boot ISUZU TROOPER 1998 Service Owner's Manual

POWER ASSISTED BRAKE SYSTEM 5C – 57
3. Caliper Assembly
•Support the caliper assembly so that the brake
hose is not stretched or damaged.
4. Pad Assembly with Shim
5. Clip
INSTALLATION
5. Clip
Clip
4. Pad Assembly with Shim
•Apply special grease (approx. 0.2 g) to both
contacting surfaces of inner shims. Wipe off
extruded grease after installing.Inner shim
Wear indicator
Apply
special
grease
3. Caliper Assembly
1) Use adjustable pliers to bottom the piston into the
caliper bore. Be careful not to damage the piston
dust boot.
2) Do not damage the flexible hose by twisting or
pulling it.

5C – 62 POWER ASSISTED BRAKE SYSTEM
REBUILDING THE CALIPER
3465
7
9
1
23
8
Disassembly Steps
1. Guide bolt
2. Lock bolt
3. Dust boot
4. Dust boot ring
5. Piston
6. Dust boot; piston
7. Piston seal
8. Bleeder with cap
9. Caliper body
Reassembly Steps
9. Caliper body
8. Bleeder with cap
7. Piston seal
5. Piston
6. Dust boot; pisotn
4. Dust boot ring
3. Dust boot
2. Lock bolt
1. Guide bolt
DISASSEMBLY
1. Guide Bolt
2. Lock Bolt
3. Dust Boot
4. Dust Boot Ring
•Using a small screwdriver, remove the dust boot
ring.

POWER ASSISTED BRAKE SYSTEM 5C – 63
5. Piston
•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 dust
boot.
WARNING:
DO NOT PLACE YOUR FINGERS IN 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.
6. Dust Boot; Piston
7. Piston Seal
8. Bleeder with Cap
9. Caliper Body
REASSEMBLY
9. Caliper Body
8. Bleeder with Cap
Bleeder Torque N·m (kg·cm / lb·in)
8 (80 / 69)
7. Piston Seal
•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.
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
•Slide pin
•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.
5. Piston

5C – 64 POWER ASSISTED BRAKE SYSTEM
6. Dust Boot; Piston
•When inserting the piston into the cylinder, use
finger pressure only. Do not use a mallet or other
impact tools, since damage to the cylinder wall or
piston seal can result.
4. Dust Boot Ring
•Apply special grease (Approx. 1 g) to the piston
and attach the dust boot to the piston and caliper.
Insert the dust boot ring into the dust boot.
3. Dust Boot
•Install the dust boot on the support bracket after
applying special grease (Approx 1 g) onto the
dust boot inner surface. Also apply special grease
onto the lock bolt and guide bolt setting hole of
the support bracket.
2. Lock Bolt
1. Guide Bolt
Guide Bolt Torque N·m (kg·m / lb·ft)
44 (4.5 / 32)

6E±324
ENGINE DRIVEABILITY AND EMISSIONS
5. Secure the gasket and the throttle body with the four
bolts.

The vacuum lines must be properly routed under
the throttle body before tightening the mounting
bolts.
Tighten

Tighten the throttle body mounting bolts to 24 N´m
(17 lb ft.).
035RW024
6. Install the coolant lines.
7. Connect all the vacuum lines.
8. Install the intake air duct.
9. Tighten the intake air duct clamp.
10. Connect all the electrical connectors:

Throttle position (TP) sensor.

Idle air control (IAC) solenoid.

Intake air temperature (IAT) sensor. Refer to
Intake Air Temperature Sensor.
035RW023
11. Install the accelerator cable assembly. Refer to
Accelerator Cable in Engine Speed Control System..
12. Fill the cooling system. Refer to
Cooling System.
13. Install the negative battery cable.
Electronic Ignition System
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector at the ignition coil.
3. Remove the two screws that secure the ignition coil to
the rocker cover.
014RW108
4. Remove the ignition coil and the spark plug boot from
the spark plug.

Twist the ignition coil while pulling it straight up.
014RW091
5. Use the spark plug socket in order to remove the
spark plug from the engine.

6E±325 ENGINE DRIVEABILITY AND EMISSIONS
Spark Plug Gap Check

Check the gap of all spark plugs before installation.

Use a round wire feeler gauge to ensure an accurate
check.

Plugs installed with the wrong gap can cause poor
engine performance and excessive emissions.
Installation Procedure
NOTE: The plug must thread smoothly into the cylinder
head and be fully seated. Use a thread chaser if
necessary to clean the threads in the cylinder head.
Cross-threading or failure to fully seat the spark plug can
cause plug overheating, exhaust blow-by gas, or thread
damage. Do not overtighten the spark plugs. Over
tightening can cause aluminum threads to strip.
1. Install the spark plug in the engine. Use the
appropriate spark plug socket.
Tighten

Tighten the spark plug to 18 N´m (13 lb ft.).
2. Install the ignition coil and spark plug boot over the
spark plug.
014RW108
3. Secure the ignition coil to the rocker cover with two
screws.
014RW091
4. Connect the electrical connector at the ignition coil.
5. Connect the negative battery cable.
Catalytic Converter
Removal and Installation Procedure
Refer to Engine Exhaust in Engine.
Air Conditioning Relay
Removal Procedure
1. Remove the fuse and relay box cover from under the
hood.
2. Consult the diagram on the cover to determine which
is the correct relay.
3. Insert a small screwdriver into the catch slot on the
forward side of the fuel pump relay.

The screwdriver blade will release the catch inside.
T321092

6E±345 ENGINE DRIVEABILITY AND EMISSIONS
0014
Crankshaft Position (CKP) Sensor
The crankshaft position (CKP) sensor provides a signal
used by the powertrain control module (PCM) to calculate
the ignition sequence. The sensor initiates the 58X
reference pulses which the PCM uses to calculate RPM
and crankshaft position. Refer to
Electronic Ignition
System
for additional information.
Electronic Ignition
The electronic ignition system controls fuel combustion
by providing a spark to ignite the compressed air/fuel
mixture at the correct time. To provide optimum engine
performance, fuel economy, and control of exhaust
emissions, the PCM controls the spark advance of the
ignition system. Electronic ignition has the following
advantages over a mechanical distributor system:

No moving parts.

Less maintenance.

Remote mounting capability.

No mechanical load on the engine.

More coil cooldown time between firing events.

Elimination of mechanical timing adjustments.

Increased available ignition coil saturation time.
0013
Ignition Coils
A separate coil-at-plug module is located at each spark
plug. The coil-at-plug module is attached to the engine
with two screws. It is installed directly to the spark plug by
an electrical contact inside a rubber boot. A three-way
connector provides 12-volt primary supply from the
15-amp ignition fuse, a ground-switching trigger line from
the PCM, and a ground.
0001
Ignition Control
The ignition control (IC) spark timing is the PCM's method
of controlling the spark advance and the ignition dwell.
The IC spark advance and the ignition dwell are
calculated by the PCM using the following inputs:

Engine speed.

7C±24CLUTCH
Slave Cylinder
Disassembled View
206RW004
Legend
(1) Cylinder Body
(2) Spring(3) Piston and Piston Cup
(4) Boot
(5) Push Rod
Disassembly
1. Remove boot.
2. Remove push rod.
3. Remove piston and piston cup.
4. Remove spring.
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.
Cylinder Body
206RS003
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it
if necessary.