Isuzu N-Series. Manual — part 232
HYDRAULIC BRAKES 5A-87
10. Install the return spring (1).
Install the closed hook of return spring to pin side.
11. Install the piston (1).
Apply grease to the outer circumference of piston
and groove of piston cup (2), and install the
grease-applied piston cup.
12. Install the boot (1).
Apply grease to the boot installation groove of cyl-
inder, fill the grease to inside of boot and install it.
Grease: BESCO rubber grease
13. Install the bleeder (1) to cylinder assembly (2).
Tighten:
Bleeder to 6.9 — 11.8 N
⋅m (0.7 — 1.2 kg⋅m / 5.1 — 8.7
lb
⋅ft)
1
N5A0459E
1
2
N5A0460E
1
N5A0461E
1
2
N5A0462E
5A-88 HYDRAULIC BRAKES
Master Cylinder Assembly (NHR)
Disassembly
1. Hose Clamp
2. Hose Joint
Use a pair of pliers to remove the hose joint.
Take care not to damage the hose joint and the cyl-
inder body.
3. Stopper Screw and Gasket
4. Snap Ring
5. Primary Piston Assembly
Legend
1. Hose clamp
5. Primary piston assembly
2. Hose joint
6. Secondary piston assembly
3. Stopper screw and gasket
7. Cylinder body
4. Snap ring
N5A0266E
N5A0267E
HYDRAULIC BRAKES 5A-89
6. Secondary Piston Assembly
7. Cylinder Body
Inspection and Repair
Make the necessary adjustments, repairs, and part re-
placements if excessive wear or damage is discovered
during inspection.
Cylinder Body
Visually check that the master cylinder bore, for scuff or
scratch, if these conditions are presented, the cylinder
body must be replaced.
Piston and Master Cylinder Clearance
1. Use a micrometer to measure the piston diameter.
2. Use an inside dial indicator to measure the cylinder
bore.
3. Calculate the clearance between the wheel cylin-
der and the piston.
If the clearance exceeds the specified limit, the pis-
ton assembly must be replaced.
Reassembly
1. Cylinder Body
Clean the cylinder body and blow the return ports
with compressed air.
Do not allow the return ports clogged with any for-
eign material.
2. Secondary Piston Assembly
Piston and Master Cylinder Clearance
mm (in)
Standard
Limit
0.11 — 0.195
(0.004 — 0.008)
0.22 (0.009)
N5A0268E
N5A0269E
N5A0271E
5A-90 HYDRAULIC BRAKES
3. Primary Piston Assembly
1) Rinse the piston assembly in clean brake fluid.
2) Install the piston assembly to the master cylin-
der.
Notice:
Take care not to scratch the primary and secondary
cups when installing the piston assembly.
4. Snap Ring
5. Stopper Screw and Gasket
1) Slide the piston until the oil cavity of the sec-
ondary piston dears the stopper bolt hole.
2) Install the stopper screw and tighten it to the
specified torque.
Tighten:
Stopper screw to 27 N
⋅m (2.8 kg⋅m / 20 lb⋅ft)
6. Hose Joint
7. Hose Clamp
1) Set the clamp in position.
2) Dip the hose joint in hot water (60 — 80
°C / 140
— 176
°F) for several minutes.
3) Take out of the hose joint and blow off water im-
mediately and completely.
4) Fit the hose joint to the cylinder body.
5) Align the position of the clamp screw as shown
in the illustration.
6) Tighten the clamp screw to the specified
torque.
Tighten:
Clamp screw to 2 N
⋅m (0.2 kg⋅m / 17 lb⋅in)
N5A0272E
N5A0273E
N5A0274E
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