ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Master Cylinder

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REMOVAL & INSTALLATION




WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded.

Except Hombre

See Figures 1, 2, 3 and 4



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Fig. Fig. 1: Disconnect the level indicator harness at the master cylinder



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Fig. Fig. 2: Use a suitable flare-end or box wrench to disconnect the bake lines from the master cylinder



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Fig. Fig. 3: Remove the retainer nuts securing the master cylinder to the booster



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Fig. Fig. 4: Lift the master cylinder off the booster studs

  1. Apply the parking brake and block the drive wheels.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Using a turkey baster or other suitable device, remove as much brake fluid from the reservoir as possible.
  6.  

Brake fluid is highly corrosive to paint. Take care not to spill brake fluid on any painted surface of the vehicle.

  1. Disconnect the reservoir fluid level indicator harness at the master cylinder, if equipped.
  2.  
  3. Tag and remove all brake lines from the master cylinder using a suitable flare or box-end wrench. Plug the lines to prevent system contamination or excessive fluid loss.
  4.  
  5. Remove the retainer nuts securing the master cylinder in place.
  6.  
  7. Remove the master cylinder by pulling straight out.
  8.  
  9. Remove the reservoir from the top of the master cylinder if needed. Grasp the reservoir and gently rock it back and forth as you pull it out.
  10.  

To install:
  1. In order to ease installation, bench bleed the master cylinder before installation:
    1. Plug the master cylinder outlet ports. This can be done using rubber or plastic plugs or, more effectively, using a single length of brake line with appropriately sized flares/flare nuts on each end.
    2.  
    3. Mount the cylinder in a soft-jawed vise with the front end tilted slightly downward.
    4.  
    5. Fill the reservoir with clean brake fluid, then use a tool with a smooth rounded end (such as a wooden dowel or pencil eraser) to stroke the primary piston about 1 in. (25mm) several times. As air is bled from the cylinder, the primary piston will no longer travel the full distance.
    6.  
    7. Reposition the master cylinder in the vise with the front end tilted slightly up, then continue stroking the primary piston to further bleed air.
    8.  
    9. Reposition the master cylinder so it is level, then loosen the plugs one at a time and push the piston into the bore, forcing air from the cylinder. DO NOT allow the piston to return with the plugs loosened or air will be drawn back into the master cylinder.
    10.  
    11. Make sure the plugs are tightly sealed, then check and refill the reservoir.
    12.  

  2.  
  3. Install the reservoir to the master cylinder, if removed. Apply a coating of brake fluid to the reservoir seals, then press the reservoir in place.
  4.  
  5. Attach the master cylinder to the mounting stud in the engine compartment. Before installing the retainer nuts, make sure the master cylinder is properly seated, and the brake pedal pushrod is position correctly in the master cylinder. Install the retainer nuts and hand-tighten.
  6.  
  7. Tighten the master cylinder retainer nuts to 113 inch lbs. (13 Nm).
  8.  
  9. Install the brake lines to the master cylinder. Tighten the line fittings to 105 inch lbs. (12 Nm).
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Bleed and refill the entire brake system.
  14.  

Hombre

See Figure 5



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Fig. Fig. 5: Master cylinder assembly-Hombre

  1. Apply the parking brakes and block the drive wheels.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Using a turkey baster or other suitable device, remove as much brake fluid from the reservoir as possible.
  6.  

Brake fluid is highly corrosive to paint. Take care not to spill brake fluid on any painted surface of the vehicle.

  1. Tag the brake lines installed to the master cylinder. Use a line wrench to loosen and disconnect the hydraulic lines from the master cylinder. Immediately plug the lines to prevent system contamination or excessive fluid loss.
  2.  
  3. Disconnect the pushrod from the brake pedal.
  4.  
  5. Remove the master cylinder attachment nuts, then separate the combination valve/bracket from the master cylinder.
  6.  
  7. Remove the master cylinder and, as equipped, the gasket and/or rubber boot from the vehicle.
  8.  

To install:
  1. In order to ease installation, bench bleed the master cylinder before installation:
    1. Plug the master cylinder outlet ports. This can be done using rubber or plastic plugs or, more effectively, using a single length of brake line with appropriately sized flares/flare nuts on each end.
    2.  
    3. Mount the cylinder in a soft-jawed vise with the front end tilted slightly downward.
    4.  
    5. Fill the reservoir with clean brake fluid, then use a tool with a smooth rounded end (such as a wooden dowel or pencil eraser) to stroke the primary piston about 1 in. (25mm) several times. As air is bled from the cylinder, the primary piston will no longer travel the full distance.
    6.  
    7. Reposition the master cylinder in the vise with the front end tilted slightly up, then continue stroking the primary piston to further bleed air.
    8.  
    9. Reposition the master cylinder so it is level, then loosen the plugs one at a time and push the piston into the bore, forcing air from the cylinder. DO NOT allow the piston to return with the plugs loosened or air will be drawn back into the master cylinder.
    10.  
    11. Make sure the plugs are tightly sealed, then check and refill the reservoir.
    12.  

  2.  
  3. Position the master cylinder in the engine compartment, then attach the combination valve bracket over the studs.
  4.  
  5. Install the master cylinder/combination valve bracket retaining nuts and tighten to 27 ft. lbs. (36 Nm).
  6.  
  7. Working on one line at a time, remove the plugs and quickly connect the brake lines to the master cylinder. Tighten each of the line nuts to 20 ft. lbs. (27 Nm).
  8.  
  9. Connect the pushrod to the brake pedal.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Refill the master cylinder with clean brake fluid, then bleed the hydraulic brake system and check the brake pedal travel.
  14.  
  15. When all service is finished, remove the blocks from the drive wheels.
  16.  

 
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