ISUZU KB P190 2007 Workshop Repair Manual

5C-52 BRAKES
BRAKE CONTROL
REMOVAL AND INSTALLATION

BRAKE PEDAL ASSEMBLY


This illustration is based on the RHD model
310R300001

Removal Steps
1. Nut; Fulcrum pin
2. Pin; Fulcrum, pedal to bracket
3. Pedal arm
4. Return spring
5. Pedal pad

Installation steps
To install, follow the removal procedure in
reverse order.
Before installation, apply grease to the entire
circumference of the fulcrum pin (2).
Refer to “SERVICING” in this section for
adjustment procedure of brake pedal.



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ISUZU KB P190 2007

BRAKES 5C-53
MASTER CYLINDER
REMOVAL AND INSTALLATION

MASTER CYLINDER ASSEMBLY






This illustration is based on the RHD model

RTW 75CMF000901

Removal Steps
▲ 1. Brake line
2. Nut; Master cylinder to vacuum booster
3. Master cylinder assembly

Installation Steps
3. Master cylinder assembly
▲ 2. Nut; Master cylinder to vacuum booster
▲ 1. Brake line






RTW 75CSH002701

Important Operation - Removal
1. Brake Line
Be very careful not to spill brake fluid on the painted surface.
Damage to the painted surface will result.








Important Operation - Installation
2. Nut; Master Cylinder to Vacuum Booster
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
10 – 16 (1.0 – 1.6 / 7 – 12)

1. Brake Line
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
13 – 19 (1.3 – 1.9 / 9 – 14)

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ISUZU KB P190 2007

5C-54 BRAKES
DISASSEMBLY




RTW 75CMF000701

Disassembly Steps
1. Cap
2. Diaphragm
3. Filter
4. Pin
5. Reservoir tank
6. Grommet
▲ 7. Front seal


8. Guide assembly
▲ 9. Snap ring
▲ 10. Stopper bolt and gasket
▲ 11. Primary piston
▲ 12. Secondary piston
13. Cylinder body


Note:
• Be sure to replace the designated with new ones.
• W ash the disassembled parts in clean brake fluid.
• Use compressed air to clean the ports.
• Do not allow dirt and dust to contaminate the disassembled
parts.



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ISUZU KB P190 2007

BRAKES 5C-55
Important Operations
W hen disassembling, inspecting or reassembling the master
cylinder assembly, take care not to bring the parts into contact
with mineral oil or dust. W ash the piston cups only with brake
fluid. Do not use gasoline or other mineral-base cleaning
solvents.



7. Front Seal
Front seal remain in the vacuum booster side, when removing
master cylinder.
9. Snap Ring
Remove the snap ring from the cylinder body with pushing in
the primary and secondary pistons.
10. Stopper Bolt and Gasket
Remove the stopper bolt from the cylinder body with pushing in
the primary and secondary pistons.


RTW 75CSH002201

11. Primary Piston
12. Secondary Piston
Don’t remove the spring from the piston.



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ISUZU KB P190 2007

5C-56 BRAKES
INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found
through inspection.




• Cylinder body inside face
• Piston
• Piston cup
• Return port, Supply port
• Return spring
• Guide assembly (O-ring, Cup)
• Front seal



Visual Check
Inspect the following parts for wear, distortion, cuts, nicks,
corrosion, or other abnormal conditions.






RTW 75CSH002401

Return Port
Check the return port for obstructions and if necessary, clean
with a tag wire.
Blow away foreign matter with compressed air.


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ISUZU KB P190 2007

BRAKES 5C-57
REASSEMBLY



RTW 75CMF000801

Reassembly Steps
▲ 1. Secondary piston
▲ 2. Primary piston
▲ 3. Guide assembly
▲ 4. Cylinder body
▲ 5. Stopper bolt and gasket
▲ 6. Snap ring
▲ 7. Grommet


▲
8. Reservoir tank
▲ 9. Pin
▲ 10. Filter
▲ 11. Diaphragm
▲ 12. Cap
▲ 13. Front seal



1. Secondary Piston
Lubricate the piston cups on the secondary piston assemblies
with brake fluid.
Note:
Be sure to use a new piston.


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ISUZU KB P190 2007

5C-58 BRAKES




RTW 75CSH002301






























2. Primary Piston
Lubricate the piston cup on the primary piston assemblies with
brake fluid (1).
Note:
Be sure to use a new piston.
3. Guide Assembly
Lubricate the O-ring of guide assembly with brake fluid (2) and
the cup of guide assembly with rubber grease (3) (0.2 ~ 0.3g).



RTW 75CSH002001

4. Cylinder Body
Install the secondary piston and the primary piston to the
cylinder body.
Note:
The secondary piston long hole and the cylinder body stoppe
r
bolt hole must be aligned at installation.










5. Stopper Bolt and Gasket
Install the stopper bolt to the cylinder body (the piston long hole
must be aligned with the cylinder body installation hole).
Tighten the bolts to the specified torque.

Torque N ⋅m (kgf ⋅m/lb ⋅in)
2 - 3 (0.2 - 0.3 / 17 - 26)




6. Snap Ring
Press down on the primary piston and install the snap ring to
the cylinder body groove.
Note:
Be sure to use new snap ring.


7. Grommet
1. Install the grommets to the reservoir tank.
Note:
Be sure to use are new grommets.
2. Install the reservoir tank to the cylinder body.

8. Reservoir Tank
9. Pin


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ISUZU KB P190 2007

BRAKES 5C-59



10. Filter
11. Diaphragm
12. Cap



RTW 75CSH002501








13. Front Seal
1. Lubricate the front seal with silicon grease (0.3 ~ 0.5g).



RTW 75CSH002601







2. Lubricate the front cylinder shell of vacuum booster with
silicon grease (0.2g).


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ISUZU KB P190 2007

5C-60 BRAKES
VACUUM BOOSTER
REMOVAL AND INSTALLATION




This illustration is based on the RHD model
RTW 75CMF000501


Removal Steps
▲ 1. Brake pipe
▲ 2. Master cylinder fixing nut
▲ 3. Bracket
▲ 4. Master cylinder assembly
5. Vacuum hose
6. Snap pin
7. Vacuum booster fixing nut
8. Gasket
9. Spacer
10. Vacuum booster assembly

Installation Steps
▲
10. Vacuum booster assembly
▲ 9. Spacer
▲ 8. Gasket
▲ 7. Vacuum booster fixing nut
▲ 6. Snap pin
▲ 5. Vacuum hose
4. Master cylinder assembly
3. Bracket
2. Master cylinder fixing nut
1. Brake pipe



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ISUZU KB P190 2007

BRAKES 5C-61




RTW 75CSH002701

Important Operation-Removal
1. Brake pipe
W hen hurdling, be careful not to spill brake fluid over the
painted surfaces, as damage to the paint finish will result.
2. Master Cylinder Fixing Nut
3. Bracket
4. Master Cylinder Assembly
NOTE:
W hen 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.
W hile removing the master cylinder, do not hold the piston as it
can be easily pulled out.



Inspection and Repair
Vacuum Hose (The built in check valve)
360R300002

1) Inspect the check valve, which is installed inside the
vacuum hose.
2) Blow air into the hose from the booster side as shown in the illustration. The air should pass freely through the
hose.
3) Blow air into the hose from the engine side. The check valve should close to block the passage of air.
The vacuum hose and built-in check valve must be
replaced as a set if either is found to be defective.

Important Operation-Installation
10. Vacuum Booster Assembly
Note:
•
Adjustment of push rod of vacuum booster is not carried
out. W hen vacuum booster is damaged it exchanges for a
new article. (Push rod is adjusted)
• Measurement of primary piston position by the side o
f
master cylinder is unnecessary.
9. Spacer
8. Gasket
7. Vacuum Booster Fixing Nut
6. Snap Pin
Install the vacuum booster assembly to the dash panel and
pedal mounting bracket.


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ISUZU KB P190 2007