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2004 impreza service manual quick reference index chassis section

1. BR 00104 1 Clutch pedal 2 Brake pedal BR 00105 1 Brake pedal 2 Check the position of pedal pad Pedal height L 148 mm 5 83 in BR 71 Brake Pedal BRAKE Brake pedal free play A 1 3 mm 0 04 0 12 in Depress brake pedal pad with a force of less than 10 N 1 kof 2 Ib BR 00106 Stop light switch Mat Toe board Brake booster operating rod 3 If it is not within specified value adjust it by ad justing the brake booster operating rod length BR 72 Stop Light Switch 19 Stop Light Switch A REMOVAL 1 Disconnect the ground cable from battery 2 Disconnect the stop light switch connector 3 Loosen nuts and unscrew stop light switch to re move BR 00107 1 Stop light switch B INSTALLATION 1 Screw the stop light switch onto a bracket and secure it temporarily with a nut 2 Adjust the stop light switch position and then tighten the nut Ref to BR 73 ADJUSTMENT Stop Light Switch Tightening torque T 8 N m 0 8 kgf m 5 8 ft Ib BR 00108 C INSPECTION 1 If the stop light switch does not operate properly or if it does not stop at the specified position re place with a new one BRAKE Specified position L 2 mm 0 079 in L We EE BR 00109 2 Measure the clearance between threaded end of sto
2. BR 00022 6 Raise the caliper body and then move it toward vehicle center to separate it from support 7 Remove the support from housing BRAKE NOTE Remove the support only when replacing it or the rotor It need not be removed when servicing the caliper body assembly BR 00023 8 Clean mud and foreign particles from the caliper body assembly and support 2 16 INCH TYPE CAUTION Do not allow brake fluid to come in contact with vehicle body wash away with water and wipe off completely if spilled 1 Set the vehicle on lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the front wheel 4 Remove the union bolt and then disconnect the brake hose from caliper body assembly 5 Remove the caliper body from housing BR 00298 6 Clean mud and foreign particles from the caliper body assembly and support 3 17 INCH TYPE CAUTION Do not allow brake fluid to come in contact with vehicle body wash away with water and wipe off completely if spilled 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the front wheel BR 31 Front Disc Brake Assembly BRAKE 4 Remove the brake pads from caliper body Ref to BR 26 17 INCH TYPE REMOVAL Front Brake Pad gt 5 Remove the union bolt and brake hose from cal iper body assembly 6 Remove two installation bolts from housing
3. BR 00299 1 Union bolt 2 Installation bolt 7 Clean mud and foreign particles from the caliper body assembly B INSTALLATION 1 14 INCH AND 15 INCH TYPE 1 Install the support on housing Tightening torque 80 N m 8 2 kgf m 59 ft Ib 2 Apply thin coat of Molykote AS880N Part No K0777Y A010 to the frictional portion between pad and pad clip 3 Apply thin coat of Molykote AS880N Part No K0777Y A010 to the frictional portion between pad and inner shim ANS BR 00015 4 Install the pads on support 5 Install the caliper body on support Tightening torque 37 N m 3 8 kgf m 27 5 ft Ib 6 Replace the brake hose gaskets with new ones and then connect the brake hose Tightening torque 18 N m 1 8 kgf m 13 0 ft Ib 7 Bleed air from the brake system 2 16 INCH TYPE 1 Install the caliper body on housing Tightening torque 80 N m 8 2 kgf m 59 ft Ib 2 Apply thin coat of Molykote AS880N Part No K0777Y A010 to the frictional portion between pad and pad inner shim BR 00328 3 Install the pads on caliper body 4 Install the pad pins and cross spring on caliper body 5 Install the M clip 6 Replace the brake hose gaskets with new ones and then connect the brake hose Tightening torque 18 N m 1 8 kgf m 13 0 ft Ib 7 Bleed air from the brake system 3 17 INCH TYPE 1 Install the caliper body assembly on housing Tightening
4. 1 Upper shoe return spring 2 Adjusting spring B INSTALLATION 1 Clean the back plate and wheel cylinder 2 Apply grease to portions indicated by arrows in the figure Brake grease Dow Corning Molykote No 7439 Part No 003602001 3 Apply grease to the adjusting screw and both ends of adjuster BR 00053 Brake grease Dow Corning Molykote No 7439 Part No 003602001 Zei BR 00054 4 Connect the upper shoe return spring to shoes 5 Connect the parking brake cable to parking le ver 6 While positioning the shoes one at a time in groove on wheel cylinder secure the shoes BR 00055 1 Wheel cylinder 2 Shoe Trailing 7 Fix the shoes by connecting hold down cup to hold down pin 8 Connect the lower shoe return spring 9 Set the outside diameter of brake shoes less than 0 5 to 0 8 mm 0 020 to 0 031 in in compari son with inside diameter of brake drum C INSPECTION 1 Measure the lining thickness If the thickness of lining is outside the service limit replace the shoes Lining thickness Standard 4 1 mm 0 161 in Service limit 1 5 mm 0 059 in 2 If the deformation or wear of back plate shoe etc are notable replace them 3 When the shoe return spring tension is exces sively weakened replace it taking care to identify the upper and lower springs BR 48 Drum Brake Drum BRAKE
5. 9 Rear Drum Brake Drum A REMOVAL 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the wheels 4 Release the parking brake 5 Remove the brake drum from brake assembly NOTE If it is difficult to remove the brake drum remove the adjusting hole cover from back plate and then turn the adjuster assembly pawls using a flat tip screwdriver until brake shoe separates from drum Do 6 BR 00046 1 2 3 4 5 6 Back plate Wheel cylinder Adjuster ASSY pawls Adjusting lever Tightening direction Push RR RR f the brake drum is difficult to remove drive it out by installing an 8 mm bolt into bolt hole in the brake drum BR 00047 B INSTALLATION Set the outside diameter of brake shoes less than 0 5 to 0 8 mm 0 020 to 0 031 in in comparison with inside diameter of brake drum C INSPECTION 1 If the inside surface of brake drum is streaked correct the surface And if it is unevenly worn ta peringly streaked or the outside surface of brake drum is damaged correct or replace it 2 Measure the drum inner diameter If the inner di ameter of drum is outside the service limit replace the drum Drum inner diameter L Standard 228 6 mm 9 in Service limit 230 6 mm 9 08 in BR 00058 BR 49 Rea
6. Cable end portion of lever Grease SUNLIGHT 2 Part No 003602010 3 Adjust the PHV cable Ref to BR 77 ADJUST MENT Hill Holder CAUTION After replacing with new one operate the clutch pedal about 30 times as a running in operation prior to adjustment BR 76 Hill Holder BRAKE D ADJUSTMENT Confirm stopping and starting performances by ac tivating the hill holder on an uphill road of 3 or high er inclination 1 If the vehicle does not stop Tighten the adjusting nut of PHV cable 2 If the vehicle does not start properly Case A When the hill holder is released later than engagement of clutch pedal Engine tends to stall Loosen adjusting nut gradually until smooth start ing is enabled Case B When the hill holder is released earlier than engagement of clutch pedal Vehicle slips down slightly Tighten the adjusting nut so that hill holder is re leased later than engagement of clutch pedal sta tus in Case A Then make adjustment the same as in Case A CAUTION Whenever turning the adjusting nut prevent the PHV cable from revolving BR 00131 1 Adjusting nut 2 Lock nut 3 PHV 3 Tighten the lock nut Tightening torque 3 5 N m 0 35 kgf m 2 5 ft Ib BR 77 BRAKE General Diagnostics 21 General Diagnostics A INSPECTION Trouble and possible cause Corrective action 1 Insufficient braking 1 Fluid leakage from the
7. LOT 1 BR 00076 BR 55 Brake Booster BRAKE 2 Mount the brake booster in position 3 Connect the operating rod to brake pedal with clevis pin and snap pin BR 00073 Nuts Clevis pin Snap pin Operating rod 5 Mount the master cylinder onto brake booster 6 Connect the brake pipes to master cylinder 7 Connect the electric connector for brake fluid level indicator 8 Measure the clearance between threaded end of stop light switch and stopper If it is not within spec ified value adjust it by adjusting the position of stop light switch Ref to BR 73 ADJUSTMENT Stop Light Switch If it is not within specified value adjust it by adjust ing the position of stop light switch CAUTION Be careful not to rotate the stop light switch Stop light switch clearance A 0 3 mm 0 012 in BR 00079 9 Apply grease to operating rod connecting pin to prevent it from wearing 10 Bleed air from the brake system Tightening torque Air bleeder screw Except for 17 inch type 8 N m 0 8 kgf m 5 8 ft Ib 17 inch type 20 N m 2 0 kgf m 14 5 ft Ib 11 Conduct road tests to ensure brakes do not drag C INSPECTION 1 OPERATION CHECK WITHOUT GAUG ES CAUTION When checking operation be sure to securely apply the parking brake Checking without gauges This method cannot determine the exact portion which has
8. sembly etc Brake pipe tightening torque 15 N m 1 5 kgf m 10 8 ft Ib C INSPECTION Ensure there are no cracks breakage or damage on pipes Check the joints for fluid leakage If any cracks breakage damage or leakage is found re pair or replace the pipe NOTE Use a mirror when inspecting low visible part or back side BR 67 Brake Pedal BRAKE 18 Brake Pedal A REMOVAL 1 LHD 1 6 L MT MODEL 1 Disconnect the ground cable from battery 2 Disconnect the clutch cable from release lever 3 Remove the instrument panel lower cover from instrument panel 4 Disconnect the connectors for stop light switch etc from pedal bracket 5 Remove the clevis pin which secures the pedal to push rod 6 Remove the bolts and nuts which secure the brake and clutch pedals and then remove the ped al bracket and clutch cable as a unit CAUTION Before removing the clutch cable from toe board remove the grommet Slowly remove the clutch cable being careful not to scratch it BR 00320 A Clutch pedal B Brake pedal 7 Depress the clutch pedal and then disconnect the clutch cable from clutch pedal 2 LHD 2 0 L MT MODEL 1 Remove the steering shaft 2 Disconnect the connectors for stop light switch etc from pedal bracket 3 Remove the clevis pin which secures the lever to push rod 4 Remove the nut which secures the
9. 5 Plunger valve 9 Operating rod 2 Return spring 6 Key 10 Silencer 3 Diaphragm plate 7 Poppet valve 11 Filter 4 Reaction disc 8 Valve return spring 12 Valve body BR 18 General Description BRAKE 8 BRAKE PEDAL 1 6 L MODEL BR 00286 A LHD B RHD 1 Stopper 10 Clutch pedal Tightening torque N m kgf m ft Ib 2 Bushing 11 Clutch cable T1 5 9 0 6 4 3 3 Pedal bracket 12 Clutch cable clamp T2 8 0 8 5 8 4 Snap pin 13 Clip 18 1 8 13 0 5 Brake pedal pad 14 Spring assist T4 30 3 1 22 4 6 Brake pedal 15 Stop light switch T5 33 3 3 24 3 7 pin 16 Brake pedal bracket ASSY 8 Spring 17 Cover 9 Clutch pedal pad 18 Protector BR 19 General Description BRAKE 2 0 L AND 2 5 L MODEL BR 00287 RHD LHD 1 Stopper 13 Assist rod A 25 Clutch master cylinder bracket 2 Bushing 14 Clip 26 Lever 3 Spring pin 15 Assist spring 27 Brake pedal bracket ASSY 4 Snap pin 16 Assist bushing 28 Cover 5 Brake pedal pad 17 Assist rod B 29 Protector 6 Brake pedal 18 Spring S 7 Clevis pin 19 RodS Tightening torque N m kgf m ft Ib
10. that the end of wear indicator contacts disc rotor a squeaking sound is produced as the wheel rotates If this sound is heard replace the pad Replace the pad if there is oil or grease on it BR 27 Front Brake BRAKE 2 16 INCH TYPE Replace the pad if there is oil or grease on it Check the pad thickness A BR 00296 Standard value 10 mm 0 393 in Wear limit 1 5 mm 0 59 in Pad thickness NOTE Always replace the pads for both right and left wheels at the same time Also replace the pad clips if they are twisted or worn A wear indicator is provided on the inner disc brake pad If the pad wears down to such an extent that the end of wear indicator contacts disc rotor a squeaking sound is produced as the wheel rotates If this sound is heard replace the pad Replace the pad if there is oil or grease on it 3 17 INCH TYPE Check the pad thickness A BR 00296 Standard value 9 2 mm 0 362 in Wear limit 1 2 mm 0 047 in Pad thickness NOTE Always replace the pads for both right and left wheels at the same time Also replace the pad clips if they are twisted or worn A wear indicator is provided on the inner disc brake pad If the pad wears down to such an extent that the end of wear indicator contacts disc rotor a squeaking sound is produced as the wheel rotates If this sound is heard replace the pad BR 28 Front Disc
11. 1 Piston seal D ASSEMBLY 1 14 INCH AND 15 INCH TYPE 1 Clean the caliper body interior using brake fluid 2 Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body 3 Apply a coat of brake fluid to the entire inner sur face of cylinder and outer surface of piston 4 Apply a coat of specified grease to the boot and install the piston boot to the groove on ends of cyl inder Grease NIGLUBE RX 2 Part No K0779GA102 5 Insert the piston into cylinder CAUTION Do not force the piston into cylinder BR 00306 1 Piston 2 Piston boot BR 34 Front Disc Brake Assembly BRAKE 6 Position the boot in grooves on cylinder and pis ton BR 00122 Piston Piston boot Caliper body Piston seal 7 Apply a coat of specified grease to the lock pin and guide pin outer surface cylinder inner surface and boot grooves Grease NIGLUBE RX 2 Part No K0779GA102 8 Install the lock and guide pin boot on support BR 00030 1 Pin boot 2 Lock pin or guide pin 3 Apply grease 2 16 INCH TYPE 1 Clean the caliper body interior using brake fluid 2 Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body 3 Apply a coat of brake fluid to the entire inner sur face of cylinder and outer surface of piston 4 Apply a coat of specified grease to the boot
12. 17 9 0 mm 0 354 in 1 2 mm 0 047 in Rear brake Disc type 14 10 mm 0 39 in 8 5 mm 0 335 in Disc thickness 15 18 mm 0 71 in 16 mm 0 63 in 17 20 mm 0 79 in 18 mm 0 71 in Disc runout 0 07 mm 0 0028 in Rear brake Drum type diameter 228 6 mm 9 in 230 6 mm 9 08 in Lining thickness 4 1 mm 0 161 in 1 5 mm 0 059 in Rear brake Disc type Inside diameter 170 mm 6 69 in 171 mm 6 73 in parking Lining thickness 3 2 mm 0 126 in 1 5 mm 0 059 in Parking brake Lever stroke 7 to 8 notches 196 N 20 kgf 44 Ib BR 3 BRAKE General Description Brake pedal force Fluid pressure BASE TS Without ABS With ABS GX RS OBK WRX Brake booster Brake pedal Free play Brake fluid pressure without engine running 147 N 15 kgf 33 Ib 686 kPa 7 kg cm 100 psi 588 kPa 6 kg cm 85 psi 588 kPa 6 kg cm 85 psi 294 30 kgf 66 Ib 1 961 kPa 20 kg cm 284 psi 1 667 kPa 17 kg cm 242 psi 15 kg cm 213 psi 1 471 kPa Brake fluid pressure with engine running and vacuum at 66 7 kPa 500 mmHg 19 69 inHg 147 N 15 kgf 33 Ib 5 982 kPa 61 kg cm 868 psi 5 982 kPa 61 kg cm 868 psi 5 296 kPa 54 kg cm 768 psi 4 707 kPa 48 kg cm 683 psi 4 021 kPa 41 kg cm 583 psi 294 30 kgf 66 Ib 7 649 kPa 78 kg cm 1 109 psi 1 3 mm 0 04 0 12 in Depress
13. 8 Brake pedal spring 20 Bushing S T1 8 0 8 5 8 9 Clutch pedal pad 21 O ring T2 18 1 8 13 0 10 Clutch pedal 22 Clip 30 3 1 22 4 11 Bushing C 23 Stop light switch T4 33 3 3 24 3 12 Clutch clevis pin 24 Pedal bracket BR 20 General Description BRAKE LHD AT MODEL BR 00139 1 Stopper 6 Brake pedal pad Tightening torque N m kgf m ft Ib 2 Bushing 7 Brake pedal T1 8 0 8 5 8 3 Pedal bracket 8 Clevis pin T2 18 1 8 13 0 4 Stop light switch 9 Brake pedal spring 29 3 0 21 7 5 Snap pin BR 21 General Description BRAKE RHD MODEL BR 00010 1 Stopper 6 Brake pedal pad Tightening torque N m kgf m ft Ib 2 Snap pin 7 Brake pedal bracket ASSY T1 8 0 8 5 8 3 Clevis pin 8 Cover T2 18 1 8 13 0 4 Stop light switch 9 Protector 33 3 3 24 3 5 Brake pedal BR 22 General Description BRAKE 9 HILL HOLDER BR 00121 1 Clamp 4 Adjusting nut 2 PHV cable 5 Lock nut 3 PHV Pressure hold valve 6 To clutch pedal C CAUTION Wear working clothing including a cap protec tive goggles and protective shoes during opera tion Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Use SUBARU genuine grease etc
14. Apply thin coat of Molykote AS880N Part No K0779Y A010 to the frictional portion between pad and pad inner shim d TO BR 00015 3 Install the pads on support 4 Install the caliper body on support Tightening torque 37 N m 3 8 kgf m 27 5 ft Ib NOTE If itis difficult to push the piston during pad replace ment loosen the air bleeder to facilitate work 2 16 INCH TYPE 1 Apply thin coat of Molykote AS880N Part No K0779Y A010 to the frictional portion between pad and pad inner shim cm Install the pads on caliper body Install the pad pins on caliper body Install the M clip Install the cross spring BR 00328 2 3 4 5 BRAKE 3 17 INCH TYPE 1 Apply thin coat of Molykote AS880N Part No K0779Y A010 to the frictional portion between pad and pad shim cm BR 00381 2 Install the pads on caliper body 3 Install the cross spring 4 Install the pad pins 5 Install the clip C INSPECTION 1 14 INCH AND 15 INCH TYPE Check the pad thickness A BR 00016 Standard value Wear limit 11 mm 0 43 in Pad thickness 1 5 mm 0 059 in NOTE Always replace the pads for both right and left wheels at the same time Also replace the pad clips if they are twisted or worn A wear indicator is provided on the inner disc brake pad If the pad wears down to such an extent
15. DS 23 INSPECTION Front Axle 2 Secure the disc rotor by tightening five wheel nuts 3 Set a dial gauge 10 mm 0 39 in inward of rotor outer perimeter Turn the disc rotor to check runout BR 29 Front Disc Rotor BRAKE If the disc rotor runout is above specified value re place the disc rotor BR 00019 Disc rotor runout limit 0 075 mm 0 0030 in 4 Set a micrometer 10 mm 0 39 in inward of the rotor outer perimeter and then measure the disc rotor thickness If the thickness of disc rotor is out side the service limit replace the disc rotor BR 00018 Standard Service Disc outer value limit dia 24 mm 22 mm 260 mm 0 94 in 0 87 in 10 24 in 24 mm 22 277 Disc rotor 0 94 in 0 87 in 10 91 in thickness A 24 mm 22 mm 294 mm 0 94 in 0 87 in 11 57 in 30 mm 28 mm 326 mm 1 18 in 1 10 in 12 83 in BR 30 Front Disc Brake Assembly 4 Front Disc Brake Assembly A REMOVAL 1 14 INCH AND 15 INCH TYPE CAUTION Do not allow brake fluid to come in contact with vehicle body wash away with water and wipe off completely if spilled 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the front wheel 4 Remove the union bolt and then disconnect the brake hose from caliper body assembly BR 00021 5 Remove the bolt securing lock pin to caliper
16. N m kgf m ft lb 2 Filter 7 Cylinder body T1 15 1 5 10 8 3 Reservoir tank 8 Cylinder pin 4 Piston retainer 9 Seal 5 Primary piston 10 Pin BR 14 General Description BRAKE 5 FRONT BRAKE PIPES AND HOSE LHD MODEL BR 00283 Model with ABS with hill holder Model with ABS B Model without ABS A Tightening torque N m kgf m ft Ib ISS S g 99 E Ss DN Gi ERE 2 3 D gt er A 50 g 0 5 2 Et 3 c 5 E 9 2c my uS c5 o gt oc s YV o NF E o lt o mz LE AS SS 5 o T gj GC i o o o gt o E oo CC og o 5 5 uo ou en E c occ E F GO o er ENES END LD oo I BR 15 General Description BRAKE RHD MODEL B
17. Rear Brake Pad ak eorr REUS 37 Rear DISC iiit ete oor e TIER eroe Poet ebe dev de uk vs dri 40 Rear Disc Brake Assembly 42 Hear Drum Brake lier ducto ent dud 47 Rear Drum Brake Drum 49 Rear Drum Brake 50 Master Cylinder Nea 53 Brake Booster HA HD ERR E VOV EXE ERE FR 55 Proportioning V Al EE 59 Brake Te E 60 Air Ee e 62 Brake OSC EE 65 Iii Mallet EE 67 Brake iste era a ERO 68 lee UE 73 all a Koe E ett TED ETT E 75 General Diagnostl6s u oer Fe blo eec a qe 78 BRAKE General Description 1 General Description A SPECIFICATIONS Model BASE TS GX RS OBK WRX STi Size 14 inch type 15 inch type 16 inch type 17 inch type Type Disc Floating type ventilated Disc Fixed type ventilated Effective disc diameter 210 mm 8 27 in 228 mm 8 98 in 255 mm 10 04 in 268 mm 10 55 in Disc thickness x Outer diameter 24 x 260 mm 0 94 x 10 24 in 24 x 277 mm 0 94 x 10 91 in 24 x 294 mm 0 94 x 11 57 in 30 x 326 mm 1 18 x 12 83 in Effective cylinder diameter 57 2 mm 2 252 in 42 8 mm 1 685 in x 2 40 4 mm 1 591 i
18. a new gas Tightening torque Union bolt 18 N m 1 8 kgf m 13 0 ft Ib BR 00021 3 Position the disc in straight forward direction and route brake hose through hole in bracket on wheel apron side CAUTION Be sure brake hose is not twisted 4 Temporarily tighten the flare nut to connect brake pipe and hose 5 Fix the brake hose with clamp at wheel apron bracket 6 While holding the hexagonal part of brake hose fitting with a wrench tighten the flare nut to the specified torque Tightening torque Brake pipe flare nut 15 N m 1 5 kgf m 10 8 ft Ib 7 Bleed air from the brake system BR 65 Brake Hose BRAKE 2 REAR BRAKE HOSE DISC BRAKE 1 Pass the brake hose through hole of bracket and then lightly tighten the flare nut to connect brake pipe 2 Insert the clamp upward to fix brake hose 3 Install the brake hose to caliper using a new gas ket Tightening torque Union bolt 18 N m 1 8 kgf m 13 0 ft Ib 4 While holding the hexagonal part of brake hose fitting with a wrench tighten the flare nut to the specified torque Tightening torque Brake pipe flare nut 15 N m 1 5 kgf m 10 8 ft Ib BR 00096 1 Brake pipe 2 Brake hose 3 Brake hose clamp 5 Bleed air from the brake system 3 REAR BRAKE HOSE DRUM BRAKE 1 Install the brake hose to wheel cylinder Tightening torque 15 N m 1 5 kgf m 10 8 ft Ib 2 Secure the brake hose to bracket
19. and fit in groove on ends of cylinder and piston Grease NIGLUBE RX 2 Part No K0779GA102 5 Insert the piston into cylinder CAUTION Do not force the piston into cylinder BR 00307 6 Position the boot in grooves on cylinder and pis ton BR 00308 1 2 3 4 Piston Piston boot Piston seal Boot ring RR 7 Install the boot ring Be careful not scratch the boot 3 17 INCH TYPE 1 Clean the caliper body interior using brake fluid 2 Apply a coat of brake fluid to the piston seal and then install the piston seal in groove on caliper body 3 Apply a coat of brake fluid to the entire inner sur face of cylinder and outer surface of piston 4 Apply a coat of specified grease to the boot and install it in the groove on piston Grease NIGLUBE RX 2 Part No K0779GA102 5 Insert the piston into cylinder BR 35 Front Disc Brake Assembly BRAKE CAUTION Do not force the piston into cylinder BR 00307 6 Position the boot in grooves on cylinder and pis ton BR 00309 1 Piston seal 2 Piston boot 3 Piston E INSPECTION 1 Repair or replace the faulty parts 2 Check the caliper body and piston for uneven wear damage or rust 3 Check the rubber parts for damage or deteriora tion BR 36 Rear Brake Pad 5 Rear Brake Pad A REMOVAL 1 14 INCH TYPE 1 Set the vehicle
20. brake pedal pad with a force of less than 10 1 kgf 2 Ib 8 434 kPa 86 kg cm 1 223 psi BR 4 9 120 kPa 93 kg cm 1 323 psi 8 336 kPa 85 kg cm 1 209 psi General Description BRAKE B COMPONENT 1 FRONT DISC BRAKE 14 INCH TYPE 10 12 11 Z gt P BR 00377 1 Caliper body 9 Support 17 Bushing 2 Air bleeder screw 10 Pad clip 3 Guide pin Green 11 Outer shim Tightening torque N m kgf m ft lb 4 Pin boot 12 Inner shim T1 8 0 8 5 8 b Piston seal 13 Pad Outside T2 18 1 8 13 0 6 Piston 14 Pad Inside 37 3 8 27 5 7 Piston boot 15 Disc rotor T4 80 8 2 59 8 Lock pin Yellow 16 Disc cover BR 5 General Description BRAKE 15 INCH TYPE BR 00378 1 Caliper body 9 Support 17 Bushing 2 Air bleeder screw 10 Pad clip 3 Guide pin Green 11 Outer shim Tightening torque N m kgf m ft Ib 4 Pin boot 12 Inner shim T1 8 0 8 5 8 b Piston seal 13 Pad Outside T2 27 2 8 19 9 6 Piston 14 Pad Inside 37 3 8 27 5 7 Piston boot 15 Disc rotor T4 80 8 2 59 8 Lock pin Yellow 16 Disc cover BR 6 General Description BRAKE 16 INCH TYPE BR 00379 1 Housing 9 Piston boot 17 Spacer 2 Air bleeder screw 10 Boot ring 3 Caliper body 11 Outer shim Tightening torque N m
21. clutch master cylinder 5 Remove the accelerator pedal 6 Remove the bolts and nuts which the secure pedal bracket BR 00128 3 LHD 2 5 L MT MODEL Refer to LHD 2 0 L MT MODEL for removal Ref to BR 68 LHD 2 0 L MT MODEL REMOVAL Brake Pedal 4 LHD AT MODEL 1 Disconnect the ground cable from battery 2 Remove the instrument panel lower cover from instrument panel 3 Remove the clevis pin which secures the brake pedal to brake booster operating rod Also discon nect the stop light switch connector BR 68 Brake Pedal 4 Remove the four bolts and four nuts which se cure the brake pedal to pedal BR 00140 1 Clevis pin 2 Snap pin 3 Operating rod 5 RHD AT MODEL 1 Disconnect the ground cable from battery 2 Remove the instrument panel lower cover from instrument panel 3 Disconnect the connectors for stop light switch etc from pedal bracket 4 Remove the snap pin and clevis pin BRAKE 5 Remove the four bolts which secure the brake pedal bracket rear side 6 5 EN d KO lp np BR 00135 6 Remove the nuts which secure the brake pedal bracket front side BR 00137 7 Remove the brake pedal without prying the bracket 6 RHD MT MODEL Refer to RHD AT MODEL Ref to BR 69 RHD AT MODEL REMOVAL Brake Ped
22. disconnecting PHV cable _ TT 1 2 1 PHV cable 2 Clamp 4 Disconnect the brake pipes from PHV CAUTION Pay attention not to drop the brake fluid onto body painting since it may dissolve paint Pay attention not to damage hexagonal head of the flare nut by using pipe wrench without fail 5 Detach the PHV along with support from side frame BRAKE CAUTION Exercise utmost care to prevent foreign matter from entering into the PHV when removing it TEN Fr JF so JO 00133 1 PHV 2 PHV CABLE 1 Remove the adjusting nut and lock nut BR 00131 1 Adjusting nut 2 Lock nut 3 PHV 2 Remove the cable clamp and disconnect PHV cable from PHV CAUTION Carefully protect the boot and inner cable from damage when disconnecting PHV cable TT 1 2 1 PHV cable 2 Clamp BR 75 Hill Holder BRAKE 3 Remove the cable clamp from clutch pedal bracket LHD MODEL BR 00144 1 Clamp 2 PHV cable 3 Clutch pedal e RHD MODEL Ca Su e Ly BR 00145 Ne 1 Clamp 2 PHV cable 3 Clutch pedal 4 Remove the PHV cable B INSPECTION Check up removed parts as follows and replace defective ones 1 Check if the boots of PHV cable are damaged or degraded the inner cable is damaged or corroded 2 Check if the retu
23. failed but it can provide a rough under standing of the nature of failure if checking is con ducted in accordance with the following procedures BR 56 Brake Booster BRAKE Air tightness check Start the engine and run it for 1 to 2 minutes then turn it off Depress the brake pedal several times applying same pedal force as that used in ordinary braking operations The pedal stroke should be greatest on 1st depression and it should become smaller with each successive depression If no change occurs in the pedal height while in a de pressed state the brake booster is faulty 1 2 NS 4 3 BR 00080 in ee ee ee OK NOT OK 151 2nd 3rd n the event of defective operation inspect the condition of check valve and vacuum hose Replace them if faulty and conduct the test again f no improvement is observed check precisely with gauges Operation check 1 With the engine off depress the brake pedal several times applying same pedal force and make sure that pedal height does not vary with each de pression of pedal 1 Ny BR 00081 1 When engine is stopped 2 When engine is started 2 With the brake pedal depressed start the en gine 3 As the engine starts the brake pedal should move slightly toward the floor If no change occurs in the pedal height the brake booster is faulty NOTE If fau
24. hydraulic mechanism Repair or replace cup piston seal piston boot master cylinder piston kit pipe or hose 2 Entry of air into the hydraulic mechanism Bleed the air Adjust the clearance 2 3 Excessively wide shoe clearance 4 Wear deteriorated surface material adhering water or fluid on the lining Replace grind or clean b Improper operation of master cylinder disc cal iper brake booster or check valve Correct or replace 2 Unstable or uneven braking 1 Fluid on the lining drum or rotor Eliminate cause of fluid leakage clean or replace 2 Drum or rotor eccentricity Correct or replace the drum or rotor 3 Worn brake drum or damage to the drum caused by sand Correct by grinding or replace 4 Improper lining contact deteriorated surface material improper inferior material or wear Correct by grinding or replace b Deformed back plate Correct or replace 6 Improper tire inflation Inflate to correct pressure 7 Disordered wheel alignment Adjust alignment 8 Loosened back plate or the support installing bolts Retighten 9 Loosened wheel bearing Retighten to normal tightening torque or replace 10 Trouble in the hydraulic system Replace the cylinder brake pipe or hose 11 Uneven effect of the parking brake Check adjust or replace the rear brake and cable system 3 Excessiv
25. kgf m ft lb 4 12 Inner shim Ti 8 0 8 5 8 5 Cross spring 13 Pad Outside T2 18 1 8 13 0 6 Pad pin 14 Pad Inside 80 8 2 59 7 Piston seal 15 Disc rotor 8 Piston 16 Disc cover BR 7 General Description BRAKE 17 INCH TYPE BR 00380 1 Housing 8 Piston boot 15 Disc rotor 2 Caliper body 9 Piston 16 Disc cover 3 Air bleeder screw 10 Piston seal 4 Guide plate 11 Pad shim Outside Tightening torque N m kgf m ft Ib 5 Cross spring 12 Pad shim Inside 1 18 1 8 13 0 6 Clip 13 Pad Outside T2 20 2 0 14 5 7 Pad pin 14 Pad Inside 155 15 8 114 3 BR 8 General Description BRAKE 2 REAR DISC BRAKE 14 INCH TYPE 15 BR 00326 1 Caliper body 14 Shim 27 Primary shoe return spring 2 Air bleeder screw 15 Shoe hold down pin 28 Adjusting spring 3 Guide pin Green 16 Cover 29 Adjuster 4 Pin boot 17 Back plate 30 Shoe hold down cup 5 Piston seal 18 Retainer 31 Shoe hold down spring 6 Piston 19 Spring washer 32 Disc rotor 7 Piston boot 20 Parking brake lever 33 Bushing 8 Boot ring 21 Parking brake shoe Secondary 9 Lock pin Yellow 22 Parking brake shoe Primary Tightening torque N m kgf m ft Ib 10 Support 23 Strut Ti 8 0 8 5 8 11 Pad clip 24 Strut shoe spring T2 37 3 8 27 5 12 Inner pa
26. or the equiv alent Do not mix grease etc with that of another grade or from other manufacturers Be sure to tighten fasteners including bolts and nuts to the specified torque Place shop jacks or safety stands at the specified points Before securing a part on a vise place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vise BR 23 T2 18 1 8 13 0 Tightening torque N m kgf m ft Ib T1 3 5 0 35 2 5 BRAKE General Description D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925460000 WHEEL CYLINDER Used for installing cup onto wheel cylinder piston 11 16 ADAPTER Size 11 16 ST 925460000 2 GENERAL PURPOSE TOOLS TOOL NAME REMARKS SNAP RING PLIERS Used for removing and installing snap ring BR 24 Front Brake 2 Front Brake A REMOVAL 1 14 INCH AND 15 INCH TYPE 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the front wheel 4 Remove the lower caliper bolt 5 Raise the caliper body upward and support it NOTE Do not disconnect the brake hose from caliper 6 Remove the pad BR 00012 NOTE If the brake pad is difficult to remove proceed as follows 1 Remove the caliper body from support 2 Remove the support 3 Place a support in a vise between wooden b
27. torque 155 N m 15 8 kgf m 114 3 ft Ib 2 Apply thin coat of Molykote AS880N Part No K0777Y A010 to the frictional portion between pad and pad shim ctm BR 00381 3 Install the pads on caliper body 4 Install the cross spring 5 6 Install the pad pins Install the clip BR 32 Front Disc Brake Assembly 7 Replace the brake hose gaskets with new ones and then connect the brake hose Tightening torque 18 N m 1 8 kgf m 13 0 ft Ib 8 Bleed air from the brake system C DISASSEMBLY 1 14 INCH AND 15 INCH TYPE 1 Clean mud and foreign particles from the caliper body assembly and support CAUTION Be careful to allow foreign particles to enter the brake hose connector 2 Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged 3 Gradually supply compressed air via the installa tion hole of brake hose to force the piston out BR 00026 1 Place a 30 mm 1 18 in wide wooden block here 4 Remove the piston boot 5 Remove the piston seal from caliper body cylin der CAUTION Do not damage the cylinder and piston seal groove BR 00027 1 Piston seal 6 Remove the guide pin and boot from caliper BRAKE 2 16 INCH TYPE 1 Clean mud and foreign particles from the caliper body assembly CAUTION Be careful not to allow foreign partic
28. with new ones and then connect the brake hose Tightening torque 18 N m 1 8 kgf m 13 0 ft Ib 6 Bleed air from the brake system 2 15 INCH TYPE 1 Install the caliper body on housing Tightening torque 52 N m 5 3 kgf m 38 3 ft Ib 2 Apply thin coat of Molykote AS880N Part No K0777Y A010 to the frictional portion between pad and pad clip 3 Install the pads on caliper body 4 Replace the brake hose gaskets with new ones and then connect the brake hose Tightening torque 18 N m 1 8 kgf m 13 0 ft Ib 5 Bleed air from the brake system 3 17 INCH TYPE 1 Install the caliper body on housing Tightening torque 65 N m 6 6 kgf m 47 9 ft Ib 2 Install the pads on caliper body 3 Replace the brake hose gaskets with new ones and then connect the brake hose Tightening torque 18 N m 1 8 kgf m 13 0 ft Ib 4 Bleed air from the brake system BRAKE C DISASSEMBLY 1 14 INCH TYPE 1 Remove the boot ring BR 00040 1 Boot ring 2 Remove the piston boot BR 00041 3 Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged 4 Gradually supply compressed air via the installa tion hole of brake hose to force the piston out BR 00042 1 Place a 30 mm 1 18 in wide wooden block here 5 Remove the piston seal from caliper body cylin der BR 43 Rear Disc Brake Assembly BRAKE
29. 2 hissing sound 1 Worn lining Replace the shoe assembly or pad 2 Improper installed shoe or pad Correct or replace the shoe assembly or pad 3 Loose or bent drum or rotor BR 78 Retighten or replace General Diagnostics BRAKE Trouble and possible cause Corrective action 7 Brake noise 3 click sound In the case of the disc brake 1 Excessively worn pad or the support Replace the pad or the support In the case of the drum brake 1 Excessively worn shoe ridge Replace the back plate 2 Lack of oil on the shoe ridge surface and anchor BR 79 Add more grease General Diagnostics BRAKE BR 80
30. 2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX CHASSIS SECTION FRONT SUSPENSION REAR SUSPENSION RS WHEEL AND TIRE SYSTEM WT DIFFERENTIALS DI This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles This manual includes the procedures for maintenance disassembling reas sembling inspection and adjustment of ABS ABS components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition BRAKE BR When replacement of parts during repair work is needed be sure to use SUBARU genuine parts PARKING BRAKE PB TRANSFER CASE TC DRIVE SHAFT SYSTEM DS ABS DIAGNOSTICS POWER ASSISTED SYSTEM POWER STEERING All information illustration and specifi cations contained in this manual are based on the latest product information available at the time of publication approval FUJI HEAVY INDUSTRIES LTD G1870GE5 Et O OO 4 O RoOIN N N sch sch r OOO NO OBO MO Page General Description esses enne 2 Front Brake tee Eee rea 25 29 Front Disc Brake geeiert eeneg veer 31
31. 4 6 Suspend the disc brake assembly so that hose is not stretched 7 Remove the disc rotor NOTE If the disc rotor is difficult to remove try following two methods in order 1 Turn the adjusting screw using a flat tip screwdriver until brake shoe gets away enough from the disc rotor BR 00155 Adjusting screw Cover Flat tip screwdriver Back plate 2 If the disc rotor seizes up within hub drive the disc rotor out by installing an 8 mm bolt in holes B on rotor BR 00036 B INSTALLATION 1 Install in the reverse order of removal 2 Adjust the parking brake Ref to PB 8 AD JUSTMENT Parking Brake Assembly Rear Disc Brake gt C INSPECTION 1 Check bearing axial end play and hub runout be fore disc rotor runout limit inspection lt Ref to DS 32 INSPECTION Rear Axle AWD Modell Ref to DS 34 INSPECTION Rear Axle FWD Model 2 Secure the disc rotor by tightening five wheel nuts 3 Set a dial gauge 10 mm 0 39 in inward of rotor outer perimeter Turn the disc rotor to check runout If the disc rotor runout is above specified value re place the disc rotor Disc rotor runout limit 0 070 mm 0 0027 in BR 40 Rear Disc Rotor BRAKE 4 Set a micrometer 10 mm 0 39 in inward of the rotor outer perimeter and then measure the disc rotor thickness If the thickness of disc rotor is out side the service limit replace t
32. 779GA102 5 Insert the piston into cylinder BR 45 Rear Disc Brake Assembly BRAKE CAUTION Do not force piston into cylinder 6 Install the piston boot to the caliper body and then attach boot ring 4 3 BR 00308 Piston Piston boot Piston seal Boot ring 3 17 INCH TYPE 1 Clean the caliper body interior using brake fluid 2 Apply a coat of brake fluid to the piston seal and install the piston seal in groove on caliper body 3 Apply a coat of brake fluid to the entire inner sur face of cylinder and outer surface of piston 4 Apply a coat of specified grease to the boot and install it in the groove on piston Grease NIGLUBE RX 2 Part No K0779GA102 5 Insert the piston into cylinder CAUTION Do not force the piston into cylinder 6 Position the boot in grooves on cylinder and pis ton BR 00309 1 Piston seal 2 Piston boot 3 Piston E INSPECTION 1 Repair or replace the faulty parts 2 Check the caliper body and piston for uneven wear damage or rust 3 Check the rubber parts for damage or deteriora tion BR 46 Rear Drum Brake Shoe BRAKE 8 Rear Drum Brake Shoe A REMOVAL 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the wheels 4 Release the parking brake 5 Remove the brake drum from brake assembly NOTE e lf it is difficult to remove the brake drum remove the adjust
33. CAUTION Do not damage the cylinder and piston seal groove BR 00043 6 Remove the lock pin sleeve and boot from cali per body 7 Remove the guide pin boot 2 15 INCH TYPE 1 Remove the boot ring BR 00316 1 Boot ring 2 Remove the piston boot BR 00317 3 Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged 4 Gradually supply compressed air via the installa tion hole of brake hose to force the piston out BR 00318 1 Place a 30 mm 1 18 in wide wooden block here 5 Remove the piston seal from caliper body cylin der CAUTION Do not damage the cylinder and piston seal groove BR 00319 3 17 INCH TYPE 1 Remove the piston boot from piston end BR 00317 2 Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged BR 44 Rear Disc Brake Assembly BRAKE 3 Gradually supply compressed air via the installa tion hole of brake hose to force the piston out BR 00318 1 Place a 20 mm 0 79 in wide wooden block here 4 Remove the piston seal from caliper body cylin der CAUTION Do not damage the cylinder and piston seal groove BR 00319 D ASSEMBLY 1 14 INCH TYPE 1 Clean the caliper body interior using brake f
34. E NOTE During the bleeding operation keep the brake reservoir tank filled with brake fluid to eliminate en try of air The brake pedal operating must be very slow For convenience and safety two people should do the work 1 Make sure that there is no leak from the joints and connections of brake system 2 Fit one end of vinyl tube into the air bleeder and put the other end into a brake fluid container BR 00087 BR 62 Air Bleeding BRAKE CAUTION Brake fluid replacement sequence A Front right B Rear left C Front left D Rear right A 1 D fec C 3 B BR 00089 1 Master cylinder 2 Hydraulic unit 3 Proportioning valve 3 Slowly depress the brake pedal and keep it de pressed Then open the air bleeder to discharge air together with the fluid Release the air bleeder for 1 to 2 seconds Next with the bleeder closed slowly release the brake pedal Repeat these steps until there are no more air bub bles in the vinyl tube Allow 3 to 4 seconds between two brake pedal op erations CAUTION Cover the bleeder with waste cloth when loos ening it to prevent brake fluid from being splashed over surrounding parts NOTE If caliper has two air bleeder screws bleed air from inner first then outer BR 00376 1 Inner air bleeder screw 2 Outer air bleeder screw 4 Tighten th
35. R 00284 A Model without ABS B Model with ABS C Model with ABS With hill holder 1 Front brake pipe assembly 7 ABS control module and hydraulic Tightening torque N m kgf m ft lb 2 Proportioning valve control unit ABSCM amp H U T1 15 1 5 10 8 3 Front brake hose RH 8 Bracket T2 18 1 8 13 0 4 Front brake hose LH 9 Master cylinder 32 3 3 23 6 5 Clamp 10 Hill holder 6 Gasket 11 Two way connector BR 16 General Description CENTER AND REAR BRAKE PIPES AND HOSES BRAKE BR 00007 Center brake pipe assembly Two way connector Rear brake pipe assembly Rear brake hose RH Disc brake model Rear brake hose RH Drum brake model 6 7 E e Rear brake hose LH Disc brake model Rear brake hose LH Drum brake model Clamp Gasket BR 17 T1 T2 15 1 5 10 8 18 1 8 13 0 Tightening torque N m kgf m ft Ib General Description BRAKE 7 BRAKE BOOSTER MODEL With ABS BR 00008 1 Push 5 Filter 9 Valve body 2 Return spring 6 Silencer 10 Plunger valve 3 Reaction disc 7 Operating rod 11 Diaphragm plate 4 Key 8 Poppet valve 12 Valve return spring MODEL Without ABS BR 00285 1 Push
36. Rotor 3 Front Disc Rotor A REMOVAL 1 14 INCH AND 15 INCH TYPE 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the front wheel 4 Remove the caliper body and support from housing and suspend it from strut using a wire BR 00017 5 Remove the disc rotor NOTE If the disc rotor seizes up within the hub drive the disc rotor out by installing an 8 mm bolt in holes B on rotor BR 00018 6 Clean mud and foreign particles from the caliper body assembly and support 2 16 INCH AND 17 INCH TYPE 1 Set the vehicle on a lift 2 Loosen the wheel nut 3 Lift up the vehicle and then remove the front wheel BRAKE 4 Remove the caliper body from housing and sus pend from strut using a wire BR 00297 5 Remove the disc rotor from hub NOTE If the disc rotor seizes up within the hub drive the disc rotor out by installing an 8 mm bolt in holes B on rotor BR 00018 6 Clean mud and foreign particles from the caliper body assembly and support B INSTALLATION 1 Install the disc rotor 2 Install the caliper body and support to housing Tightening torque Except 17 inch type 80 N m 8 2 kgf m 59 ft Ib 17 inch type 155 N m 15 8 kgf m 114 3 ft Ib 3 Install the wheel C INSPECTION 1 Check bearing axial end play and hub runout be fore disc rotor runout limit inspection Ref to
37. al B INSTALLATION 1 Install in the reverse order of removal CAUTION If the cable clamp is damaged replace it with a new one Never fail to cover the outer cable end with boot Be careful not to kink the accelerator cable Always use new clevis pins 2 Adjust the clutch pedal Ref to CL 45 AD JUSTMENT Clutch Pedal BR 69 Brake Pedal BRAKE 3 Inspect the brake pedal after installation Ref to BR 71 INSPECTION Brake Pedal C DISASSEMBLY 1 LHD 1 6 L MT MODEL 1 Remove the stop light switch Ref to BR 73 REMOVAL Stop Light Switch 2 Remove the nut and pull out the bolt until brake pedal is able to remove then remove brake pedal 00321 3 Remove the bushing spring and stopper 4 2 BR 00322 Stopper Bushing Brake pedal Brake pedal spring 4 Remove the brake pad 2 LHD 2 0 L MT MODEL 1 Remove the brake switch lt Ref to BR 73 REMOVAL Stop Light Switch gt 2 Remove the clutch pedal lt Ref to CL 42 DISASSEMBLY Clutch Pedal gt 3 Remove the clutch master cylinder bracket BR 00130 1 Stopper 2 Bushing 3 Brake pedal 4 Brake pedal spring 5 Remove the brake pedal pad 3 LHD 2 5 L MT MODEL Refer to LHD 2 0 L MT MODEL for disassembly lt Ref to BR 70 LHD 2 0 L MT MODEL DISAS SEMBLY Brake Pedal gt 4 LHD AT MODEL 1 Remove the brake switch 2 Unbo
38. brake pipes from master cylinder 4 Remove the master cylinder mounting nuts and take out master cylinder from brake booster B INSTALLATION 1 To install the master cylinder to body reverse the sequence of removal procedure Tightening torque Master cylinder mounting nut 14 N m 1 4 kgf m 10 1 ft Ib Piping flare nut 15 N m 1 5 kgf m 10 8 ft Ib CAUTION Be sure to use recommended brake fluid 2 Bleed air from the brake system Ref to BR 62 PROCEDURE Air Bleeding C REPLACEMENT 1 Remove mud and dirt from the surface of brake master cylinder 2 Secure the master cylinder on a vise NOTE To avoid damaging master cylinder use aluminum plate while holding with vise 3 Remove the pin which secures reservoir tank to master cylinder and then remove the reservoir tank and grommet 4 Remove the cylinder pin with magnetic pick up tool while pushing in primary piston by screwdriver which wrapped with tape Model with ABS 9 9 1 00069 1 Cylinder pin straight pin 5 Pry up the pawl and then remove the piston re tainer Hold piston retainer tight because the pis ton may jump out from master cylinder Nr je NJ BR 00070 6 Extract the primary piston assembly and sec ondary piston assembly straight out while taking care not to scratch the inner surface of cylinder 7 Clean the inside of master cylinder with brake fluid Check the inside of
39. cylinder for damage de form and wear Replace the master cylinder as as sembly if faulty 8 Apply recommended brake fluid to the inside wall of cylinder and to outer surface of the piston assembly 9 Ensure that the inside wall of cylinder and piston assembly are free from dirt when assembling In stall the primary piston assembly and secondary piston assembly while taking care not to damage scratch or dent the cylinder inside wall and piston assembly 10 Install the cylinder pin while pushing in primary piston by screwdriver which wrapped with tape Model with ABS 11 Install the piston retainer and then secure it by pressing the pawl St Je BR 00070 BR 53 Master Cylinder BRAKE 12 Install the seal to reservoir tank 1 BR 00072 1 Seal 13 Install the reservoir tank to master cylinder and secure with pin D INSPECTION Inspect for oil leakage from the master cylinder NOTE After replacing piston kit when the oil leakage is found without damaging or scratching the inside of cylinder wear of master cylinder inner wall may be the cause In this case replace the master cylinder as assembly BR 54 Brake Booster BRAKE 12 Brake Booster A REMOVAL 1 Remove or disconnect the following parts at en gine compartment 1 Disconnect the connector for brake fluid lev el indicator 2 Remove
40. d 25 Shoe guide plate 52 5 3 38 3 13 Outer pad 26 Secondary shoe return spring BR 9 General Description BRAKE 15 INCH TYPE BR 00327 1 Caliper body 14 Washer 27 Secondary shoe return spring 2 Air bleeder screw 15 Cross spring 28 Primary shoe return spring 3 Pad pin 16 Shoe hold down pin 29 Adjusting spring 4 Piston seal 17 Cover 30 Adjuster 5 Piston 18 Back plate 31 Shoe hold down cup 6 Piston boot 19 Retainer 32 Shoe hold down spring 7 Boot ring 20 Spring washer 33 Disc rotor 8 Pad clip 21 Parking brake lever 9 Inner pad 22 Parking brake shoe Secondary Tightening torque N m kgf m ft Ib 10 Outer pad 23 Parking brake shoe Primary T1 8 0 8 5 8 11 Inner shim 24 Strut T2 52 5 3 38 3 12 Outer shim 25 Strut shoe spring 13 M clip 26 Shoe guide plate BR 10 General Description BRAKE 17 INCH TYPE S in V R N 25 26 o 29 28 BR 00281 1 Caliper body 13 Shoe hold down pin 25 Primary shoe return spring 2 Air bleeder screw 14 Cover 26 Adjusting spring 3 Guide plate 15 Back plate 27 Adjuster 4 Cross spring 16 Retainer 28 Shoe hold down cup 5 Piston boot 17 Spring washer 29 Shoe hold down spring 6 Piston 18 Parking brake lever 30 Disc rotor 7 Piston seal 19 Parking brake shoe Secon
41. d to prevent degrading the quality of fluid Be careful not to allow dirt or dust to get into the reservoir tank NOTE During bleeding operation keep the brake reser voir tank filled with brake fluid to eliminate entry of air The brake pedal operating must be very slow For convenience and safety two people should do the work The amount of brake fluid required is approx 500 m 0 16 9 US fl oz 17 6 Imp fl oz for total brake system 1 Either lift up the vehicle and place a safety stand under it or lift up vehicle 2 Remove both front and rear wheels 3 Draw out the brake fluid from master cylinder with syringe 4 Refill the reservoir tank with recommended brake fluid Recommended brake fluid FMVSS No 116 fresh DOT3 brake fluid 5 Install one end of a vinyl tube onto the air bleeder and insert the other end of the tube into a container to collect the brake fluid BR 00087 BR 00088 1 Air bleeder screw CAUTION Brake fluid replacement sequence A Front right B Rear left C Front left D Rear right B BR 00089 1 Master cylinder 2 Hydraulic unit 3 Proportioning valve 6 Instruct your co worker to depress the brake pedal slowly two or three times and then hold it de pressed 7 Loosen the bleeder screw approx 1 4 turn until a small amount of brake fluid drains into container and then quickly tighten the sc
42. dard value Wear limit 11 5 mm 0 452 in Pad thick ad thickness 1 5 mm 0 059 in NOTE Always replace the pads for both right and left wheels at the same time Also replace the pad clips if they are twisted or worn A wear indicator is provided on the inner disc brake pad If the pad wears down to such an extent that the end of wear indicator contacts disc rotor a squeaking sound is produced as the wheel rotates If this sound is heard replace the pad Replace the pad if there is oil or grease on it 3 17 INCH TYPE Check the pad thickness A BR 00314 Standard value Wear limit 9 0 mm 0 354 in Pad thick 1 2 0 047 Always replace the pads for both right and left wheels at the same time Also replace the pad clips if they are twisted or worn A wear indicator is provided on the inner disc brake pad If the pad wears down to such an extent that the end of wear indicator contacts disc rotor a squeaking sound is produced as the wheel rotates If this sound is heard replace the pad Replace the pad if there is oil or grease on it BR 39 Rear Disc Rotor BRAKE 6 Rear Disc Rotor A REMOVAL 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the wheels 4 Pull down and release the parking brake 5 Remove the two mounting bolts and then re move the disc brake assembly BR 0012
43. dary 8 Clip 20 Parking brake shoe Primary Tightening torque N m kgf m ft Ib 9 Pad pin 21 Strut T1 20 2 0 14 5 10 Pad shim 22 Strut shoe spring T2 52 5 3 38 3 11 Pad Outside 23 Shoe guide plate 65 6 6 47 9 12 Pad Inside 24 Secondary shoe return spring BR 11 General Description BRAKE 3 REAR DRUM BRAKE x DISK wee E is E 6 7 5 14 4 15 17 M 18 Par 19 22 20 21 23 BR 00004 1 Air bleeder cap 11 Upper shoe return spring 21 Lower shoe return spring 2 Air bleeder screw 12 Retainer 22 Adjusting spring 3 Boot 13 Washer 23 Drum 4 Piston 14 Parking brake lever 24 Plug 5 15 Brake shoe Trailing 6 Spring 16 Brake shoe Leading Tightening torque N m kgf m ft Ib 7 Wheel cylinder body 17 Shoe hold down spring 1 8 0 8 5 8 8 Pin 18 Cup T2 10 1 0 7 2 9 Plug 19 Adjusting lever 52 5 3 38 3 10 Back plate 20 Adjuster BR 12 General Description BRAKE 4 MASTER CYLINDER es LHD MODEL BR 00153 1 Cap 6 Secondary piston Tightening torque N m kgf m ft Ib 2 Filter 7 Cylinder body T1 15 1 5 10 8 3 Reservoir tank 8 Cylinder pin 4 Piston retainer 9 Seal 5 Primary piston 10 Pin BR 13 General Description BRAKE RHD MODEL BR 00196 1 Cap 6 Secondary piston Tightening torque
44. der piston and spring or damage or rust for mation 2 Assemble in the reverse order of disassembly 1 When installing the cup use ST apply brake fluid to the frictional surface for smooth in stallation and pay attention to cup direction 2 STs are available in different sizes CAUTION When replacing the repair kit make sure that the sizes of cylinder and cup are same as those which were replaced ST ADAPTER Applicable size Part No 11 16 925460000 CAUTION While assembling be careful to prevent any metal chip dust or dirt from entering the wheel cylinder BR 00067 1 Cup 2 Piston 3 Apply rubber grease to the boot inside as shown in the figure CAUTION Never use brake grease BR 51 Rear Drum Brake Assembly BRAKE Grease NIGLUBE RX 2 Part No K0779GA102 00 D lt BR 00068 E INSPECTION If the deformation or wear of back plate shoe etc are notable replace them BR 52 Master Cylinder BRAKE 11 Master Cylinder A REMOVAL CAUTION Do not allow brake fluid to come in contact with vehicle body wash away with water and wipe off completely if spilled 1 Thoroughly drain brake fluid from reservoir tank 2 Disconnect the fluid level indicator harness con nector 3 Remove the
45. e air bleeder securely when no air bubbles are visible Air bleeder tightening torque Except for 17 inch type 8 N m 0 8 kgf m 5 8 ft Ib 17 inch type 20 N m 2 0 kgf m 14 5 ft Ib 5 Perform these steps for the brakes connecting to secondary chamber of master cylinder first and then for the ones connecting to primary chamber With all procedures completed fully depress the brake pedal and keep it in that position for approx 20 seconds to make sure that there is no leak evi dent in the entire system 6 Check the pedal stroke While the engine is idling depress the brake pedal with a 490 50 kgf 110 Ib load and measure the distance between brake pedal and steering wheel With the brake pedal released measure the dis tance between pedal and steering wheel again The difference between the two measurements must not be more than specified BR 00094 1 Steering wheel 2 Toe board Specified pedal stroke 90 mm 3 54 in When depressing brake pedal with a 490 N 50 kgf 110 Ibf load 7 the distance is more than the specifications there is a possibility that air is in the brake line Bleed the brake line until pedal stroke meets the specification 8 Operate the hydraulic control unit in the se quence control mode Ref to ABS 10 ABS Se quence Control 9 Recheck the pedal stroke 10 the distance is more than specifications there is a possibility air is in the inside of hydraulic uni
46. e pedal stroke 1 Entry of air into the hydraulic mechanism Bleed the air 2 Excessive play in the master cylinder push rod Adjust 3 Fluid leakage from the hydraulic mechanism Repair or replace cup piston seal piston boot master cylinder piston kit pipe or hose 4 Improperly adjusted shoe clearance Adjust b Improper lining contact or worn lining Correct or replace 4 Brake dragging or improper brake return 1 Insufficient pedal play Adjust play 2 Improper master cylinder return Clean or replace the cylinder 3 Clogged hydraulic system Replace 4 Improper return or adjustment of parking brake Correct or adjust return spring Replace the spring 6 Excessively narrow shoe clearance Adjust the clearance 7 Improper disc caliper operation Correct or replace 8 Wheel bearing faulty Replace the wheel bearing 5 Brake noise 1 creak sound 1 Hardened or deteriorated lining Replace the shoe assembly or pad 2 Worn lining Replace the shoe assembly or pad b Weakened spring tension or breakage of shoe t 8 Loosened back plate or the support installing bolts Retighten Retighten to normal tightening torque 4 Loose wheel bearing 5 Dirty drum or rotor Clean the drum or rotor or clean and replace the brake assembly 6 Brake noise
47. eak from valve body seal and bearing portion Leak from plate and seal assembly portion Leak from poppet valve assembly portion Loaded air tightness check 1 Start the engine and depress brake pedal with pedal force of 196 N 20 kgf 44 Ib Keep the en gine running until a vacuum of 66 7 kPa 500 mmHg 19 69 inHg point B is indicated on vacu um gauge while the pedal is still depressed Pressure gauge Vacuum gauge Pedal force gauge Depress 2 Stop the engine and watch vacuum gauge If the vacuum drop range is less than 3 3 kPa 25 mmHg 0 98 inHg within 15 seconds after stopping engine the brake booster is functioning properly If defective refer to AIR TIGHTNESS CHECK Ref to BR 56 INSPECTION Brake Booster 3 If any fault is found on brake booster replace the brake booster with a new one Lack of boosting action check Turn off the engine and set the vacuum gauge reading at 0 Then check the fluid pressure when brake pedal is depressed The pressure must be greater than the standard value listed 294N 30 kgf 66 Ib 1 961 kPa Brake pedal 147 N force 15 kgf 33 Ib 686 kPa Fluid pressure 7 kg cm 100 psi 588 kPa 6 kg 85 psi 20 kg cm 284 psi 1 667 kPa 17 kg cm 242 psi 588 kPa 6 kg cm 85 psi 1 471 kPa 15 kg cm 213 psi Model with ABS Boosting action check Set the vacuum ga
48. er with waste cloth when loosening it to prevent brake fluid from being splashed over surrounding parts Do not allow brake fluid to come in contact with vehicle body wash away with water and wipe off completely if spilled Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid Be careful not to allow dirt or dust to get into the reservoir tank 1 MASTER CYLINDER NOTE f the master cylinder is disassembled or reser voir tank is empty bleed the master cylinder During the bleeding operation keep the brake reservoir tank filled with brake fluid to eliminate en try of air The brake pedal operating must be very slow For convenience and safety two people should do the work 1 Loosen the wheel nuts jack up the vehicle sup port it with safety stands and remove the wheel 2 Disconnect the brake line at primary and sec ondary sides 3 Put a plastic bag cover on master cylinder 4 Carefully depress and hold the brake pedal BR 00090 5 Close the outlet plug with your finger and then release the brake pedal BR 00091 6 Repeat step4 and 5 until the brake fluid is com pletely bled from outlet plug 7 Remove the plastic bag 8 Install the brake pipes to master cylinder Tightening torque 15 N m 1 5 kgf m 10 8 ft Ib 9 Bleed air from the brake line Ref to BR 62 BRAKE LINE PROCEDURE Air Bleeding 2 BRAKE LIN
49. essure and rear wheel cylinder fluid pres sure 2 Bleed air from the oil pressure gauges 3 Check the master cylinder fluid pressure and rear wheel cylinder fluid pressure The standard values are shown in the figure 2 BR 00086 1 Rear wheel cylinder fluid pressure 2 Master cylinder fluid pressure Po 3 When both circuits are normal 4 For the oil pressure in case of split point refer to SPECIFICATIONS lt Ref to BR 2 SPECIFICATIONS General De scription gt BR 59 Brake Fluid BRAKE 14 Brake Fluid A INSPECTION 1 Check that the brake fluid level remains between MIN and If out of the specified range refill or drain fluid If the fluid level becomes close to MIN refill the fluid 2 Check the fluid for discoloration If the fluid color has excessively changed drain the fluid and refill with new fluid B REPLACEMENT CAUTION To always maintain the brake fluid character istics replace the brake fluid according to maintenance schedule or earlier than that when used in severe condition The FMVSS No 116 fresh DOT3 brake fluid must be used Cover the bleeder with waste cloth when loosening it to prevent brake fluid from being splashed over surrounding parts Do not allow brake fluid to come in contact with vehicle body wash away with water and wipe off completely if spilled Avoid mixing different brands of brake flui
50. he bolts to install back plate Tightening torque 52 N m 5 3 kgf m 38 3 ft lb BR 00060 5 Install the hub lt Ref to DS 28 INSTALLATION Rear Axle AWD Model Ref to DS 33 INSTAL LATION Rear Axle FWD Modell 6 Connect the brake hose and tighten the brake hose flange nut Tightening torque 15 N m 1 5 kgf m 10 8 ft lb 7 Connect the ABS wheel speed sensor to back plate BR 50 Rear Drum Brake Assembly BRAKE Tightening torque 32 N m 3 3 kgf m 24 ft Ib 8 Apply grease to the adjusting screw and both ends of adjuster Brake grease Dow Corning Molykote No 7439 Part No 003602001 BR 00054 9 Install the brake shoe Ref to BR 48 INSTAL LATION Rear Drum Brake Shoe 10 Install the brake drum Ref to BR 49 IN STALLATION Rear Drum Brake Drum 11 After installing the brake assembly bleed air from the brake line Ref to BR 62 Air Bleeding C DISASSEMBLY 1 Remove the right and left dust boots from wheel cylinder L N C2 3 4 7 BR 00066 1 Bleeder cap 2 Bleeder screw 3 Spring 4 Oylinder 5 Cup 6 Piston 7 Boot RR RR 2 Remove the piston cup spring and air bleeder screw and cap D ASSEMBLY 1 Clean all parts in brake fluid Check and replace the faulty parts Cup and boot for damage or fatigue Cylin
51. he disc rotor BR 00036 Standard value Service limit Disc outer dia 10 mm 0 39 in 8 5 mm 0 335 in 266 mm 10 47 in Disc rotor 18 mm thickness A 0 71 in 16 mm 0 63 in 290 mm 11 42 in 20 mm 0 79 in 18 mm 0 71 in 316 mm 12 44 in BR 41 Rear Disc Brake Assembly BRAKE 7 Rear Disc Brake Assembly A REMOVAL 1 14 INCH TYPE CAUTION Do not allow brake fluid to come in contact with vehicle body wash away with water and wipe off completely if spilled 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the wheels 4 Disconnect the brake hose from caliper body as sembly 5 Remove the bolt securing lock pin to caliper BR 00247 6 Raise the caliper body and move it toward vehi cle center to separate it from support 7 Remove the support from housing NOTE Remove the support only when replacing it or the rotor It need not be removed when servicing the caliper body assembly 8 Clean mud and foreign particles from the caliper body assembly and support CAUTION Be careful to allow foreign particles to enter brake hose connector 2 15 INCH TYPE CAUTION Do not allow brake fluid to come in contact with vehicle body wash away with water and wipe off completely if spilled 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Lif
52. ing hole cover from back plate and then turn adjuster assembly pawls using a flat tip screw driver until brake shoe separates from the drum Do 6 BR 00046 1 2 3 4 5 6 Back plate Wheel cylinder Adjuster ASSY pawls Adjusting lever Tightening direction Push aOR f the brake drum is difficult to remove drive it out by installing an 8 mm bolt into bolt hole in brake drum BR 00047 6 Hold the hold down pin by securing rear of back plate with your hand BR 00048 1 Hold down cup 2 Hold down pin 7 Disconnect the hold down cup from hold down pin by rotating hold down cup 8 Disconnect the lower shoe return spring from shoes BR 00049 9 Remove the shoes one by one from back plate with adjuster CAUTION Be careful not to bend the parking brake cable excessively when removing brake shoes BR 00050 1 Wheel cylinder 2 Adjuster 3 Back plate 4 Lower shoe return spring b Parking lever 6 Trailing shoe BR 47 Rear Drum Brake Shoe BRAKE 10 Disconnect the parking brake cable from park ing lever BR 00051 1 Parking brake cable 2 Trailing shoe 3 Parking brake lever 11 Remove the upper shoe return spring and ad justing spring from brake shoe BR 00052
53. l the pad on support 3 Install the caliper body on support Tightening torque 37 N m 3 8 kgf m 27 5 ft Ib NOTE If itis difficult to push the piston during pad replace ment loosen air bleeder to facilitate work 2 15 INCH TYPE 1 Apply a thin coat of Molykote AS880N Part No K0777Y A010 to frictional portion between pad and pad inner shim 2 Install the pads on caliper body 3 Install the cross spring 4 Install the pad pins on caliper body 5 Install the M clip 3 17 INCH TYPE 1 Apply a thin coat of Molykote AS880N Part No K0777Y A010 to frictional portion between pad and pad inner shim 2 Install the pads on caliper body 3 Install the cross spring and pad pins 4 Install the Clip C INSPECTION 1 14 INCH TYPE Check pad thickness A BR 00016 Standard value Wear limit 9 0 mm 0 354 in 1 5 mm 0 059 in Pad thickness NOTE Always replace the pads for both right and left wheels at the same time Also replace the pad clips if they are twisted or worn A wear indicator is provided on the inner disc brake pad If the pad wears down to such an extent that the end of wear indicator contacts disc rotor a squeaking sound is produced as the wheel rotates If this sound is heard replace the pad Replace the pad if there is oil or grease on it BR 38 Rear Brake Pad BRAKE 2 15 INCH TYPE Check the pad thickness A BR 00314 Stan
54. les to enter the brake hose connector 2 Using a standard screwdriver remove the boot ring from piston BR 00302 1 Boot ring 3 Remove the boot from piston end BR 00303 4 Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged 5 Gradually supply compressed air via the installa tion hole of brake hose to force the piston out BR 00304 1 Place a 30 mm 1 18 in wide wooden block here 6 Remove the piston seal from caliper body cylin der BR 33 Front Disc Brake Assembly BRAKE CAUTION Do not damage the cylinder and piston seal groove BR 00305 1 Piston seal 3 17 INCH TYPE 1 Clean mud and foreign particles from the caliper body assembly CAUTION Be careful to allow foreign particles to enter the brake hose connector 2 Remove the piston boots from each piston end BR 00303 3 Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged 4 Gradually supply compressed air via the installa tion hole of brake hose to force the piston out BR 00304 1 Place a 30 mm 1 18 in wide wooden block here 5 Remove the piston seal from caliper body cylin der CAUTION Do not damage the cylinder and piston seal groove BR 00305
55. locks BR 00013 1 Support 2 Wooden blocks BRAKE 4 Attach a rod of less than 12 mm 0 47 in dia to the shaded area of brake pad and strike the rod with a hammer to drive brake pad out of place BR 00014 2 16 INCH TYPE 1 Set the vehicle on lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the front wheel 4 Remove the M clip BR 00288 1 M clip 5 Remove the pad pins then remove the cross spring BR 00289 1 Pad pin 2 Cross spring BR 25 Front Brake BRAKE 6 Use a wrench to expand the pads and then 5 Remove the pad pins and cross spring push the piston back BR 00293 BR 00290 1 Pad pin 2 Cross spring 6 Use a wrench to expand the pads and then push the piston back BR 00291 3 17 INCH TYPE BR 00290 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the front wheel 4 Remove the clip BR 00291 BR 00292 BR 26 Front Brake B INSTALLATION 1 14 INCH AND 15 INCH TYPE 1 Apply thin coat of Molykote AS880N Part No K0779Y A010 to the frictional portion between pad and pad clip 2
56. lt and then remove the brake pedal BR 00100 BR 70 Brake Pedal 3 Remove the bushing spacer and spring BR 00101 Plug Stopper Brake pedal Brake pedal spring 4 Remove the brake pedal pad 5 RHD AT MODEL Do not disassemble the brake pedal because it has non disassemble structure 6 RHD MT MODEL Do not disassemble the brake pedal because it has non disassemble structure D ASSEMBLY 1 Attach the stop light switch etc to pedal bracket temporarily 2 Clean the inside of bores of clutch pedal and brake pedal apply grease and set the bushings into bores 3 Align bores of the pedal bracket clutch pedal and brake pedal attach the brake pedal return spring and clutch pedal effort reducing spring model with hill holder and then install the pedal bolt NOTE Clean up the inside of bushings and apply grease before installing spacer Tightening torque T 29 N m 3 0 kgf m 21 7 ft Ib BR 00102 BRAKE 4 Adjust the stop light switch position after install ing the brake pedal to vehicle E INSPECTION 1 Move the brake and clutch pedal pads in the lat eral direction with a force of approx 10 N 1 kgf 2 Ib to ensure pedal deflection is in specified range CAUTION If excessive deflection is noted replace the bushings with new ones Deflection of brake and clutch pedal Service limit 5 0 mm 0 197 in or less
57. lty check precisely with gauges Loaded air tightness check Depress the brake pedal while engine is running and turn off the engine while pedal is still de pressed Keep the pedal depressed for 30 sec onds if no change occurs in the pedal height the brake booster is functioning normally if the pedal height increases it is faulty NOTE If faulty check precisely with gauges 2 OPERATION CHECK WITH GAUGES CAUTION When checking operation be sure to securely apply the parking brake Checking with gauges Connect gauges as shown in the figure After bleeding air from pressure gauges proceed to each check BR 00082 1 Pressure gauge 2 Vacuum gauge 3 Adapter hose 4 Vacuum hose 5 Pedal force gauge BR 57 Brake Booster BRAKE Air tightness check 1 Start the engine and keep it running until a vac uum of 66 7 kPa 500 mmHg 19 69 inHg point A is indicated on vacuum gauge Do not depress the brake pedal BR 00083 1 Pressure gauge 2 Vacuum gauge 2 Stop the engine and watch the gauge If the vac uum drop range is less than 3 3 kPa 25 mmHg 0 98 inHg within 15 seconds after stopping engine the brake booster is functioning properly If defective the cause may be one of those listed below Check valve malfunction Leak from vacuum hose Leak from the shell jointed portion or stud bolt welded portion Damaged diaphragm L
58. luid 2 Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body 3 Apply a coat of brake fluid to the entire inner sur face of cylinder and outer surface of piston 4 Insert the piston into cylinder CAUTION Do not force piston into cylinder 5 Apply a coat of specified grease to the boot and fit in groove on ends of cylinder and piston Grease NIGLUBE RX 2 Part No K0779GA102 6 Install the piston boot to caliper body and then attach boot ring BR 00029 Piston boot Boot ring Piston seal Caliper body 7 Apply a coat of specified grease to the guide pin outer surface sleeve outer surface cylinder inner surface and boot grooves Grease NIGLUBE RX 2 Part No K0779GA102 ARN 8 BR 00030 1 Pin boot 2 Lock pin or guide pin 3 Apply grease 8 Install the guide pin boot on support 9 Install the lock pin boot on support and then in sert the lock pin sleeve into place 2 15 INCH TYPE 1 Clean the caliper body interior using brake fluid 2 Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body 3 Apply a coat of brake fluid to the entire inner sur face of cylinder and outer surface of piston 4 Apply a coat of specified grease to the boot and install it in the groove on piston Grease NIGLUBE RX 2 Part No K0
59. n x 4 40 0 mm x 2 46 0 mm x 2 1 575 in x 2 1 811 in x 2 Pad dimensions length x width x thickness 115 0 x 44 3 x 11 0 mm 4 528 x 1 744 x 0 433 in 117 8 x 50 5 x 11 0 mm 4 638 x 1 988 x 0 433 in 116 0 x 47 7 x 10 0 mm 4 567 x 1 878 x 0 394 in 129 8 x 60 5 x 9 2 mm 5 110 x 2 382 x 0 362 in Clearance adjust ment Automatic adjustment Size 14 inch type 15 inch type 17 inch type Type Disc Floating type Disc Fixed type ventilated Effective disc diameter 230 mm 9 06 in 261 mm 10 28 in 268 mm 10 55 in Disc thickness x Outer diameter 10 x 266 mm 0 39 x 10 47 in 18 x 290 mm 0 71 x 11 42 in 20 x 316 mm 0 79 x 12 44 in Effective cylinder diameter 38 1 mm 1 500 in 36 0 mm 1 417 in Pad dimensions length x width x thickness 89 4 x 33 7 x 9 0 mm 3 520 x 1 327 x 0 354 in 71 8 x 35 0 x 11 5 mm 2 827 x 1 378 x 0 453 in 74 8 x 45 0 x 9 0 mm 2 945 x 1 772 x 0 354 in Clearance adjust ment Automatic adjustment Type Drum Leading Trailing type Effective drum diameter 228 6 mm 9 in Effective cylinder diameter 17 5 mm 0 689 in Lining dimensions length x width x thickness 218 8 35 0 4 1 mm 8 61 x 1 378 x 0 161 in Clearance adjust ment Automatic adjustment Master cylinder Type Tandem Effective diamete
60. on a lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the rear wheel 4 Remove the lower caliper bolt BR 00123 5 Raise the caliper body upward and support it NOTE Do not disconnect the brake hose from caliper 6 Remove the pad NOTE If the brake pad is difficult to remove use the same procedure as for front disc brake pad Ref to BR 25 REMOVAL Front Brake Pad BR 00032 2 15 INCH TYPE 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the rear wheel BRAKE 4 Remove the M clip BR 00310 1 M clip 2 Caliper 5 Remove the two pad pins 6 Remove the cross spring 00311 1 Cross spring 2 Pad pin 7 Expand the pads and push piston back 8 Remove the pad and shim BR 00312 1 Brake pad 3 17 INCH TYPE 1 Set the vehicle on lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the rear wheel BR 37 Rear Brake Pad BRAKE 4 Remove the clip BR 00313 BR 00811 1 Cross spring 2 Pad pin 6 Expand the pads and push piston back 7 Remove the pad 00312 1 Rear brake pad B INSTALLATION 1 14 INCH TYPE 1 Apply a thin coat of Molykote AS880N Part No K0777Y A010 to the frictional portion between pad and pad clip 2 Instal
61. on strut using a clamp 3 Connect the brake hose through hole in bracket body Tightening torque 15 N m 1 5 kgf m 10 8 ft Ib BR 00126 1 Brake pipe 2 Brake hose 3 Brake hose clamp 4 Bleed air from the brake system C INSPECTION Ensure there are no cracks breakage or damage on the hoses Check the joints for fluid leakage If any cracks breakage damage or leakage is found repair or replace the hose BR 66 Brake Pipe BRAKE 17 Brake Pipe A REMOVAL NOTE Airbag system wiring harness is routed near the center brake pipe CAUTION All airbag system wiring harness and con nectors are colored yellow Do not use electri cal test equipment on these circuits Be careful not to damage the airbag system wiring harness when servicing the center brake pipe When removing the brake pipe make sure that it is not bent B INSTALLATION NOTE Airbag system wiring harness is routed near the center brake pipe CAUTION All airbag system wiring harness and con nectors are colored yellow Do not use electri cal test equipment on these circuits Be careful not to damage the airbag system wiring harness when servicing the center brake pipe When installing the brake pipe make sure that it is not bent After installing the brake pipe and hose bleed the air After installing the brake hose make sure that it does not touch the tire or suspension as
62. p light switch and stopper CAUTION Be careful not to rotate stop light switch Stop light switch clearance A 0 3 mm 0 012 in BR 00110 1 Stop light switch 2 Stopper 3 Brake pedal 3 If it is not within specified value adjust it by ad justing position of stop light switch CAUTION Be careful not to rotate the stop light switch D ADJUSTMENT Loosen the lock nut and adjust the stop light switch position until the clearance between threaded end of stop light switch and stopper A becomes 0 3 mm 0 012 in Then tighten the lock nut BR 73 Stop Light Switch BRAKE Tightening torque 8 N m 0 8 kgf m 5 8 ft Ib BR 00111 1 Stop light switch 2 Lock nut A 3 Lock nut B 4 Stopper 5 Brake pedal NOTE Tighten the lock nut B until the clearance between threaded end of stop light switch and stopper be comes 0 in Hold the stop light switch to pre vent turning and then loosen the lock nut B approx 60 The clearance A will become 0 3 mm 0 012 in BR 74 Hill Holder 20 Hill Holder A REMOVAL 1 PHV PRESSURE HOLD VALVE 1 Drain the brake fluid from reservoir of master cyl inder 2 Remove the adjusting nut and lock nut BR 00131 1 Adjusting nut 2 Lock nut 3 PHV 3 Remove the cable clamp and disconnect the PHV cable from PHV CAUTION Carefully protect the boots and inner cable from damage when
63. r 23 81 mm 0 9374 in 25 4 mm 1 in 26 99 mm 1 1 16 in Reservoir type Sealed type Brake fluid reser voir capacity 205 cm 12 51 cu in Brake booster Type Vacuum suspended Effective diameter 230 mm 9 06 in 180 205 mm 7 09 8 07 in BR 2 205 230 mm 8 07 9 06 in General Description BRAKE Model BASE TS GX RS OBK WRX STi 2 1 961 oper Split point 2 3 tioning 20 kg cm 285 psi valve Reduce ratio 0 4 Brake line Dual circuit system Brake fluid CAUTION Avoid mixing brake fluid of different brands to pre vent the fluid performance from degrading When brake fluid is sup plemented be careful not to allow any dust into the res ervoir Use fresh DOT3 brake fluid when replacing or refilling the fluid Model with ABS FMVSS No 116 DOT3 NOTE Refer to section for parking brake SPECIFICATIONS Ref to PB 2 SPECIFICATIONS General De scription gt ITEM STANDARD SERVICE LIMIT 14 15 11 mm 0 43 in 1 5 mm 0 059 in Pad thickness 16 10 mm 0 39 in 1 5 mm 0 059 in 17 9 2 mm 0 362 in 1 2 mm 0 047 in Front krake SER cu 24 mm 0 94 in 22 mm 0 87 in 17 30 mm 1 18 in 28 mm 1 10 in Disc runout 0 075 mm 0 0030 in 14 9 0 mm 0 354 in 1 5 mm 0 059 in Pad thickness 15 11 5 mm 0 452 in 1 5 mm 0 059 in
64. r Drum Brake Assembly BRAKE 10 Rear Drum Brake Assembly A REMOVAL CAUTION Do not allow brake fluid to come in contact with vehicle body wash away with water and wipe off completely if spilled 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the wheels 4 Release the parking brake 5 Remove the brake drum from brake assembly Ref to BR 49 REMOVAL Rear Drum Brake Drum 6 Remove the brake shoe Ref to BR 47 RE MOVAL Rear Drum Brake Shoe 7 Disconnect the brake hose Ref to BR 65 REAR BRAKE HOSE DRUM BRAKE REMOV AL Brake Hose 8 Remove the hub Ref to DS 25 REMOVAL Rear Axle AWD Model Ref to DS 33 RE MOVAL Rear Axle FWD Modell 9 Disconnect the ABS wheel speed sensor from back plate 10 Remove the brake assembly BR 00060 11 Remove the bolts installing wheel cylinder on back plate and remove it BR 00061 B INSTALLATION 1 Clean the back plate and wheel cylinder 2 Install the wheel cylinder on back plate and tighten bolts Tightening torque 10 N m 1 0 kgf m 7 2 ft Ib BR 00061 3 Apply grease to the portions indicated by arrows in the figure Brake grease Dow Corning Molykote No 7439 Part No 003602001 BR 00053 4 Install the brake assembly on housing and tight en t
65. rew BR 60 Brake Fluid BRAKE 8 Release the brake pedal slowly Repeat steps 6 through 8 until there are no air bubbles in the drained brake fluid and new fluid flows through vi nyl tube NOTE Add brake fluid as necessary while performing air bleed operation in order to prevent the tank from running short of brake fluid f caliper has two air bleeder screws bleed air from inner first then outer BR 00376 1 Inner air bleeder screw 2 Outer air bleeder screw 9 After completing the bleeding operation hold brake pedal depressed and tighten screw and in stall bleeder cap Tightening torque Bleeder screw Except for 17 inch type 8 N m 0 8 kgf m 5 8 ft Ib 17 inch type 20 N m 2 0 kgf m 14 5 ft Ib 10 Bleed air from each wheel cylinder using the same procedures as described in steps 6 through 8 above 11 Depress the brake pedal with a force of approx 294 N 30 kg 66 Ib and hold it there for approx 20 seconds At this time check for mix in air and pedal height change Visually inspect the bleeder screws and brake pipe joints to make sure that there is no fluid leakage 12 Install the wheels and drive the vehicle for a short distance between 2 to 3 km 1 to 2 miles to make sure that brakes are operating properly BR 61 Air Bleeding BRAKE 15 Air Bleeding A PROCEDURE CAUTION The FMVSS No 116 fresh DOT3 brake fluid must be used Cover the bleed
66. rn spring is worn out damaged or corroded 3 Confirm that rolling sound of the ball is heard with PHV inclined and lever rotates smoothly CAUTION Never disassemble the PHV Replace entire PHV assembly if necessary C INSTALLATION 1 PHV PRESSURE HOLD VALVE 1 Install the PHV onto side frame Tightening torque 18 N m 1 8 kgf m 13 0 ft lb 2 Connect the brake pipes to PHV Tightening torque 15 N m 1 5 kgf m 10 8 ft lb CAUTION Confirm that the brake pipes are not deformed and or damaged Replace them with new ones if necessary 3 Install the PHV cable to PHV CAUTION e If the cable clamp and clips is damaged re place it with a new one Avoid sharp bending of PHV cable as it may cause breakage 4 Connect the PHV cable with clips 5 Apply grease to the following points Hook portion of return spring Cable end portion of lever Grease SUNLIGHT 2 Part No 003602010 6 Be sure to bleed air from the brake system 7 Adjust the PHV cable Ref to BR 76 PHV CA BLE INSTALLATION Hill Holder CAUTION After replacing with new one operate the clutch pedal about 30 times as a running in operation prior to adjustment 2 PHV CABLE 1 Install in the reverse order of removal CAUTION If the cable clamp is damaged replace it with a new one Avoid sharp bending of PHV cable as it may cause breakage 2 Apply grease to the following points Hook portion of return spring
67. t Repeat above steps 2 to 9 above until pedal stroke meets the specification 11 Add brake fluid to the required level MAX lev el of reservoir tank BR 63 Air Bleeding BRAKE 12 As a final step test run the vehicle at low speed and apply brakes relatively hard 2 to 3 times to en sure that brakes provide normal braking action on all four wheels without dragging and uneven brak ing BR 64 Brake Hose 16 Brake Hose A REMOVAL 1 FRONT BRAKE HOSE 1 Separate the brake pipe from brake hose Always use the flare nut wrench and be careful not to deform the flare nut 2 Pull out the clamp to remove brake hose 3 Remove the bolt at strut and union bolt BR 00095 1 Brake hose 2 Brake pipe 2 REAR BRAKE HOSE DISC BRAKE 1 Separate the brake pipe from brake hose NOTE Always use the flare nut wrench and be careful not to deform the flare nut 2 Remove the clamp and union bolt BR 00096 1 Brake pipe 2 Brake hose 3 Brake hose clamp 3 REAR BRAKE HOSE DRUM BRAKE 1 Separate the brake pipe from brake hose using a flare nut wrench 2 Remove two clamps BRAKE 3 Separate the brake hose from wheel cylinder BR 00126 1 Brake pipe 2 Brake hose 3 Brake hose clamp B INSTALLATION 1 FRONT BRAKE HOSE 1 Secure the brake hose to strut Tightening torque 32 N m 3 3 kgf m 23 6 ft Ib Se the brake hose to caliper using
68. t up the vehicle and then remove the wheels 4 Remove the pads from caliper body Ref to BR 37 REMOVAL Rear Brake Pad 5 Disconnect the brake hose from caliper body as sembly 6 Remove the caliper body from housing BR 00315 7 Clean mud and foreign particles from the caliper body assembly CAUTION Be careful not to allow foreign particles to enter brake hose connector 3 17 INCH TYPE CAUTION Do not allow brake fluid to come in contact with vehicle body wash away with water and wipe off completely if spilled 1 Set the vehicle on a lift 2 Loosen the wheel nuts 3 Lift up the vehicle and then remove the wheels 4 Remove the brake pads from caliper body Ref to BR 37 17 INCH TYPE REMOVAL Rear Brake Pad 5 Disconnect the brake hose from caliper body 6 Remove the caliper body from housing BR 00315 7 Clean mud and foreign particles from the caliper body CAUTION Be careful not to allow foreign particles to enter brake hose connector BR 42 Rear Disc Brake Assembly B INSTALLATION 1 14 INCH TYPE 1 Install the support on housing Tightening torque 52 N m 5 3 kgf m 38 3 ft Ib 2 Apply thin coat of Molykote AS880N Part No K0777Y A010 to the frictional portion between pad and pad clip 3 Install the pads on support 4 Install the caliper body on support Tightening torque 37 N m 3 8 kgf m 27 5 ft Ib 5 Replace the brake hose gaskets
69. the brake pipes from master cylin der 3 Remove the master cylinder installing nuts 4 Disconnect the vacuum hose from brake booster 2 Remove the following parts from pedal bracket 1 Snap pin and clevis pin 2 Four brake booster installing nuts BR 00073 Nuts Clevis pin Snap pin Operating rod 3 Remove the brake booster while shunning brake pipes NOTE Be careful not to drop the brake booster The brake booster should be discarded if it has been dropped Use special care when handling the operating rod If excessive force is applied to the operating rod sufficient to cause a change in the angle in excess of 3 it may result in damage to the power piston cylinder Use care when placing the brake booster on floor Donot change the push rod length If it has been changed reset the projected length L to standard length Standard L 10 05 mm 0 40 in BR 00074 CAUTION If external force is applied from above when the brake booster is placed in this position the res in portion as indicated by P may be dam aged BR 00075 1 Force B INSTALLATION 1 Adjust the operating rod of brake booster Standard L LHD model 144 6 mm 5 69 in RHD model 173 2 mm 6 82 in If it is not within specified value adjust it by adjust ing the brake booster operating rod L
70. uge reading at 66 7 kPa 500 mmHg 19 69 inHg by running engine Then check the fluid pressure when brake pedal is de pressed The pressure must be greater than the standard value listed Brake pedal force 147 N 15 kgf 33 Ib 294N 30 kgf 66 Ib 5 982 kPa 61 kg cm 868 psi 7 649 kPa 78 kg cm 1 109 psi 8 434 kPa 86 kg 1 223 psi Fluid pressure 5 296 kPa 54 kg cm 768 psi 4 707 kPa 48 kg cm 683 psi 9 120 kPa 93 kg cm 1 323 psi 4 021 kPa 41 kg cm 583 psi Model with ABS BR 58 8 336 kPa 85 kg cm 1 209 psi Proportioning Valve BRAKE 13 Proportioning Valve A REMOVAL BR 00085 1 Remove the brake pipe from proportioning valve at four places 2 Remove the proportioning valve from its bracket NOTE Do not disassemble or adjust the proportioning valve The proportioning valve must be replaced as an assembly B INSTALLATION 1 Install the proportioning valve to bracket 2 Connect the brake pipes correctly to proportion ing valve 3 Bleed air and then check each joint of the brake pipe for oil leaks Tightening torque Proportioning valve to brake pipe flare nut 15 N m 1 5 kgf m 10 8 ft Ib Proportioning valve to bracket 18 N m 1 8 kgf m 13 0 ft Ib C INSPECTION 1 Install the oil pressure gauges to measure the master cylinder fluid pressure front wheel brake fluid pr

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