installation Steps
▲
10. Vacuum booster assembly
▲ 9. Spacer
▲ 8. Gasket
▲ 7. Vacuum booster fixing nut
▲ 6. Snap pin
▲ 5. Vacuum hose
4. Master cylinder assembly
3. Bracket
2. Master cylinder fixing nut
1. Brake pipe



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ISUZU KB P190 2007

BRAKES 5C-61




RTW 75CSH002701

Important Operation-Removal
1. Brake pipe
W hen hurdling, be careful not to spill brake fluid over the
painted surfaces, as damage to the paint finish will result.
2. Master Cylinder Fixing Nut
3. Bracket
4. Master Cylinder Assembly
NOTE:
W hen removing the master cylinder from the vacuum booster,
be sure to get rid of the internal negative pressure of the
vacuum booster (by, for instance, disconnecting the 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.
W hile removing the master cylinder, do not hold the piston as it
can be easily pulled out.



Inspection and Repair
Vacuum Hose (The built in check valve)
360R300002

1) Inspect the check valve, which is installed inside the
vacuum hose.
2) Blow air into the hose from the booster side as shown in the illustration. The air should pass freely through the
hose.
3) Blow air into the hose from the engine side. The check valve should close to block the passage of air.
The vacuum hose and built-in check valve must be
replaced as a set if either is found to be defective.

Important Operation-Installation
10. Vacuum Booster Assembly
Note:
•
Adjustment of push rod of vacuum booster is not carried
out. W hen vacuum booster is damaged it exchanges for a
new article. (Push rod is adjusted)
• Measurement of primary piston position by the side o
f
master cylinder is unnecessary.
9. Spacer
8. Gasket
7. Vacuum Booster Fixing Nut
6. Snap Pin
Install the vacuum booster assembly to the dash panel and
pedal mounting bracket.


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ISUZU KB P190 2007

5C-62 BRAKES

360r300003
5. Vacuum Hose
The check valve (2) is built-in to the vacuum hose.
W hen installing the vacuum hose make sure that the arrow on
the hose is facing the engine (1).
Note:
• Do not apply oil to the vacuum hose.
• Installation direction is very important. The booster will not
operate if the vacuum hose is installed in the wrong
direction.



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ISUZU KB P190 2007

BRAKES 5C-63
DISASSEMBLY

VACUUM BOOSTER ASSEMBLY





Disassembly Steps
1. Clevis; Yoke
2. Nut; VLV rod
3. Retainer; Guard
4. Guard; VLV body
5. Silencer
6. Filter








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ISUZU KB P190 2007

5C-64 BRAKES
REASSEMBLY
VACUUM BOOSTER ASSEMBLY




Reassembly Steps
1. Filter
2. Silencer
3. Guard; VLV body
▲ 4. Retainer; Guard
▲ 5. Nut; VLV rod
▲ 6. Clevis; Yoke


RTW 75CSH002901



Important Operations
4. Retainer; Guard
Ensure that the lug of the inner surface is fitted into the groove
of the ROD.

5. Nut; VLV Rod
Install the nut.

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ISUZU KB P190 2007