torque ISUZU TROOPER 1995 Workshop Manual

5A-1 0 HYDRAULIC BRAKES
8. Turn the ignition key off.
• If the warning light does not come on during
steps 3 and
6, but does light when a jumper is
connected to ground, the warning switch
portion
of the valve is faulty. Do not
disassemble any portion of the valve. It must
be replaced.
9. Remove the safety stands.
• Lower the vehicle.
• Check and fill the master cylinder to the proper
level.
VALVE REPLACEMENT
Removal steps 1. Hydraulic pipes
2. Warning switch
connector (Combination valve only)
3. Bolt
4. Combination valve/P&B valve
Installation
steps
To install, follow the removal steps in the reverse order.
Fig. 5A-5
1••1 REMOVAL
• The combination valve/P & 8 valve is not
repairable and must be replaced as a complete
assembly.
• Care must be taken to prevent brake fluid from
contacting any painted surface.
1. Hydraulic pipes
• Plug the pipes to prevent the loss of fluid or the
entrance
of dirt.
2. Warning switch connector (Combination valve
only)
3. Bolt
4. Combination valve/P & B valve
1••1 INSTALLATION
4.
3. Combination valve/P & B valve
Bolt
I~I_T_o_r_qu_e_N_·_m_(lb_·_in_) ___,_ ___ 1_3_(_1_13_) __ _
2. Warning switch connector (Combination valve
only)
1. Hydraulic pipes
~~~ Torque N·m (lb·ft) 16 (12)
After installing the brake pipes, bleed brakes as
described in this section.
•

HYDRAULIC BRAKES SA-13
BRAKE PEDAL ASSEMBL V
CHECKING PEDAL HEIGHT (Fig. SA-1 0)
The push rod serves as the brake pedal stopper when
the pedal is fully released. Brake pedal height
adjustment
should be performed as follows:
I~FI Adjust brake pedal
1. Measure the brake pedal height after making sure
the pedal is
fully returned by the pedal return
spring. Pedal height
(L2) must be measured after starting
the engine and revving
it several times (Fig. 5A-
10).
1~1 Pedal Free Play (L 1) mm (in) 6-10 (0.23- 0.39)
Pedal Height (L2)
NOTE:
mm (in) 208-218
(8.19-8.58)
Pedal free play (L 1) must be measured after turning off
the engine and stepping on the brake pedal firmly five
times
or more.
2. If the measured value is not within the above
range, adjust the brake
pedal as follows:
a) Disconnect the stoplight switch connector.
b) Loosen the stoplight switch lock nut.
c) Rotate the stoplight switch so that it moves
away
from the brake pedal.
d) Loosen the lock nut on the push rod.
e) Adjust the brake pedal to the specified height
by rotating the push rod in the appropriate
direction.
f) Tighten the lock nut to the specified torque.
~~~ Torque N·m (lb·ft) 20 (15) --------~----~---
Fig. 5A-10
g) Adjust the stoplight switch to the specified
clearance (between switch housing and brake
pedal)
by rotating the switch housing (Fig. 5A-
11 ).
1@1 Clearance mm (in) I 0.5-1.0 (0.02-0.04)
NOTE:
While adjusting the stoplight switch, make sure that
the threaded part of the stoplight switch does not push
the brake
pedal.
h) Tighten the stoplight switch lock nut.
i) Connect the stoplight switch connector.
Fig.
5A-11
CHECKING PEDAL TRAVEL (Fig. SA-1 0)
1. Pedal height (L3) must be measured after starting
the engine and revving
it several times to apply
vacuum
to the vacuum booster fully.
NOTE:
Pedal height (L3) must be 55 mm (2.2 in) or more when
about 50 kg (11 0.25 I b) of stepping force is applied.
2. If the measured value is lower than the above
range, air existing in the hydraulic system is
suspected and perform bleeding procedure.

5A-14 HYDRAULIC BRAKES
BRAKE PEDAL REPLACEMENT
5
3
1
13
Removal steps MIT
1. Shift knob 6. Anti-theft controller 12. Pin, fulcrum
2. Front console assembly 7. Stoplight switch connector 13. Brake pedal
3. Lower cluster assembly
4.1nstrument panel
driver lower
cover
5. Driver knee bolster assembly
8. Return spring
9. Snap pin
10. Pin
11. Nut
Installation steps
To install, follow the removal steps
in the reverse order.
Fig. 5A-12
EJ REMOVAL
1. Shift knob
2. Front console assembly
3. Lower cluster assembly
4. Instrument panel driver lower cover
5. Driver knee bolster assembly
6. Anti-theft controller
7. Stoplight switch connector
8. Return spring
9. Snap pin
10. Pin
11.
Nut
12. Pin, fulcrum
13. Brake pedal
1•+1 INSTALLATION
13.
Brake pedal
12. Pin, fulcrum
§)• Apply grease to the entire circumference of the
fulcrum pin.
~~~ Torque N·m (lb·ft) ___ __._ ___ _ 33 (24)
11. Nut
~~~--T-o-rq_u_e __ N-.m--(-lb-.ft-)-.-----3-3-(-24_) ____ _
10. Pin
r:::;:] • Apply grease to the entire circumference of the
D push rod pin. ·
9. Snap pin
f;C1 • Adjust pedal free travel. Refer to "Brake Pedal
lED Adjustment" previously in this section.
8. Return spring
7. Stoplight switch connector
6. Anti-theft connector
5. Driver knee bolster assembly
4. Instrument panel driver lower cover
3. Lower cluster assembly
2. Front console assembly
1. Shift knob
•

SA 16 HYDRAULIC BRAKES
MASTER CYLINDER ASSEMBLY
GENERAL DESCRIPTION
The master cylinder contains two pistons that supply
the hydraulic pressure
for a dual-circuit braking
system. The primary piston provides the fluid pressure
to the
front brakes, while the secondary piston
provides the fluid pressure
to the rear brakes. l.f ~he
pressure is lost from either system, the rema1n1ng
system will function to stop the vehicle.
\fl CAUTION:
VI • The master cylinder is not repairable. If found
defective,
it must be replaced as complete
assembly.
• If any hydraulic component is removed or
disconnected, it may be necessary to bleed all
or part of the brake system. (Refer to "On­
Vehicle Service" previously in this section.)
• The torque values specified are for dry,
unlubricated fasteners.
• Perform service operations on a clean bench
free
from all mineral oil materials.
Fig.
5A-15
•

SA-18 HYDRAULIC BRAKES
MASTER CYLINDER ASSEMBL V
6
2
Removal steps
1.
Electrical connector
2. Brake pipes
3. 2 attaching nuts
4. Combination valve/P&B
valve and bracket
5. Master cylinder
6.
Spacer and 2gaskets
Installation steps
To
install, follow the removal steps in the reverse order.
5
4
Fig. 5A-19
1••1 REMOVAL
\i7 CAUTION:
'V When removing master cylinder from vacuum
booster, be sure
to get rid of the internal negative
pressure
of the vacuum booster (by, for instance,
disconnecting 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 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.
1.
Electrical connector
2. Brake pipes
• After disconnecting the brake pipe, cap or tape
the openings
of the brake pipe to prevent the
entry of foreign matter.
3. 2
attaching nuts
4. Combination valve/P & B valve and bracket
5. Master cylinder
6. Spacer and 2 gaskets
1••1 INSTALLATION
6. Spacer and 2 gaskets
5. Master cylinder
• When replacing the master cylinder or vacuum
booster
or both, always measure the vacuum
booster push rod protrusion and adjust
it as
necessary. (Refer to "Vacuum Booster
Assembly" in Section 5A 1.)
4. Combination valve/P & B valve and bracket
3. 2 attaching nuts
• Tighten the attaching nuts to the specified
torque.
~~~ Torque N·m (lb·in) 13 (113)
2. Brake pipes
• Tighten the brake pipe to the specified torque.
1~1 Torque Master cylinder side 12 (1041b·in)
N·m (lb·ft) Others
16 (12)
1. Electrical connector
•

HYDRAULIC BRAKES 5A-21
MAIN DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
Brake pedal
Pedal
free play
Pedal
height
Parking brake
Type Brake
handle(stem) travel
Master cylinder
Type
Piston bore diameter
TORQUE SPECIFICATIONS
mm (in)
mm (in)
mm (in)
13 (1131b·in)
Fig. 5A-23 6
to 10 (0.23 to 0.39)
208 to 218
(8.19 to 8.58)
Duo-servo
6 to 7 notches
When
pulled with a force of 30 kg (66 lb)
Dual-circuit
25.4 (1.000)
4-Wheel Antilock Brake System
N·m {lb·ft}
-Brake fluid pipe line -Flexible hose
Rear Wheel Antilock Brake System
-Brake fluid pipe line -Flexible hose

BRAKE BOOSTER SYSTEM 5A 1-1
SECTION 5A1
BRAKE BOOSTER SYSTEM
W CAUTION:
• Fasteners are an important attaching part in that they could affect performance of vital parts and systems,
and/or could result in major repair expense. They must be replaced with one of the same part number or with
an equivalent part if replacement becomes necessary. Do not use replacement parts of lesser quality or
substitute design. Torque values must be used as specified during reassembly to assure proper retention of
these parts.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . SA 1-1 Vacuum Booster .................... SA1-6
Diagnosis ..................... See Section SA Main Data and Specifications ........... SA1-6
On-Vehicle Service ................... SA1-2 General Specifications ............... SA1-6
Vacuum Booster Assembly ........... SA1-2 Torque Specifications ................ SA1-6
Exterior Components ................ SA1-4 Special Tools ......................... SA1-7
Unit Repair .......................... SA1-6
GENERAL DESCRIPTION
This booster is a tandem vacuum unit with a
diaphragm effective diameter
205 mm + 230 mm. In
normal operating mode, with the service brakes in the
released position, the tandem vacuum booster
operates
with vacuum on both sides of its diaphragms.
When the brakes are
applied, air at atmospheric
pressure is admitted
to one side of each diaphragm to
provide the power assist. When the service brake is
released, the atmospheric air is shut off from the one
side
of each diaphragm. The air is then drawn from the
booster through the vacuum check
valve to the
vacuum source.
W CAUTION:
• If any hydraulic component IS removed or
disconnected, it may be necessary to bleed all
or part of the brake system.
Fig.
5A1-1
• The torque values specified are for dry,
unlubricated fasteners.
• The vacuum booster is not repairable and must
be replaced as complete assembly.

[1!) INSPECTION AND REPAIR
Visual check:
'-"' Make necessary parts replacement if cuts, nicks,
excessive wear,
or other abnormal conditions are
found through inspection.
Check the following parts.
• Yoke clevis
• Valve
body guard
• Silencer
• Filter
• Plate
and seal assembly.
I••IINSTALLATION
11. Plate and seal assembly
1 0. Retainer
9. 2 gaskets and spacer
8. Filter
7. Silencer
6. Valve body guard
5. Retainer
4. Lock nut
20 (15) 1~1 Torque N·m (lb·ft) ----------1....---
3. Yoke clevis
2. Vacuum booster
• Refer to "Vacuum Booster Installation" in this
section.
'-"" 1. Master cylinder
• Refer to "Master Cylinder Installation" in
Section 5A.
• After installation, perform brake pedal check
and adjustment. Refer
to "Brake Pedal
Assembly" in Section 5A.
BRAKE BOOSTER SYSTEM 5A 1-5

5A 1-6 BRAKE BOOSTER SYSTEM
UNIT REPAIR
VACUUM BOOSTER
• The vacuum booster cannot be disassembled
for repair. Replace a defective vacuum booster
with a new one.
MAIN DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
Vacuum booster diaphragm diameter
Front
Rear
Push rod stroke
Plunger diameter
Push rod diameter
TORQUE SPECIFICATIONS
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
13 (1131b·in)
Fig. 5A1-10
205 (8.07)
230 (9.06)
More than 32.0 (1.26)
10.25 (0.40)
27.4 (1.08)
N·m (lb·ft)
.............................................. ----------------------------------~ .

DISC BRAKES 5A2-1
SECTION 5A2
DISC BRAKES
w CAUTION:
All brake attaching fasteners are an important attaching part in that they could affect performance of vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of the same
part
number or with an equivalent part if replacement becomes necessary. Do not use replacement parts of
lesser quality or substitute design. Torque values must be used as specified during reassembly to assure
proper retention of these parts.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . 5A2-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A2-1
Diagnosis
..................... See Section SA
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 5A2-2
Front Disc Brakes . . . . . . . . . . . . . . . . . . . . 5A2-2
Brake Pads
Inspection . .

. . . . . . . . . . . . 5A2-2
Brake Pads Replacement . . . . . . . . . . . 5A2-3
Servicing
the Rotor . . . . . . . . . . . . . . . . 5A2-4
Caliper Replacement . .

. . . . . . . . . . . . . 5A2-6
Rebuilding
the Caliper . . . . . . . . . . . . . 5A2-8 Rear
Disc Brakes .................... 5A2-1 0
Brake
Pads Inspection ............. 5A2-1 0
Brake Pads Replacement ........... 5A2-1 0
Servicing the Rotor ............... 5A2-12
Caliper Replacement .............. 5A2-14
Rebuilding the
Caliper ............. 5A2-17
Parking Brakes . . . . . . . . . . . . . . . .
See Section SC
Main Data and Specifications ........... 5A2-19
General Specifications ............... 5A2-19
Torque Specifications
............... 5A2-19
GENERAL DESCRIPTION
The disc brake assembly consists of a caliper, piston,
rotor, pad assembly and
support bracket. The caliper
assembly has a single bore and is mounted to the
support bracket with 2 mounting bolts. The support
bracket allows the caliper to move laterally against the
rotor. The
caliper is a one-piece casting with the
inboard side containing the piston bore. A square cut
rubber
seal is located in a groove in the piston bore
which provides the hydraulic seal between the piston
and the cylinder
wall.
NOTE:
• Replace all components included in repair kits
used
to service this caliper.
• Lubricate rubber parts with clean brake fluid to
ease assembly.
• If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or
part of the brake system.
• Replace pads in axle sets only.
•
The torque values specified are for dry,
unlubricated fasteners.
• Perform service operation a clean bench free
from all mineral oil materials.
OPERATION
Hydraulic pressure, created by applying the brake
pedal, is converted by the caliper to a stopping force.
This force acts
equally against the piston and the
bottom of the caliper bore to move the piston outward
and to move (slide) the caliper inward resulting in a
clamping action on the rotor. This clamping action
forces the
linings against the rotor, creating friction to
stop the vehicle.