Installation - Isuzu 1999 RODEO Workshop Manual

Functional Inspection of Master Cylinder
Piston
Push the primary piston (1) with your fingers to check that
it travels smoothly. If the motion is questionable, replace
the master cylinder as a complete assembly.
Functional Inspection of Master Cylinder
Inspect the master cylinder for function as follows. If any
abnormal function is found, replace with a new one.
Install the primary piston holder (3) J–39242 (including
the master cylinder attachment (5) and master cylinder
plug (7)) onto the master cylinder (4). Make sure the
spacer (2) (2 bolts) with its adjusting bolt is screwed in up
to the "0" line
Connect the master cylinder attachment (5) J–39242 with
the end of the radiator cap tester (6) J–24460–01, and
apply air pressure with the cap tester. Make sure there is
no rise in pressure and that with the adjusting bolt further
screwed in 5 mm (align the adjusting bolt to the "5" line).
There should be a pressure increase of 0.5 kg/cm
more.
POWER–ASSISTED BRAKE SYSTEM
NOTE: When checking the front (or primary) side, be
sure to mount the master cylinder plug in the rear (or
secondary) port.
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Apply air
pressure to the
front and rear
ports
Remarks
NOTE:
1. Do not use an air compressor, as the air from the
compressor is mixed with compressor oil.
2. When installing the master cylinder onto the vacuum
booster, always adjust the vacuum booster push rod.
(Refer to "Vacuum Booster" in this section).
3. After the master cylinder is installed onto the vehicle,
check for leakage, pedal travel and pedal free play.

Installation

1. Install spacer and the 2 gaskets.
2. Install 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" in section).
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3. Install P&B valve and bracket.
4. Install 2 attaching nuts and tighten the attaching nuts
to the specified torque.
Torque: 13 N·m (113 lb in)
2
or
"0" Line "5" Line
No pressure Pressure
rise. increase of 0.5
2
kg/cm
Checks port Checks air
into the tightness of the
atmospheric pressure
pressure chamber
chamber
5C–23
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or more