Isuzu N-Series. Service manual — part 225
HYDRAULIC BRAKES 5A-59
2. ATF Pipe
• Install ATF pipes to hydraulic booster.
3. Brake Pipe and Hose
• Install master cylinder hydraulic lines to master
cylinder.
4. Steering Wheel and Column Assembly
• Set steering wheel and column assembly.
• Install mounting bolts, nuts and screws to body.
• Install key bolt and nut.
Tighten:
Key bolt to 38 N
⋅m (3.9 kg⋅m / 28 lb⋅ft)
• Install inspection window.
5. Heat Protector
• Install hydraulic booster heat protector.
6. Instrument Panel and Duct
• Install ventilation duct and instrument panel as-
sembly.
7. Meter
• Install meter assembly and harness connector.
8. Meter CIuster
• Install meter cluster.
9. Battery ground cable.
10. After attaching it to the vehicle, always replenish
with new hydraulic oil (Besco ATF Ill), and com-
pletely release the air from the hydro boost.
11. Bleed brake lines.
12. Release the parking brake and remove the wheel
blocks.
N5A0208E
N5A0207E
5A-60 HYDRAULIC BRAKES
Hydraulic Booster
Legend
1. Clevis pin
4. Master cylinder
2. Hydraulic booster nut
5. Hydraulic booster
3. Master cylinder nut
N5A0212E
HYDRAULIC BRAKES 5A-61
Removal
1. Clevis Pin
2. Hydraulic Booster Nut
• Four hydraulic booster mounting nuts at pedal
bracket.
• Remove master cylinder with hydraulic boost-
er.
3. Mastcr Cylinder Nut
• Four nuts retaining master cylinder to hydraulic
booster.
4. Master Cylinder
5. Hydraulic Booster
Installation
1. Hydraulic Booster
2. Master Cylinder Assembly
3. Master Cylinder Nut
Tighten:
Master cylinder nut to 14 N
⋅m (1.4 kg⋅m / 122 lb⋅in)
4. Hydraulic Booster Nut
• Four hydraulic booster mounting nuts to pedal
bracket.
Tighten:
Hydraulic booster nut to 14 N
⋅m (1.4 kg⋅m / 122 lb⋅in)
5. Clevis Pin
• Connect hydraulic booster clevis to brake pedal
and install clevis pin.
N5A0213E
5A-62 HYDRAULIC BRAKES
Accumulator and O-ring Replacement
Removal
• BIock the vehicle and apply the parking brake.
• Disconnect the battery ground cable.
• Reduce the pressure of the hydraulic oil in the ac-
cumulator by brake pedal operation with the engine
off, and after confirming that the temperature of the
hydro boost assembly has been reduced, remove
the hydro boost assembly from the vehicle.
1) Remove meter cluster.
2) Remove meter assembly and harness connec-
tor.
3) Remove ventilation duct.
4) Using an oil filter wrench, remove accumulator
and O-ring.
Installation
1. Verify that there is no foreign matter adhering to
the screw part of the accumulator or to the attach-
ment part on the booster side.
2. Put an O-ring coated with new hydraulic oil (ATF
DEXRON
®
-III) into the screw part of the accumula-
tor, being careful not to damage it.
Always use a new O-ring.
3. Using an oil filter wrench, hold the accumulator
shell fixed, and tighten it via the wrench to the
specified torque.
Tighten:
Accumulator to 29 N
⋅m (3.0 kg⋅m / 22 lb⋅ft)
4. Install ventilation duct.
5. Connect harness connector and install meter as-
sembly.
6. Install meter cluster.
7. Connect the battery ground cable.
8. After attaching it to the vehicle, always replenish
with new hydraulic oil (ATF DEXRON
®
-III), and
completely release the air from the hydro boost.
9. Release the parking brake and remove the wheel
blocks.
Notice:
How to dispose of the accumulator
To dispose of the accumulator, drill a hole in the position
shown in the diagram according to the indications print-
ed on the accumulator, completely release the nitrogen
gas scaled inside the accumulator, then dispose of the
accumulator.
Concerning disposal with the hydro boost assembly as
well, dispose of it after first letting out all the nitrogen gas
inside the accumulator, by the above method.
Legend
1. Accumulator
2. Stud bolt
3. Cover boss
4. Lock nut
5. Clevis
6. Operating rod
7. Guard
8. Flange
N5A0010E
Legend
1. Accumulator
2. HEX25
3. Thread
4. O-ring
5. Drilling point for gas releasing
N5A0216E
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