torque ISUZU AXIOM 2002 Service Repair Manual

5C±92
POWER±ASSISTED BRAKE SYSTEM
3. Carefyully use adjustable pliers to bottom the piston
into the caliper bore. Do not pull or twist the flexible
hose or damage will occur.
Install caliper assembly.
Set caliper assembly in place.
4. Install lock bolt (5) and tighten the bolt to the specified
torque.
Torque: 45 N´m (33 lb ft)
302R200008
5. Install wheel and tire assembly, refer to Wheels and
Tires System
in Section 3E.
6. Pump the brake pedal several times to make sure that
the pedal is firm. Check the brake fluid level in the
reservoir after pumping the brakes.

5C±96
POWER±ASSISTED BRAKE SYSTEM
4. Since the brake fluid flows out from the connecting
coupler, place a drain pan under the vehicle.
5. Remove pin bolt (2).
302R200020
6. Remove caliper assembly.
7. Remove support bracket with pad assembly and take
care not to damage the flexible brake hose when
removing the support bracket.
8. Remove pad assembly with shim and mark the lining
locations if they are to be reinstalled.
9. Remove clip.
Installation
1. Install clip.
302R200023
2. Apply special grease (approximately 0.2 g) to both
contacting surfaces of the inner shims (4). Wipe off
extruded grease after installing. Install pad assembly
with shim.
302R200025
Legend
(4) Inner Shim
(5) Wear Indicator
(6) Inner Side
3. Install support bracket and tighten the bolt (7) to the
specified torque.
Torque: 155 N´m (115 lb ft)
302R200009

5C±97 POWER±ASSISTED BRAKE SYSTEM
4. Install caliper assembly.
5. Install pin bolt (8) and tighten the bolt to the specified
torque.
Torque: 45 N´m (33 lb ft)
302R200010
6. Install brake flexible hose, always use new gaskets
and be sure to put the hooked edge of the flexible
hose end into the anti±rotation cavity then tighten the
I±bolt (9) to the specified torque.
Torque: 35 N´m (26 lb ft)
302R200021
7. Install wheel and tire assembly, referring to Wheels
and Tires System
in Section 3E.
8. Bleed brakes. Refer to
Hydraulic Brakes in this
section.

5C±99 POWER±ASSISTED BRAKE SYSTEM
2. Remove dust boot: piston.
3. Remove piston seal.
4. Remove bleeder with cap.
5. Remove caliper body.
Inspection and Repair
Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:

Rotor

Cylinder body

Cylinder bore

Piston

Guide pin, lock pin

Support bracket
NOTE: The piston seal, boot ring and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace them with new ones.
Reassembly
1. Install caliper body.
2. Install bleeder with cap and tighten the cap to the
specified torque.
Torque: 8 N´m (69 lb in)
3. Apply special rubber grease to the piston seal and
cylinder wall, then insert the piston seal into the
cylinder. The special rubber grease is included in the
repair kit.
302R200013
4. When inserting the piston into the cylinder, use finger
pressure only and do not use a mallet or other impact
tool, since damage to the cylinder wall or piston seal
can result.
Install piston.
302R200015
5. Apply special grease (approximately 1 g) to the piston
and attach the dust boot to the piston and caliper.
Insert the dust boot ring into the dust boot.
6. Install guide bolt and lock bolt dust boot.
7. Install the dust boot on the support bracket after
applying special grease (approximately 1 g) onto the
dust boot inner surface. Apply special grease onto the
lock pin and guide pin setting hole of the support
bracket.
302R200022
Legend
(1) Guide Pin
(2) Lock Pin
(3) Pin Boot
8. Install pin bolt and tighten the bolt to the specified
torque.
Torque: 45 N´m (33 lb ft)

5C±100
POWER±ASSISTED BRAKE SYSTEM
Main Data and Specifications
General Specifications
TypeFloating, pin slide
Pad dimension48.7 cm
(7.55 in
)
Adjusting methodSelf±adjusting
Piston diameter45.4 mm (1.79 in) y2
Disc typeVentilated
Disc thickness26 mm (1.02 in)
Disc effective diameter242 mm (9.53 in)
Torque Specifications
E05R200008

5C±103 POWER±ASSISTED BRAKE SYSTEM
306RW005
3. Carefyully use adjustable pliers to bottom the piston
into the caliper bore. Do not pull or twist the flex hose
or damage will occur.
302RS008
4. Install lock bolt (5) and tighten the bolt to the specified
torque.
Torque: 44 N´m (32 lb ft)
306R200003
5. Install wheel and tire assembly, referring to Wheels
and Tires System
in Section 3E.
6. Pump the brake pedal several times to make sure that
the pedal is firm. Check the brake fluid level in the
reservoir after pumping the brakes.

5C±107 POWER±ASSISTED BRAKE SYSTEM
10. Remove clip.
Installation
1. Install clip (4).
306RW010
2. Apply special grease (approximately 0.2 g) to both
contacting surfaces of the inner shims (5). Wipe off
extruded grease after installing. Install pad assembly
with shim.
306RW011
Legend
(5) Inner Shim
(6) Wear indicator
3. Install support bracket and tighten the bolt (7) to the
specified torque.
Torque: 103 N´m (76 lb ft)
306RW012
4. Install caliper assembly.
5. Install lock bolt and guide bolt (8) and tighten the bolt
to the specified torque.
Torque: 44 N´m (32 lb ft)
306R200004
6. Install brake flexible hose, always use new gaskets
and be sure to put the hooked edge of the flexible
hose end into the anti±rotation cavity then tighten the
eye±bolt (9) to the specified torque.
Torque: 35 N´m (26 lb ft)

5C±109 POWER±ASSISTED BRAKE SYSTEM
Disassembly
1. Remove guide bolt.
2. Remove lock bolt.
3. Remove dust boot; guide bolt and lock bolt.
4. Remove dust boot ring, using a small screwdriver.
302RS016
5. Insert a block of wood into the caliper and force out
the piston by blowing compressed air into the caliper
at the flexible hose attachment. This procedure must
be done prior to removal of the dust boot.
Remove piston.
WARNING: D O N O T P L A C E Y O U R F I N G E R S I N
FRONT OF THE PISTON IN AN ATTEMPT TO CATCH
OR PROTECT IT WHEN APPLYING COMPRESSED
AIR. THIS COULD RESULT IN PERSONAL INJURY.
CAUTION: Use just enough air to ease the piston
out of the bore. If the piston is blown out, it may be
damaged.
302RS017
6. Remove dust boot: piston.
7. Remove piston seal.
8. Remove bleeder with cap.
9. Remove caliper body.
Inspection and Repair
Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:

Rotor

Cylinder body

Cylinder bore

Piston

Guide bolt, lock bolt

Support bracket
NOTE: The piston dust seal and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace with new ones.
Reassembly
1. Install caliper body.
2. Install bleeder with cap and tighten the cap to the
specified torque.
Torque: 8 N´m (69 lb ft)
3. Install piston seal and apply special rubber grease to
the piston seal and cylinder wall, then insert the piston
seal into the cylinder. The special rubber grease is
included in the repair kit.
302RS018
4. When inserting the piston into the cylinder, use finger
pressure only and do not use a mallet or other impact
tool, since damage to the cylinder wall or piston seal
can result.
Install piston.

5C±110
POWER±ASSISTED BRAKE SYSTEM
302RS019
5. Apply special grease (approximately 1g) to the piston
and attach the dust boot to the piston and caliper.
Insert the dust boot ring into the dust boot.
302RS020
6. Install guide bolt and lock bolt dust boot.
7. Install the dust boot on the support bracket after
applying special grease (Approx. 1g) onto the dust
boot inner surface. Also apply special grease onto the
lock bolt and guide bolt setting hole of the support
bracket.
302RS021
8. Install lock bolt and guide bolt and tighten the bolt to
the specified torque.
Torque: 44 N´m (32 lb ft)

5C±111 POWER±ASSISTED BRAKE SYSTEM
Main Data and Specifications (4y4 Model)
General Specifications
TypeFloating, pin slide
Pad dimension33 cm
(5.11 in
)
Adjusting methodSelf±adjusting
Piston diameter41.3 mm (1.63 in)
Disc typeVentilated
Disc thickness18 mm (0.71 in)
Disc effective diameter269.2 mm (10.60 in)
Torque Specifications
E05RW005