2004 IMPREZA SERVICE MANUAL QUICK
Contents
1. 1 Brake caliper assembly 3 Suspend the brake caliper assembly so that the hose is not stretched 4 Remove the disc rotor NOTE If the disc rotor is difficult to remove try the two fol lowing 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 Adjusting hole cover rubber Flat tip screwdriver Back plate 2 If the disc rotor seizes up within hub drive the disc rotor out by installing two 8 mm bolts in holes B on rotor BR 00036 5 Remove the shoe return spring from parking brake assembly 6 Remove the front shoe hold down spring and pin with pliers PB 00013 7 Remove the strut and strut spring 8 Remove the adjuster assembly from parking brake assembly 9 Remove the brake shoe 10 Remove the rear shoe hold down spring and pin with pliers 11 Remove the parking brake cable from parking brake lever PB 00014 1 Parking brake cable 2 Parking brake lever 12 Using a standard screwdriver raise the retain er Remove the parking brake lever and washer from brake shoe PB 6 Parking Brake Assembly Rear Disc Brake PARKING BRAKE INSTALLATION CAUTION Be sure the lining surface is free from oil and grease contamination 1 Apply brake grease to the following places Brak2. a cap protec tive goggles and protective shoes during operation Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replacement Be careful not to burn your hands because each part on the vehicle is hot after running e Use SUBARU genuine grease etc 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 e Place shop jacks or rigid racks 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 Keep grease etc away from parking brake shoes PB 3 T3 32 3 3 23 6 1 Parking brake lever 7 Clamp 2 Parking brake switch 8 Parking brake cable RH 3 Lock nut 9 Cable guide 4 Adjusting nut 10 Clamp Rear disc brake model 5 Equalizer 11 Parking brake cable LH 6 Bracket Tightening torque N m kgf m ft lb T1 5 9 0 6 4 3 Parking Brake Lever PARKING BRAKE 2 Parking Brake Lever If not as specified adjust the parking brake lt Ref to PB 8 ADJUSTMENT Parking Brake Assembly A REMOVAL Rear Disc Brake gt 1 Set the wheel stopper to wheels D ADJUSTMENT 2 Remove the console box ore g Adjust the parking brake lever stroke lt Ref to PB 3 Loosen the parking cab
3. 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 INZNGIET 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 ee Es PARKING BRAKE Page 1 General D secription uikssengesgmonmdirepdmerdd senuesedoetthentetaneniacee 2 2 Parking Brake L ve irrin erede aee i ea i A A e d d 4 3 Parking Brake Cable spente ease teken 5 4 Parking Brake Assembly Rear Disc Brake rrrrnrnnnnnnnnnnnrrrrnnnnnnnnnnrnrnnnnn 6 5 General
4. Diagnostic Table rrrnnnnnnnnnnnnvnnnnnnnnnnnnnvnnnnnnnnnnnnnnnnnnnnnennnnnnnnennn 9 General Description PARKING BRAKE 1 General Description A SPECIFICATIONS Rear disc brake Rear drum brake Rear disc brake STi model Mechanical on rear Type brakes Mechanical on rear brakes drum in disc Effective drum diameter mm in 228 6 9 170 6 69 190 7 48 Lining dimensions mm in 218 8 x 35 0 x 4 1 162 6 x 30 0 x 3 2 182 3 x 30 0 x 3 2 length x width x thickness 8 61 x 1 378 x 0 161 6 40 x 1 181 x 0 126 7 18 x 1 181 x 0 126 Clearance adjustment Automatic adjustment Manual adjustment Lever stroke notches N kgf Ib 7 to 8 196 20 44 B COMPONENT 1 PARKING BRAKE REAR DISC BRAKE 5 ae QI 9 8 ae 15 14 PB 00001 1 Back plate 8 Strut 15 Shoe hold down spring 2 Retainer 9 Shoe guide plate 16 Shoe hold down pin 3 Spring washer 10 Primary return spring 17 Adjusting hole cover 4 Lever 11 Secondary return spring 5 arking brake shoe Primary 12 justing spring ightening torque N m kgf m ft Parking brake shoe Pri Adjusti i Tighteni N m kgf m ft lb 6 Parking brake shoe Secondary 13 Adjuster T 53 5 4 39 1 7 Strut spring 14 Shoe hold down cup PB 2 General Description 2 PARKING BRAKE CABLE PARKING BRAKE 10 ow DYP PB 00002 C CAUTION e Wear working clothing including
5. e grease Brake Grease Part No 003602002 e Six contact surfaces of shoe rim and back plate packing e Contact surface of shoe wave and anchor pin e Contact surface of lever and strut Contact surface of shoe wave and adjuster as sembly e Contact surface of shoe wave and strut e Contact surface of lever and shoe wave 2 Insert the primary side brake shoe into anchor pin groove 3 Secure the brake shoe with shoe hold down pin and cup 4 Install the plate to anchor pin and then assem ble the primary return spring to anchor pin PB 00039 1 Primary return spring 2 Anchor pin 3 Plate 4 Primary shoe 5 Shoe hold down pin amp cup 5 Install the parking brake cable to parking brake lever 6 Assemble the strut and adjuster and then se cure the secondary side brake shoe with shoe hold down pin amp cup NOTE Install the strut spring of both right and left wheels facing vehicle front e Install the adjuster assembly with screw on left side Cl oa PB 00016 1 Left 7 Install the secondary return spring and adjusting spring Co 1 ga 2 I Ss 5 N S Oe I GL Fe co PB 00017 1 2 3 Lever Secondary brake shoe Strut spring Strut Return spring Adjuster Shoe hold down cup Adjusting spring oo 7 8 8 Adjust the parking brakes lt Ref to PB 8 AD JUSTMENT Parking Brake Assembly Rear Disc Brake gt 9 Drive the veh
6. icle for parking brake lining break in 1 Drive the vehicle at about 35 km h 22 MPH 2 With the parking brake release button pushed in pull the parking brake lever gently 3 Drive the vehicle for about 200 meter 0 12 mile in this condition 4 Wait 5 to 10 minutes for the parking brake to cool down Repeat this procedure once more 5 After breaking in re adjust the parking brakes nn mn DE ee eS PB 7 Parking Brake Assembly Rear Disc Brake PARKING BRAKE C INSPECTION 1 Measure the brake disc rotor inside diameter If the disc is scored or worn replace the brake disc rotor Disc rotor inside diameter Standard Except STi model 170 mm 6 69 in STi model 190 mm 7 48 in Service limit Except STi model 171 mm 6 73 in STi model 191 mm 7 52 in 2 Measure the lining thickness If it exceeds the limit replace the shoe assembly Lining thickness Standard 3 2 mm 0 126 in Service limit 1 5 mm 0 059 in NOTE Replace the right and left brake shoes at the same time D ADJUSTMENT 1 SHOE CLEARANCE 1 Return the parking brake lever completely 2 Remove the adjusting hole cover from back plate 3 Turn the adjusting screw using a flat tip screw driver until brake shoe is in close contact with disc rotor PB 00032 Adjusting screw Adjusting hole cover rubber Flat tip screwdriver Back plate 4 Turn back downward the adju
7. le adjusting nut and con 8 LEVER STROKE ADJUSTMENT Parking sole bracket l 4 Disconnect the connector of parking brake Brake Dy Meat Dec Brake switch 5 Remove the parking brake lever PB 00003 6 Remove the inner cable end from equalizer PB 00008 1 Equalizer 2 Inner cable end B INSTALLATION 1 Install in the reverse order of removal Tightening torque Parking brake lever 18 N m 1 8 kgf m 13 0 ft Ib Adjusting nut 5 9 N m 0 6 kgf m 4 3 ft Ib 2 Be sure to adjust the lever stroke lt Ref to PB 4 ADJUSTMENT Parking Brake Lever gt C INSPECTION 1 Operate the parking brake lever 3 to 4 times and then return the lever completely 2 While pulling the parking brake lever upward slowly count the notches Lever stroke 7 to 8 notches when pulled with a force of 196 N 20 kgf 44 Ib PB 4 Parking Brake Cable PARKING BRAKE 3 Parking Brake Cable A REMOVAL 1 Lift up the vehicle 2 Remove the rear wheels 3 Remove the rear seat cushion 4 Remove the console box 5 Loosen the parking cable adjusting nut and con sole bracket 6 Remove the parking brake lever PB 00003 7 Roll up the floor mat and remove clamps PB 00007 8 Remove the equalizer cover 9 Remove the inner cable end from equalizer PB 00008 1 Equalize
8. r 2 Inner cable end 10 Remove the parking brake cable from rear brake Disc brake lt Ref to PB 6 REMOVAL Parking Brake Assem bly Rear Disc Brake gt Drum brake lt Ref to BR 50 REMOVAL Rear Drum Brake As sembly gt 11 Remove the clamp from rear brake 12 Remove the bolt and bracket from trailing link bracket 13 Remove the bolt and clamp from rear floor We 8 NS I PB 00009 14 Detach the grommet from rear floor 15 Remove the cable assembly from cabin by forcibly pulling it backward 16 Detach the parking brake cable from cable guide at rear trailing link B INSTALLATION 1 Install the new parking brake assembly in the reverse order of removal NOTE Be sure to pass the cable through cable guide in side the tunnel 2 Be sure to adjust the lever stroke lt Ref to PB 4 ADJUSTMENT Parking Brake Lever gt C INSPECTION Check the removed cable and replace it if dam aged rusty or malfunctioning 1 Check for smooth operation of the cable 2 Check the inner cable for damage and rust 3 Check the outer cable for damage bends and cracks 4 Check the boot for damage cracks and deterio ration PB 5 Parking Brake Assembly Rear Disc Brake PARKING BRAKE 4 Parking Brake Assembly Rear Disc Brake A REMOVAL 1 Pull down and release the parking brake 2 Remove the two mounting bolts and remove the brake caliper assembly
9. sting screw 3 or 4 notches CAUTION Be sure that the brake is not dragging 5 Install the adjusting hole cover to back plate 6 Adjust the parking brake lever stroke lt Ref to PB 8 LEVER STROKE ADJUSTMENT Parking Brake Assembly Rear Disc Brake gt 2 LEVER STROKE 1 Before adjusting the lever stroke adjust the shoe clearance lt Ref to PB 8 SHOE CLEAR ANCE ADJUSTMENT Parking Brake Assembly Rear Disc Brake gt 2 Remove the console box lid 3 Operate the parking brake lever 3 to 5 times 4 Adjust the lever stroke by turning the adjusting nut to set the stroke within specification Lever stroke When operating the force of 196 N 20 kgf 44 Ib 7 8 notches PB 00005 1 Parking brake lever 2 Lock nut 3 Adjusting nut 5 Tighten the lock nut Tightening torque Lock nut 5 9 N m 0 6 kgf m 4 3 ft Ib 6 Install the console box lid PB 8 General Diagnostic Table PARKING BRAKE 5 General Diagnostic Table A INSPECTION Symptom Possible cause Remedy Parking brake lever is maladjusted Adjustment Parking brake cable does not move Repair or replace Parking brake shoe clearance is maladjusted Adjustment Return spring is faulty Replace Return spring is faulty Replace Shoe hold down spring is faulty Replace Brake drag Noise from brake PB 9 General Diagnostic Table PARKING BRAKE PB 10
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