Isuzu KB P190. Manual — part 185

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 indicator
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.

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 caliper
bore grooves.

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 bellow

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.
When 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 or
replacement.

RTW35CSH000701

When 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.

5C-44 BRAKES

5. Bleeder

Torque N

⋅m (kgf⋅m/Ib⋅ft)

9 – 16 (0.9 – 1.6 / 6.5 – 12)

6. Cap