2007 ISUZU KB P190 brake

5C-36 BRAKES





1. Brake Flexible Hose
Attach the bolt and new gasket
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
29 -39 (3.0 - 4.0 / 22 - 29)

After installation, the bleeding and replenishing procedure must
be performed.
W ipe the circumference of the hose clean.
Note:
•
••
•
Always use new gaskets.
• Be sure to put the hooked edge of the flexible hose end
into the anti-rotation cavity.

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ISUZU KB P190 2007

BRAKES 5C-37
REMOVAL AND INSTALLATION OF DISC PAD




RUW 55CSH001501

Removal Steps
1. Lock Bolt
Remove the lock bolt from the caliper.
Note:
Don’t remove the brake hose from the caliper when
replacing pads.



2. Rotate the Caliper Upward
Remove the caliper from the support bracket and move the
caliper to the upper link or the frame.
Note:
While caliper is removed from the support bracket, neve
r
step on the brake pedal or the piston will protrude rapidly.




RUW 55CSH001601

3. Pad Assembly with Shim
Remove the pad assembly with the shim.
Mark the pad locations if they are to be reinstalled.



4. Clip; Pad
Discard the used clip and install a new one.


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ISUZU KB P190 2007

5C-38 BRAKES


Installation Steps
1. Clip; Pad
2. Pad Assembly with Shim
After attaching the pad assembly with the shim to the support
bracket, position the wear indicator to the lower side of the
inner pad and position the wear indicator to the upper side o
f
the outer pad.

RUW 55CSH001701

3. Caliper Assembly
Lower the caliper into its original position.
Do not damage the flexible hose by twisting or pulling it.




RUW 55CSH000201
4. Lock Bolt
Attach the lock bolt to the caliper.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
32 - 40 (3.3 – 4.1 / 24 - 30)




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ISUZU KB P190 2007

BRAKES 5C-39
DISASSEMBLY

CALIPER ASSEMBLY


Disassembly Steps
1. Bleeder with cap
▲ 2. Piston
3. Dust seal; piston
4. Ring seal
5. Body; caliper








Important Operations


2. Piston (with Ring Seal)
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 seal.

CAUTION:
Do not place your fingers in front of the piston in an
attempt to catch or protect it when applying compressed
air.


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ISUZU KB P190 2007

5C-40 BRAKES
INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found
through inspection.



• Rotor
• Caliper body
• Cylinder bore
• Piston
• Support bracket
• Lock bolt
• Guide pin



Visual Check
Inspect the following parts for wear, bending, distortion,
cracking, corrosion, or other abnormal conditions.





Rotor
• Thickness (t) mm (in)
StandardReplacement thickness
(Discard)
4×2
(Except HIGH RIDE) 26.0 (1.024)
24.6 (0.969)
4×2
(HIGH RIDE) 4×4 27.0 (1.063) 25.6 (1.008)


•
Run out
Limit mm (in)
0.075 (0.0029)

Before inspection, adjust the wheel bearing correctly.
Using a dial gauge, measure the run-out at the 10 mm inside
position from the rotor out-side edge of the disc pad contact
surface.


•
Parallelism (Total circumferential thickness variation)
Limit mm (in)
0.023 (0.0009)

Contact surface must be within 0.023 mm at the 10 mm inside
position from rotor-out side edge.
(Measurement; should be measured at more than 8 positions
in circumferential direction.)


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ISUZU KB P190 2007

BRAKES 5C-41












Thickness of Disc Pad
Thickness (t) mm (in)

Standard Limit
10.0 (0.394) 1.8 (0.071)

Replace the front disc pad whenever the pad wear indicato
r
makes a squeaking noise or when the pad is worn to within 1.8
mm of the shoe table.

All four brake pads should be replaced together.

302R300019


Seal and Boot
The dust seal, dust boot and ring seal should be replaced each
time the caliper is overhauled.
Discard these used rubber parts.


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ISUZU KB P190 2007

5C-42 BRAKES
REASSEMBLY
CALIPER ASSEMBLY


Reassembly Steps
▲ 1. Body; caliper
▲ 2. Ring seal
▲ 3. Dust seal; piston
▲ 4. Piston
▲ 5. Bleeder
▲ 6. Cap






Important Operations
1. Body; Caliper
2. Ring Seal
Apply clean brake fluid to the ring seal and cylinder wall, then
insert the ring seal into the cylinder.
Ensure that the piston ring seal are not twisted in the calipe
r
bore grooves.


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ISUZU KB P190 2007

BRAKES 5C-43







3. Dust seal; Piston
• Apply grease to piston groove and dust seal boot.
1) Make sure a piston and its groove area are free from dust.
2) Use 0.5g to apply grease to groove area thoroughly using a brush or finger.
Make sure color of groove changes as shown bello
w
after apply grease.





3) After assembling a dust seal boot to the piston, apply
1.5g to contact area of the piston and the dust seal boot
as shown in the picture bellow.

4. Piston
Apply clean brake fluid to the piston, and attach the caliper.
W hen inserting the piston into the cylinder, use finger pressure
only. Do not use a mallet or other impact tool, since damage to
the cylinder wall or ring seal can result.
The movement of a caliper piston into a caliper bore should be
smooth and even. If a caliper piston is frozen or difficult to
move to the bottom, the caliper requires overhaul o
r
replacement.
RTW 35CSH000701
W hen not entering with a finger, insert a discarded inner brake
pad (2) or block of wood in front of the pistons. Using 2 large
C-clamps (1) installed over the body of the caliper (3) and
against the brake pad or block of wood, slowly move the
pistons evenly into the bores.
Insert the dust seal ring into the dust seal.
CAUTION:
Pistons made of plastic material.
Do not hit the piston with a hammer etc. and don’t grasp
the face of the piston with pliers.


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ISUZU KB P190 2007