Isuzu Trooper (2000 year). Manual — part 169
5C–24 POWER ASSISTED BRAKE SYSTEM
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
J-39242
Primary Piston Holder
(including master
cylinder attachment and
master cylinder plug
J-24460-01
Radiator Cap Tester
5C–25
POWER ASSISTED BRAKE SYSTEM
Vacuum Booster Assembly
Vacuum Booster Assembly and Associated Parts
331RW001
Legend
(1) Pin
(2) Vacuum Booster Fixing Nut
(3) Vacuum Hose
(4) Master Cylinder
(5) Vacuum Booster
(6) Snap Pin
Removal
1. Before removing the vacuum booster assembly,
disconnect and remove the brake pipes.
2. Remove master cylinder, refer to “Master Cylinder
Removal” in this section.
CAUTION: When 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.
While removing the master cylinder, further, do not
hold the piston as it can be easily pulled out.
Outside surface of the piston is the surface on which
seals are to slide. Care should be taken to keep the
surface free of cuts and dents.
3. Remove vacuum hose.
4. Disconnect the yoke clevis from the brake pedal.
5. Remove vacuum booster fixing nut.
6. Remove vacuum booster.
Inspection and Repair
Vacuum Hose
1. Inspect the check valve (2), which is installed inside
the vacuum hose.
2. Air should pass freely from the vacuum booster (3) to
the engine (1).
5C–26 POWER ASSISTED BRAKE SYSTEM
3. Air should not pass from the engine (1) to the vacuum
booster (3). If it does, the check valve is inoperative
and the vacuum hose built check valve must be
replaced.
360RY00002
Installation
1. Install vacuum booster and vacuum booster push rod
adjustment.
NOTE: When replacing either the master cylinder or
vacuum booster, be sure to measure push rod, and adjust
if required.
2. Remove retainer from vacuum booster front shell
using a small screwdriver. Then gently draw plate and
seal assembly out of the shell inside.
331RS003
3. Set push rod gauge J–39216 on vacuum booster, and
apply negative pressure by means of vacuum pump
J–23738–A so that the pressure in the vacuum
booster becomes 500 mm Hg.
NOTE: Be sure to apply NEGATIVE pressure after
installing a push rod gauge on the vacuum booster.
331RS004
4. Measure dimension (4).
Dimension (4) (Standard): –0.1–0.1 mm
(–0.0039–0.0039 in)
331RW002
5C–27
POWER ASSISTED BRAKE SYSTEM
5. If dimension (4) is out of the standard range, adjust
push rod using the Push Rod Support J–39241.
331RW003
6. Mount plate and seal assembly in vacuum booster
front shell. Then install the retainer.
7. Install vacuum booster fixing nut and tighten the
specified torque.
Torque: 21 N·m (16 lb ft)
8. Install yoke clevis.
9. Connect vacuum hose and make sure that the arrow
on the hose points in the direction of the engine.
10. Install master cylinder, refer to “Master Cylinder
Installation” in this section.
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