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Subaru Impreza 2004 Service Manual

Chassis section
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2004 IMPREZA SERVICE MANUAL
CHASSIS SECTION
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
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.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
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.
QUICK REFERENCE INDEX
FRONT SUSPENSION
REAR SUSPENSION
WHEEL AND TIRE SYSTEM
DIFFERENTIALS
TRANSFER CASE
DRIVE SHAFT SYSTEM
ABS
ABS (DIAGNOSTICS)
BRAKE
PARKING BRAKE
POWER ASSISTED SYSTEM
(POWER STEERING)
FS
RS
WT
DI
TC
DS
ABS
ABS(diag)
BR
PB
PS
G1870GE5

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Summary of Contents for Subaru Impreza 2004

  • Page 1 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...

  • Page 2: Table Of Contents

    BRAKE Page General Description ..................2 Front Brake Pad ..................25 Front Disc Rotor ..................29 Front Disc Brake Assembly...............31 Rear Brake Pad..................37 Rear Disc Rotor..................40 Rear Disc Brake Assembly ...............42 Rear Drum Brake Shoe................47 Rear Drum Brake Drum ................49 Rear Drum Brake Assembly..............50 Master Cylinder ..................53 Brake Booster ...................55 Proportioning Valve...................59...

  • Page 3: General Description

    General Description BRAKE 1. General Description A: SPECIFICATIONS Model BASE, TS GX, RS, OBK Size 14 inch type 15 inch type 16 inch type 17 inch type Type Disc (Floating type, ventilated) Disc (Fixed type, ventilated) Effective disc 210 mm (8.27 in) 228 mm (8.98 in) 255 mm (10.04 in) 268 mm (10.55 in)
  • Page 4 General Description BRAKE Model BASE, TS GX, RS, OBK 1,961 kPa Propor- Split point — tioning (20 kg/cm , 285 psi) valve Reduce ratio — Brake line Dual circuit system Brake fluid CAUTION: • Avoid mixing brake fluid of different brands to pre- vent the fluid performance from degrading.
  • Page 5 General Description BRAKE Fluid pressure Brake pedal BASE, TS force GX, RS, OBK Without ABS With ABS 686 kPa 588 kPa 588 kPa 147 N (7 kg/cm (6 kg/cm (15 kgf, 33 lb) (6 kg/cm , 85 psi) 100 psi) 85 psi) Brake fluid pressure without engine running...

  • Page 6: Front Disc Brake

    General Description BRAKE B: COMPONENT 1. FRONT DISC BRAKE • 14 INCH TYPE (17) (16) (15) (11) (10) (12) (12) (11) (14) (13) BR-00377 Caliper body Support (17) Bushing Air bleeder screw (10) Pad clip Guide pin (Green) (11) Outer shim Tightening torque: N·m (kgf-m, ft-lb) Pin boot (12)
  • Page 7 General Description BRAKE • 15 INCH TYPE (17) (10) (16) (11) (12) (14) (13) (12) (11) (15) BR-00378 Caliper body Support (17) Bushing Air bleeder screw (10) Pad clip Guide pin (Green) (11) Outer shim Tightening torque: N·m (kgf-m, ft-lb) Pin boot (12) Inner shim...
  • Page 8 General Description BRAKE • 16 INCH TYPE (10) (11) (12) (14) (10) (13) (12) (17) (11) (15) (17) (16) BR-00379 Housing Piston boot (17) Spacer Air bleeder screw (10) Boot ring Caliper body (11) Outer shim Tightening torque: N·m (kgf-m, ft-lb) M clip (12) Inner shim...
  • Page 9 General Description BRAKE • 17 INCH TYPE (11) (10) (12) (14) (10) (13) (12) (11) (15) (16) BR-00380 Housing Piston boot (15) Disc rotor Caliper body Piston (16) Disc cover Air bleeder screw (10) Piston seal Guide plate (11) Pad shim (Outside) Tightening torque: N·m (kgf-m, ft-lb) Cross spring (12)

  • Page 10: Rear Disc Brake

    General Description BRAKE 2. REAR DISC BRAKE • 14 INCH TYPE ( 2) ( 3) ( 4) (1 ) (5 ) ( 10 ) ( 6) (7 ) (8 ) (1 4) (9 ) (12 ) (3 3) ( 4 ) (1 1) (1 4 ) (1 7)
  • Page 11 General Description BRAKE • 15 INCH TYPE (15) (14) (13) (10) (11) (12) (12) (18) (11) (16) (17) (19) (20) (21) (24) (33) (22) (25) (26) (27) (28) (23) (30) (29) (32) (31) BR-00327 Caliper body (14) Washer (27) Secondary shoe return spring Air bleeder screw (15) Cross spring...
  • Page 12 General Description BRAKE • 17 INCH TYPE (10) (12) (11) (10) (15) (13) (14) (16) (17) (18) (19) (30) (21) (22) (23) (24) (25) (20) (26) (27) (29) (28) BR-00281 Caliper body (13) Shoe hold-down pin (25) Primary shoe return spring Air bleeder screw (14) Cover...
  • Page 13 General Description BRAKE 3. REAR DRUM BRAKE (12) (13) (14) (17) (15) (24) (18) (10) (19) (11) (22) (16) (20) (21) (23) BR-00004 Air bleeder cap (11) Upper shoe return spring (21) Lower shoe return spring Air bleeder screw (12) Retainer (22) Adjusting spring...

  • Page 14: Master Cylinder

    General Description BRAKE 4. MASTER CYLINDER • LHD MODEL (10) BR-00153 Secondary piston Tightening torque: N·m (kgf-m, ft-lb) Filter Cylinder body T1: 15 (1.5, 10.8) Reservoir tank Cylinder pin Piston retainer Seal Primary piston (10) BR-13...
  • Page 15 General Description BRAKE • RHD MODEL (10) BR-00196 Secondary piston Tightening torque: N·m (kgf-m, ft-lb) Filter Cylinder body T1: 15 (1.5, 10.8) Reservoir tank Cylinder pin Piston retainer Seal Primary piston (10) BR-14...
  • Page 16 General Description BRAKE 5. FRONT BRAKE PIPES AND HOSE • LHD MODEL (11) (11) (10) BR-00283 Model without ABS Model with ABS Model with ABS (with hill holder) Front brake pipe assembly ABS control module and hydraulic Tightening torque: N·m (kgf-m, ft-lb) control unit (ABSCM&H/U) Proportioning valve T1: 15 (1.5, 10.8)
  • Page 17 General Description BRAKE • RHD MODEL (11) (3) (5) (11) (11) (10) BR-00284 Model without ABS Model with ABS Model with ABS (With hill holder) Front brake pipe assembly ABS control module and hydraulic Tightening torque: N·m (kgf-m, ft-lb) control unit (ABSCM&H/U) Proportioning valve T1: 15 (1.5, 10.8) Front brake hose RH...
  • Page 18 General Description BRAKE 6. CENTER AND REAR BRAKE PIPES AND HOSES BR-00007 Center brake pipe assembly Rear brake hose LH (Disc brake Tightening torque: N·m (kgf-m, ft-lb) model) Two-way connector T1: 15 (1.5, 10.8) Rear brake pipe assembly Rear brake hose LH (Drum brake T2: 18 (1.8, 13.0) model) Rear brake hose RH (Disc brake...

  • Page 19: Brake Booster

    General Description BRAKE 7. BRAKE BOOSTER • MODEL With ABS (11) (10) ( 8 ) (12) ( 7 ) ( 1 ) ( 2 ) ( 4 ) ( 5 ) ( 6 ) ( 3 ) ( 9 ) BR-00008 Push rod Filter...

  • Page 20: Brake Pedal

    General Description BRAKE 8. BRAKE PEDAL • 1.6 L MODEL (17) (16) (11) (12) (15) (18) (15) (14) (13) (13) (14) (10) BR-00286 Stopper (10) Clutch pedal Tightening torque: N·m (kgf-m, ft-lb) Bushing (11) Clutch cable T1: 5.9 (0.6, 4.3) Pedal bracket (12) Clutch cable clamp...
  • Page 21 General Description BRAKE • 2.0 L AND 2.5 L MODEL (26) (11) (25) (24) (23) (11) (28) (22) (20) (21) (19) (18) (14) (14) (13) (27) (17) (16) (15) (12) (11) (23) (29) (10) BR-00287 Stopper (13) Assist rod A (25) Clutch master cylinder bracket Bushing...
  • Page 22 General Description BRAKE • LHD AT MODEL BR-00139 Stopper Brake pedal pad Tightening torque: N·m (kgf-m, ft-lb) Bushing Brake pedal T1: 8 (0.8, 5.8) Pedal bracket Clevis pin T2: 18 (1.8, 13.0) Stop light switch Brake pedal spring T3: 29 (3.0, 21.7) Snap pin BR-21...
  • Page 23 General Description BRAKE • RHD MODEL BR-00010 Stopper Brake pedal pad Tightening torque: N·m (kgf-m, ft-lb) Snap pin Brake pedal bracket ASSY T1: 8 (0.8, 5.8) Clevis pin Cover T2: 18 (1.8, 13.0) Stop light switch Protector T3: 33 (3.3, 24.3) Brake pedal BR-22...
  • Page 24 • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary re- moval, installation, disassembly, and replacement. • Use SUBARU genuine grease etc. or the equiv- alent. Do not mix grease etc. with that of another grade or from other manufacturers.
  • Page 25 General Description BRAKE 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.

  • Page 26: Front Brake Pad

    Front Brake Pad BRAKE 2. Front Brake Pad (4) Attach a rod of less than 12 mm (0.47 in) dia. to the shaded area of brake pad, and strike the A: REMOVAL rod with a hammer to drive brake pad out of place.
  • Page 27 Front Brake Pad 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 7) Remove the pad. (2) Cross spring 6) Use a wrench to expand the pads, and then push the piston back.
  • Page 28 Front Brake Pad BRAKE B: INSTALLATION 3. 17 INCH TYPE 1) Apply thin coat of Molykote AS880N (Part No. 1. 14 INCH AND 15 INCH TYPE K0779YA010) to the frictional portion between pad 1) Apply thin coat of Molykote AS880N (Part No. and pad shim.
  • Page 29 Front Brake Pad 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) Pad thickness Wear limit 1.5 mm (0.59 in) NOTE: •...

  • Page 30: Front Disc Rotor

    Front Disc Rotor BRAKE 3. Front Disc Rotor 4) Remove the caliper body from housing and sus- pend from strut using a wire. 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.
  • Page 31 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.

  • Page 32: Front Disc Brake Assembly

    Front Disc Brake Assembly BRAKE 4. Front Disc Brake Assembly NOTE: Remove the support only when replacing it or the A: REMOVAL rotor. It need not be removed when servicing the caliper body assembly. 1. 14 INCH AND 15 INCH TYPE CAUTION: Do not allow brake fluid to come in contact with vehicle body;...
  • Page 33 Front Disc Brake Assembly BRAKE 4) Remove the brake pads from caliper body. <Ref. 7) Bleed air from the brake system. to BR-26, 17 INCH TYPE, REMOVAL, Front Brake 2. 16 INCH TYPE Pad.>. 5) Remove the union bolt and brake hose from cal- 1) Install the caliper body on housing.
  • Page 34 Front Disc Brake Assembly BRAKE 7) Replace the brake hose gaskets with new ones, 2. 16 INCH TYPE and then connect the brake hose. 1) Clean mud and foreign particles from the caliper Tightening torque: body assembly. 18 N·m (1.8 kgf-m, 13.0 ft-lb) CAUTION: 8) Bleed air from the brake system.
  • Page 35 Front Disc Brake Assembly BRAKE 5) Remove the piston seal from caliper body cylin- CAUTION: der. Do not damage the cylinder and piston seal groove. CAUTION: Do not damage the cylinder and piston seal groove. BR-00305 (1) Piston seal BR-00305 3.
  • Page 36 Front Disc Brake Assembly BRAKE 6) Position the boot in grooves on cylinder and pis- CAUTION: ton. Do not force the piston into cylinder. BR-00122 BR-00307 6) Position the boot in grooves on cylinder and pis- (1) Piston ton. (2) Piston boot (3) Caliper body (4) Piston seal 7) Apply a coat of specified grease to the lock pin...
  • Page 37 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.

  • Page 38: Rear Brake Pad

    Rear Brake Pad BRAKE 5. Rear Brake Pad 4) Remove the M clip. A: REMOVAL 1. 14 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.
  • Page 39 Rear Brake Pad BRAKE 4) Remove the clip. NOTE: If it is 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. K0777YA010) to frictional portion between pad and pad inner shim.
  • Page 40 Rear Brake Pad BRAKE 2. 15 INCH TYPE • Replace the pad if there is oil or grease on it. Check the pad thickness A. BR-00314 Standard value 11.5 mm (0.452 in) Pad thickness Wear limit 1.5 mm (0.059 in) NOTE: •...

  • Page 41: Rear Disc Rotor

    Rear Disc Rotor BRAKE 6. Rear Disc Rotor (2) If the disc rotor seizes up within hub, drive the disc rotor out by installing an 8-mm bolt in A: REMOVAL holes B on rotor. 1) Set the vehicle on a lift. 2) Loosen the wheel nuts.
  • Page 42 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 the disc rotor. BR-00036 Standard Service...

  • Page 43: Rear Disc Brake Assembly

    Rear Disc Brake Assembly BRAKE 7. Rear Disc Brake Assembly 6) Remove the caliper body from housing. 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.
  • Page 44 Rear Disc Brake Assembly BRAKE B: INSTALLATION C: DISASSEMBLY 1. 14 INCH TYPE 1. 14 INCH TYPE 1) Install the support on housing. 1) Remove the boot ring. Tightening torque: 52 N·m (5.3 kgf-m, 38.3 ft-lb) 2) Apply thin coat of Molykote AS880N (Part No. K0777YA010) to the frictional portion between pad and pad clip.
  • Page 45 Rear Disc Brake Assembly BRAKE 4) Gradually supply compressed air via the installa- CAUTION: tion hole of brake hose to force the piston out. Do not damage the cylinder and piston seal groove. BR-00318 BR-00043 (1) Place a 30 mm (1.18 in) wide wooden block 6) Remove the lock pin sleeve and boot from cali- here.
  • Page 46 Rear Disc Brake Assembly BRAKE 3) Gradually supply compressed air via the installa- 6) Install the piston boot to caliper body, and then tion hole of brake hose to force the piston out. attach boot ring. BR-00318 BR-00029 (1) Place a 20 mm (0.79 in) wide wooden block (1) Piston boot here.
  • Page 47 Rear Disc Brake Assembly BRAKE E: INSPECTION CAUTION: Do not force piston into cylinder. 1) Repair or replace the faulty parts. 2) Check the caliper body and piston for uneven 6) Install the piston boot to the caliper body, and wear, damage or rust.

  • Page 48: Rear Drum Brake Shoe

    Rear Drum Brake Shoe BRAKE 8. Rear Drum Brake Shoe 6) Hold the hold-down pin by securing rear of back plate with your hand. 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.
  • Page 49 Rear Drum Brake Shoe BRAKE 10) Disconnect the parking brake cable from park- Brake grease: ing lever. Dow Corning Molykote No. 7439 (Part No. 003602001) BR-00051 BR-00054 (1) Parking brake cable 4) Connect the upper shoe return spring to shoes. (2) Trailing shoe 5) Connect the parking brake cable to parking le- (3) Parking brake lever...

  • Page 50: Rear Drum Brake Drum

    Rear Drum Brake Drum BRAKE 9. Rear Drum Brake Drum 2) Measure the drum inner diameter. If the inner di- ameter of drum is outside the service limit, replace A: REMOVAL the drum. 1) Set the vehicle on a lift. Drum inner diameter: “L”...

  • Page 51: Rear Drum Brake Assembly

    Rear Drum Brake Assembly BRAKE 10.Rear Drum Brake Assembly Tightening torque: 10 N·m (1.0 kgf-m, 7.2 ft-lb) 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.
  • Page 52 Rear Drum Brake Assembly BRAKE Tightening torque: D: ASSEMBLY 32 N·m (3.3 kgf-m, 24 ft-lb) 1) Clean all parts in brake fluid. Check and replace 8) Apply grease to the adjusting screw and both the faulty parts. ends of adjuster. •...
  • Page 53 Rear Drum Brake Assembly BRAKE Grease: NIGLUBE RX-2 (Part No. K0779GA102) BR-00068 E: INSPECTION If the deformation or wear of back plate, shoe, etc. are notable, replace them. BR-52...

  • Page 54: Master Cylinder

    Master Cylinder BRAKE 11.Master Cylinder 5) Pry up the pawl, and then remove the piston re- tainer. Hold piston retainer tight, because the pis- A: REMOVAL ton may jump out from master cylinder. CAUTION: Do not allow brake fluid to come in contact with vehicle body;...
  • Page 55 Master Cylinder BRAKE 12) Install the seal to reservoir tank. 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.

  • Page 56: Brake Booster

    Brake Booster BRAKE 12.Brake Booster • Use care when placing the brake booster on floor. A: REMOVAL • Do not change the push rod length. If it has been 1) Remove or disconnect the following parts at en- changed, reset the projected length “L” to standard gine compartment.
  • Page 57 Brake Booster BRAKE 2) Mount the brake booster in position. CAUTION: 3) Connect the operating rod to brake pedal with Be careful not to rotate the stop light switch. clevis pin and snap pin. 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.
  • Page 58 Brake Booster BRAKE • Air tightness check 3) As the engine starts, the brake pedal should move slightly toward the floor. If no change occurs Start the engine, and run it for 1 to 2 minutes, then in the pedal height, the brake booster is faulty. turn it off.
  • Page 59 Brake Booster BRAKE • Air tightness check 2) Stop the engine and watch vacuum gauge. If the vacuum drop range is less than 3.3 kPa (25 1) Start the engine and keep it running until a vac- mmHg, 0.98 inHg) within 15 seconds after stopping uum of 66.7 kPa (500 mmHg, 19.69 inHg) = point A engine, the brake booster is functioning properly.

  • Page 60: Proportioning Valve

    Proportioning Valve BRAKE 13.Proportioning Valve The standard values are shown in the figure. A: REMOVAL BR-00086 BR-00085 (1) Rear wheel cylinder fluid pressure: P (2) Master cylinder fluid pressure: P 1) Remove the brake pipe from proportioning valve at four places. (3) When both circuits are normal 2) Remove the proportioning valve from its bracket.

  • Page 61: Brake Fluid

    Brake Fluid BRAKE 14.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 A: INSPECTION to collect the brake fluid. 1) Check that the brake fluid level remains between “MIN”...
  • Page 62 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.

  • Page 63: Air Bleeding

    Air Bleeding BRAKE 15.Air Bleeding 5) Close the outlet plug with your finger, and then release the brake pedal. A: PROCEDURE CAUTION: • 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.
  • Page 64 Air Bleeding BRAKE Air bleeder tightening torque: CAUTION: Except for 17 inch type: Brake fluid replacement sequence; (A) Front right → → → → (B) Rear left → → → → (C) Front left → → → → (D) Rear 8 N·m (0.8 kgf-m, 5.8 ft-lb) 17 inch type: right...
  • Page 65 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.

  • Page 66: Brake Hose

    Brake Hose BRAKE 16.Brake Hose 3) Separate the brake hose from wheel cylinder. 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.
  • Page 67 Brake Hose BRAKE 2. REAR BRAKE HOSE (DISC BRAKE) Tightening torque: 15 N·m (1.5 kgf-m, 10.8 ft-lb) 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.

  • Page 68: Brake Pipe

    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. •...

  • Page 69: Brake Pedal

    Brake Pedal BRAKE 18.Brake Pedal 4) Remove the nut which secures the clutch master cylinder. A: REMOVAL 5) Remove the accelerator pedal. 6) Remove the bolts and nuts which the secure 1. LHD 1.6 L MT MODEL pedal bracket. 1) Disconnect the ground cable from battery. 2) Disconnect the clutch cable from release lever.
  • Page 70 Brake Pedal BRAKE 4) Remove the four bolts and four nuts which se- 5) Remove the four bolts which secure the brake cure the brake pedal to pedal. pedal bracket (rear side). BR-00140 BR-00135 6) Remove the nuts which secure the brake pedal (1) Clevis pin bracket (front side).
  • Page 71 Brake Pedal BRAKE 3) Inspect the brake pedal after installation <Ref. to 3) Remove the clutch master cylinder bracket. 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.
  • Page 72 Brake Pedal BRAKE 3) Remove the bushing, spacer and spring. 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 lb) to ensure pedal deflection is in specified range.
  • Page 73 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 kgf, 2 lb).] BR-00106 (1) Stop light switch (2) Mat (3) Toe board (4) Brake booster operating rod 3) If it is not within specified value, adjust it by ad- justing the brake booster operating rod length.

  • Page 74: Stop Light Switch

    Stop Light Switch BRAKE 19.Stop Light Switch Specified position: L 2 mm (0.079 in) 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.
  • Page 75 Stop Light Switch BRAKE Tightening torque: 8 N·m (0.8 kgf-m, 5.8 ft-lb) 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 mm (0 in).

  • Page 76: Hill Holder

    Hill Holder BRAKE 20.Hill Holder CAUTION: Exercise utmost care to prevent foreign matter A: REMOVAL from entering into the PHV when removing it. 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-00133 (1) PHV 2.
  • Page 77 Hill Holder BRAKE 3) Remove the cable clamp from clutch pedal C: INSTALLATION bracket. 1. PHV (PRESSURE HOLD VALVE) • LHD MODEL 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:...
  • Page 78 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;...

  • Page 79: General Diagnostics

    General Diagnostics BRAKE 21.General Diagnostics A: INSPECTION Trouble and possible cause Corrective action 1. Insufficient braking (1) Fluid leakage from the 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.
  • Page 80 General Diagnostics BRAKE Trouble and possible cause Corrective action 7. Brake noise (3) In the case of the disc brake: (click sound) (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.
  • Page 81 General Diagnostics BRAKE BR-80...

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