2007 ISUZU KB P190 brakes

5C-26 BRAKES

A bleeding operation is necessary to remove air from the
hydraulic brake system whenever air is introduced into the
hydraulic system. It may be necessary to bleed the hydraulic
system at all four brakes if air has been introduced through a
low fluid level or by disconnecting brake pipes at the maste
r
cylinder. If a brake pipe is disconnected at one wheel, only that
wheel cylinder/caliper needs to be bled. If the pipes are
disconnected at any fitting located between the master cylinde
r
and brakes, then the brake system served by the disconnected
pipe must be bled.

1. Set the parking brake completely, then start the engine.
NOTE:
The vacuum booster will be damaged if the bleeding operation
is performed with the engine off.
2. Remove the master cylinder reservoir cap.


RTW 75CSH001701
3. Fill the master cylinder reservoir with brake fluid. Keep the
reservoir at least half full during the air bleeding operation.
4. Always use new brake fluid for replenishment.
5. In replenishing brake fluid, take care that air bubbles do not enter the brake fluid.

W hen the master cylinder is replaced or overhauled, first
bleed the air from the master cylinder, then from each
wheel cylinder and caliper following the procedures
described below.



RTW 75CSH001801
Bleeding the Master Cylinder
6. Disconnect the rear wheel brake pipe (1) from the master
cylinder.
Check the fluid level and replenish as necessary. I
f
replenished, leave the system for at least one minute.
7. Depress the brake pedal slowly once and hold it depressed.
8. Completely seal the delivery port of the master cylinder with your finger, where the pipe was disconnected, then release
the brake pedal slowly.
9. Release your finger from the delivery port when the brake pedal returns completely.
10. Repeat steps 7 through 9 until the brake fluid comes out o
f
the delivery port during step 7.
NOTE: Do not allow the fluid level in the reservoir to go belo
w
the half-way mark.
11. Reconnect the brake pipe (1) to the master cylinder and tighten the pipe.
12. Depress the brake pedal slowly once and hold it depressed.
13. Loosen the rear wheel brake pipe (1) at the master cylinder.
14. Retighten the brake pipe, then release the brake pedal slowly.

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ISUZU KB P190 2007

BRAKES 5C-27

15. Repeat steps 12 through 14 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.



RTW 75CSH001801
16. Bleed the air from the front wheel brake pipe connection (2)
by repeating steps 6 through 15.

Bleeding the Caliper
17. Bleed the air from each wheel in the order listed below: • Right rear wheel cylinder
• Left rear wheel cylinder
• Left front caliper
• Right front caliper
Conduct air bleeding from the wheels in the above order. I
f
no brake fluid comes out, it suggests that air is mixed in the
master cylinder. In this case, bleed air from the maste
r
cylinder in accordance with steps 6 through 16, and then
bleed air from the caliper or wheel cylinder.


RTW 35CSH000501
18. Place the proper size box end wrench over the bleeder
screw.
19. Cover the bleeder screw with a transparent tube, and submerge the free end of the transparent tube in a
transparent container containing brake fluid.


3
5042
20. Pump the brake pedal (3) slowly three times (once/sec),
then hold it depressed.
21. Loosen the bleeder screw until fluid flows through the tube.
22. Retighten the bleeder screw.
23. Release the brake pedal slowly.
24. Repeat steps 20 through 23 until the air is completel
y
removed.
It may be necessary to repeat the bleeding procedure 10 o
r
more times for front wheels and 15 or more times for rear
wheels.
25. Go to the next wheel in the sequence after each wheel is bled.
Be sure to monitor reservoir fluid level.
26. 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.




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ISUZU KB P190 2007

5C-28 BRAKES

27. After the bleeding operation is completed on each individual
wheel, check the level of the brake fluid in the reservoir and
replenish up to the “MAX" level as necessary.
28. Attach the reservoir cap.
29. Stop the engine.




05007-1

BRAKE LINE (HOSES AND PIPES)
• Inspect all hoses and pipes for wear, bending, chafing,
cracks, dents, or any other damage.
Make necessary correction or replace parts if these abnormal conditions are found through inspection.
• All hoses, pipes and joints can be damaged easily.
Do not allow the hose to become excessively twisted and bent when working with them, and pay special attention to
all the brake lines not to damage them when repairing o
r
replacing other parts (axle, suspension, etc).
• Inspection for leakage should be performed by depressing
the brake pedal fully.
If leakage is apparent at the circumference of joints, retighten or replace these parts.
This procedure must be performed whenever brake lines are installed.
• After disconnecting the hoses and pipes, cap or tape the
openings to prevent entry of foreign material.



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ISUZU KB P190 2007

BRAKES 5C-29
ADJUSTMENT PROCEDURE OF SERVICE AND PARKING BRAKE


Stick type
All brakes are self-adjusting.
Brakes are adjusted by repeated stepping on the brake pedal.
(After stepping on the pedal and releasing it, the rear brake
auto-adjuster, produces a clicking sound.
The same operation should be repeated until the sound
disappears.)
Take the following steps after overhauling the rear brake
assembly.
1. Move the parking brake lever to its fully released position.

311R300007





























































2. Parking cable must be loosened sufficiently.
(Loosen the adjust nut and the lock nut.)
3. Repeat stepping on the brake pedal firmly and releasing it until the clicking sound can no longer be heard.
If the difference between the brake drum inside diameter o
f
the brake shoes is adjusted to be 0.5 mm, the number of
times for depressing the brake pedal can be reduced.
4. Remove the drum.
Measure the brake drum inside diameter and diameter o
f
the brake shoes.
Shoe Clearance mm (in)
0.25 - 0.40 (0.0098 - 0.0157)
If incorrect, check the brake auto-adjusting system.
5. Turn the adjuster nut so that the parking brake lever travels 10 notches when pulled up with a force 30 kg (66 lbs.).
6. Make sure there is no brake drag.




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5C-30 BRAKES

Floor mount type
All brakes are self-adjusting.
Brakes are adjusted by repeated stepping on the brake pedal.
(After stepping on the pedal and releasing it, the rear auto-
adjuster, in the rear brake, produces a clicking sound.
The same operation should be repeated until the sound
disappears.)
Take the following steps after overhauling the rear brake
assembly.
1. Move the parking brake lever to its fully released position.
2. Parking cable must be loosened sufficiently.
(Loosen the adjust nut and the lock nut.)
3. Repeat stepping on the brake pedal firmly, and releasing it until the clicking sound can no longer be heard.
If the difference between the brake drum inside diameter o
f
the brake shoes is adjusted to be 0.5 mm (0.020 in), the
number of times for depressing the brake pedal can be
reduced.
4. Remove the drum.
Measure the brake drum inside diameter and diameter o
f
the brake shoes.


Shoe Clearance mm (in)
0.25 - 0.40 (0.010 - 0.016)
If incorrect, check the brake auto-adjusting system.



RUW 55CSH000301
5. Turn the adjuster nut so that the parking brake lever travels
7 notches when pulled up with a force 294N (30 kg / 66 lb).
6. Make sure there is no brake dragging.





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BRAKES 5C-31
ADJUSTMENT PROCEDURE OF BRAKE PEDAL



The push rod serves as the brake pedal stopper when the
pedal is fully released.
Brake pedal height adjustment should be performed as follows.

RTW 35CSH000601


Brake Pedal - Height
Measure the brake pedal height after making sure the pedal is
fully returned by the pedal return spring.
Note:
Pedal height (L2) must be measured after starting the
engine and increasing the revolution several times by
stepping on the accelerator pedal. mm (in)
Pedal free play (L1) 6 - 10 (0.24 - 0.39)
M/T 174 - 186 (6.85 - 7.32) Height (L2)
A/T 176 - 188 (6.93 - 7.40)
Note:
Pedal free play must be measured after turning off the
engine and stepping on the brake pedal firmly five times
or more.
If the measured value deviates from the above range, adjust
the brake pedal as follows:
a) Disconnect the stop lamp switch.
b) Loosen the lock nut on the push rod.
c)
Adjust the brake pedal to the specified height by rotating the
push rod in the appropriate direction.



Lock Nut Torque
N⋅m (kgf ⋅m/lb ⋅
⋅⋅
⋅
ft)
15 - 25 (1.5 – 2.5 / 11 - 18)

d) Install the stop lamp switch.

Note:
Pedal height (L
2) must be 57 mm (2.24 in.) or more when
applying about 50 kg (110.25 lbs.) of stepping force.

331R300005

How to connect the CLEVICE of the BOOSTER ROD with the
PEDAL ARM and how to adjust the PEDAL SW .
After connecting the CLEVIS of the BOOSTER ROD to the
PEDAL ARM, adjust the PEDAL SW mounted (PDA) to the
PEDAL BRACKET using the procedure explained below.
1. Set the hole of the CLEVIS of the BOOSTER & M/CYL
ROD with the hole in the PEDAL ARM.
2. Enter the PIN; PUSH ROD to the PEDAL to the holes from the left side of the PEDAL.
3. Enter and fix the PIN; SNAP PIN FIX to the DITCH o
f
the PIN; PUSH ROD to PEDAL from right side of the
PEDAL.
4. Release the LOCK by turning the SW ITCH counter- clock-wise.

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5C-32 BRAKES

5. Pull the PEDAL ARM a little towards you so that the
PEDAL ARM is not pushed in.
6. Holding the PEDAL ARM still with one hand, push in the whole SW ITCH with the other hand until the PLUNGER
of the SW ITCH is pushed in and the SW ITCH itself hits
the RUBBER of the PEDAL ARM.
In this condition, turn the SW ITCH clock-wise until a “click” sound is heard and lock it.
By doing this the SW ITCH is adjusted at 0.7 ±0.5 mm
(0.028 ± 0.020 in) clearance.



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BRAKES 5C-33
FRONT DISC BRAKE ASSEMBLY
REMOVAL AND INSTALLATION



RTW 55CMF000501

Removal Steps
1. Brake flexible hose
2. Lock bolt
3. Caliper assembly
4. Pad assembly with shim
5. Clip; pad
6. Slide pin
7. Boot
8. Support bracket
9. Front hub and disc assembly

Installation Steps
9. Front hub and disc assembly
8. Support bracket
7. Boot
6. Slide pin
5. Clip; pad
4. Pad assembly with shim
3. Caliper assembly
2. Lock bolt
1. Brake flexible hose



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