Isuzu Trooper (1998-2002 year). Service manual — part 228
5C – 64 POWER ASSISTED BRAKE SYSTEM
6. Dust Boot; Piston
•
When inserting the piston into the cylinder, use
finger pressure only. Do not use a mallet or other
impact tools, since damage to the cylinder wall or
piston seal can result.
4. Dust Boot Ring
•
Apply special grease (Approx. 1 g) to the piston
and attach the dust boot to the piston and caliper.
Insert the dust boot ring into the dust boot.
3. Dust Boot
•
Install the dust boot on the support bracket after
applying special grease (Approx 1 g) onto the
dust boot inner surface. Also apply special grease
onto the lock bolt and guide bolt setting hole of
the support bracket.
2. Lock Bolt
1. Guide Bolt
Guide Bolt Torque
N·m (kg·m / lb·ft)
44 (4.5 / 32)
POWER ASSISTED BRAKE SYSTEM 5C – 65
UNIT REPAIR
MASTER CYLINDER
The master cylinder is not repairable and must be
replaced as complete assembly if found defective.
INSPECTION
Excessive brake pedal travel, malfunction or dragging
brake suggests that the master cylinder is defective.
In such cases perform the following visual check.
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
Primary piston
FUNCTIONAL INSPECTION OF MASTER
CYLINDER PISTON
Push the primary piston with your fingers to check
that it travels smoothly. If the motion is questionable,
replace the master cylinder as a complete assembly.
FUNCTIONAL INSPECTION OF MASTER
CYLINDER
Inspect the master cylinder for function as follows. If
any abnormal function is found, replace with a new
one.
Primary piston holder: 5-8840-2306-0 (J-39242)
(including master cylinder attachment and master
cylinder plug)
•
Install the primary piston holder onto the master
cylinder with the spacer (2 bolts) with its adjusting
bolt screwed in up to the “0” line.
Master cylinder
Spacer
5-8840-2306-0
Primary piston holder
"0" line
"5" line
5C – 66 POWER ASSISTED BRAKE SYSTEM
Radiator cap tester: 5-8840-0277-0 (J-24460-01)
•
Connect master cylinder attachment with the end
of radiator cap tester, and apply air pressure with
the cap tester. Make sure there is no rise in
pressure and that with the adjusting bolt further
screwed in 5 mm (align the adjusting bolt to the
“5” line). There should be a pressure increase of
49 kpa (0.5 kg/cm
2
/7.1 psi) or more.
NOTE:
When checking the front (or primary) side, be sure to
mount master cylinder plug in the rear (or secondary)
port.
NOTE:
1) Do not use an air compressor, as the air from
compressor is mixed with compressor oil.
2) When installing the master cylinder onto the
vacuum booster, always adjust vacuum booster
push rod. (Refer to Vacuum Booster Assembly in
this section.)
3) After the master cylinder is installed onto the
vehicle, check for leakage, pedal travel and pedal
free play.
Master cylinder
plug
Master cylinder attachment
5-8840-0277-0
Radiator cap tester
5-8840-2306-0
“0” line
“5” line
Apply air
No pressure
Pressure
pressure to
rise.
increase of
the front and
49 kpa (0.5 kg/cm
2
/
rear ports
7.1 psi) more
Remarks
Check port into
Checks air
the atmospheric
tightness of the
pressure
pressure
chamber
chamber
POWER ASSISTED BRAKE SYSTEM 5C – 67
VACUUM BOOSTER
•
The vacuum booster cannot be disassembled for
repair. Replace a defective vacuum booster with a
new one.
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