Subaru 2001 IMPREZA Service Manual
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Subaru 2001 IMPREZA Service Manual

Subaru 2001 IMPREZA Service Manual

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2001 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
BR
PB
PS
G1830GE5

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  • Page 1 2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX CHASSIS SECTION 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.

  • Page 2: Table Of Contents

    BRAKE Page General Description ..................2 Front Brake Pad ..................23 Front Disc Rotor ..................26 Front Disc Brake Assembly...............28 Rear Brake Pad..................34 Rear Disc Rotor..................37 Rear Disc Brake Assembly ...............39 Rear Drum Brake Shoe................44 Rear Drum Brake Drum ................46 Rear Drum Brake Assembly..............48 Master Cylinder ..................52 Brake Booster ...................55 Proportioning Valve...................60...

  • Page 3: General Description

    GENERAL DESCRIPTION BRAKE 1. General Description A: SPECIFICATIONS Size 14 inch type 15 inch type 16 inch type Type Disc (Floating type, ventilated) Effective disc diameter 210 mm (8.27 in) 228 mm (8.98 in) 255 mm (10.04 in) Disc thickness × Outer diame- 24 ×...
  • Page 4 GENERAL DESCRIPTION BRAKE ITEM STANDARD SERVICE LIMIT 14”,15” 17 mm (0.571 in) 7.5 mm (0.295 in) Pad thickness (including back metal) 16” 14.5 mm (0.67 in) 6.0 mm (0.236 in) Front brake Disc thickness 24 mm (0.94 in) 22 mm (0.87 in) Disc runout —...
  • Page 5 GENERAL DESCRIPTION BRAKE B: COMPONENT 1. 14 INCH TYPE B4M1208C Caliper body Support Tightening torque: N·m (kgf-m, ft-lb) Air bleeder screw (10) Pad clip T1: 8 (0.8, 5.8) Guide pin (Green) (11) Outer shim T2: 18 (1.8, 13.0) Pin boot (12) Inner shim T3: 37 (3.8, 27.5)
  • Page 6 GENERAL DESCRIPTION BRAKE 2. 15 INCH TYPE B4M1151C Caliper body Lock pin (Yellow) (17) Disc cover Air bleeder screw (10) Support Guide pin (Green) (11) Pad clip Tightening torque: N·m (kgf-m, ft-lb) Pin boot (12) Outer shim T1: 8 (0.8, 5.8) Piston seal (13) Inner shim...
  • Page 7 GENERAL DESCRIPTION BRAKE 3. 16 INCH TYPE BR0003 Housing Piston boot Tightening torque: N·m (kgf-m, ft-lb) Air bleeder screw (10) Boot ring T1: 8 (0.8, 5.8) Caliper body (11) Shim A T2: 18 (1.8, 13.0) M clip (12) Shim B T3: 80 (8.2, 59) Cross spring (13)
  • Page 8 GENERAL DESCRIPTION BRAKE 4. REAR DISC BRAKE (14 INCH TYPE) H4M1355A Caliper body (14) Shim (27) Primary shoe return spring Air bleeder screw (15) Shoe hold-down pin (28) Adjusting spring Guide pin (Green) (16) Cover (29) Adjuster Pin boot (17) Back plate (30) Shoe hold-down cup...
  • Page 9 GENERAL DESCRIPTION BRAKE 5. REAR DISC BRAKE (15 INCH TYPE) BR0004 Caliper body (14) Washer (27) Secondary shoe return spring Air bleeder screw (15) Cross spring (28) Primary shoe return spring Pad pin (16) Shoe hold-down pin (29) Adjusting spring Piston seal (17) Cover...
  • Page 10 GENERAL DESCRIPTION BRAKE 6. REAR DRUM BRAKE (12) (13) (14) (17) (15) (24) (18) (10) (19) (11) (22) (16) (20) (21) (23) B4M1120A Air bleeder cap (11) Upper shoe return spring (21) Lower shoe return spring Air bleeder screw (12) Retainer (22) Adjusting spring...
  • Page 11 GENERAL DESCRIPTION BRAKE 7. MASTER CYLINDER • LHD models (11) (10) S4M0186A Secondary piston Tightening torque: N·m (kgf-m, ft-lb) Filter Cylinder body T1: 14 (1.4, 10.1) Reservoir tank Cylinder pin (with ABS) Bracket (10) Seal Piston retainer (11) Primary piston BR-10...
  • Page 12 GENERAL DESCRIPTION BRAKE • RHD models (11) (10) B4M1155C Primary piston (11) Filter Secondary piston Reservoir tank Cylinder body Tightening torque: N·m (kgf-m, ft-lb) Bracket Cylinder pin (with ABS) T1: 14 (1.4, 10.1) Piston retainer (10) Seal BR-11...
  • Page 13 GENERAL DESCRIPTION BRAKE 8. BRAKE PIPES AND HOSE • LHD model AT MODEL MT MODEL WITH HILL HOLDER MT MODEL WITHOUT HILL HOLDER WITHOUT ABS BR0073 BR-12...
  • Page 14 GENERAL DESCRIPTION BRAKE Front brake pipe assembly (12) Two-way connector (19) Rear brake hose LH (FWD drum brake model) Proportioning valve (13) Rear brake pipe assembly Front brake hose RH (14) Rear brake hose RH (Disc brake (20) Rear brake pipe LH (FWD drum model) brake model) Front brake hose LH...
  • Page 15 GENERAL DESCRIPTION BRAKE • RHD model AT MODEL MT MODEL WITH HILL HOLDER MT MODEL WITHOUT HILL HOLDER WITHOUT ABS BR0074 BR-14...
  • Page 16 GENERAL DESCRIPTION BRAKE Front brake pipe assembly (12) Two-way connector (19) Rear brake hose LH (FWD drum brake model) Proportioning valve (13) Rear brake pipe assembly Front brake hose RH (14) Rear brake hose RH (Disc brake (20) Rear brake pipe LH (FWD drum model) brake model) Front brake hose LH...

  • Page 17: Brake Booster

    GENERAL DESCRIPTION BRAKE 9. BRAKE BOOSTER • Models with ABS B4M1974A Push rod Filter Valve body Return spring Silencer (10) Plunger valve Reaction disc Operating rod (11) Diaphragm plate Poppet valve (12) Valve return spring • Models without ABS BR0059 Push rod Plunger valve Operating rod...
  • Page 18 GENERAL DESCRIPTION BRAKE 10.HILL HOLDER S4M0240B Clamp Lock nut Tightening torque: N·m (kgf-m, ft-lb) PHV cable To clutch pedal T1: 3.5 (0.35, 2.5) PHV (Pressure hold valve) T2: 18 (1.8, 13.0) Adjusting nut BR-17...
  • Page 19 GENERAL DESCRIPTION BRAKE 11.BRAKE PEDAL • 1.6 L Model BR0060 Stopper Spring (15) Stop light switch Bushing Clutch pedal pad Clutch pedal bracket (10) Clutch pedal Tightening torque: N·m (kgf-m, ft-lb) Snap pin (11) Clutch cable T1: 5.9 (0.6, 4.3) Brake pedal pad (12) Clutch cable clamp...
  • Page 20 GENERAL DESCRIPTION BRAKE • 2.0 L Model BR0061 Stopper (12) Clutch clevis pin (23) Clutch switch (With cruise control) Bushing (13) Assist rod A (24) Stop light switch Spring pin (14) Clip (25) Pedal bracket Snap pin (15) Assist spring (26) Clutch master cylinder bracket Brake pedal pad...
  • Page 21 GENERAL DESCRIPTION BRAKE 12.BRAKE PEDAL FOR AT MODEL BR0007 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-20...
  • Page 22 • Be careful not to burn your hands, because each part in the vehicle is hot after running. • Use SUBARU genuine grease etc. or the equiv- alent. Do not mix grease etc. with that of another grade or from other manufacturers.
  • Page 23 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 in). B4M2406 2. GENERAL PURPOSE TOOLS TOOL NAME REMARKS SNAP RING PLIERS Used for removing and installing snap ring.

  • Page 24: 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 25 FRONT BRAKE PAD BRAKE 8) Use a wrench to expand the pads, then push the 2. 16 INCH TYPE piston back. 1) Apply thin coat of Molykote AS880N (Part No.26298AC000) to the frictional portion between pad and pad inner shim. H4M1370 9) Remove pad.
  • Page 26 FRONT BRAKE PAD BRAKE 2. 16 INCH TYPE Check pad thickness A. BR0009 Pad thickness Standard value 14.5 mm (0.571 in) (including back Wear limit 6.0 mm (0.236 in) metal) CAUTION: • Always replace the pads for both the left and right wheels at the same time.

  • Page 27: Front Disc Rotor

    FRONT DISC ROTOR BRAKE 3. Front Disc Rotor 5) Remove caliper body from housing and suspend from strut using a wire. A: REMOVAL 1. 14 INCH AND 15 INCH TYPE 1) Set the vehicle on the lift. 2) Disconnect ground terminal from battery. 3) Loosen wheel nuts.
  • Page 28 FRONT DISC ROTOR BRAKE B: INSTALLATION C: INSPECTION 1) Install the disc rotor. 1) Install disc rotor by tightening the five wheel nuts. 2) Install caliper body on housing. 2) Set a dial gauge on the disc rotor. Turn disc rotor Tightening torque: to check runout.

  • Page 29: Front Disc Brake Assembly

    FRONT DISC BRAKE ASSEMBLY BRAKE 4. Front Disc Brake Assembly 2. 16 INCH TYPE 1) Set the vehicle on the lift. A: REMOVAL 2) Disconnect ground terminal from battery. 3) Loosen wheel nuts. 1. 14 INCH AND 15 INCH TYPE 4) Jack-up the vehicle, and remove front wheel.
  • Page 30 FRONT DISC BRAKE ASSEMBLY BRAKE B: INSTALLATION 2. 16 INCH TYPE 1) Install caliper body on housing. 1. 14 INCH AND 15 INCH TYPE Tightening torque: 1) Install support on housing. 80 N·m (8.2 kgf-m, 59 ft-lb) Tightening torque: CAUTION: 80 N·m (8.2 kgf-m, 59 ft-lb) •...
  • Page 31 FRONT DISC BRAKE ASSEMBLY BRAKE C: DISASSEMBLY 1. 14 INCH TYPE 1) Clean mud and foreign particles from caliper body assembly and support. CAUTION: Be careful not to allow foreign particles to enter inlet (at brake hose connector). 2) Gradually supply compressed air via caliper body brake hose to force piston out.
  • Page 32 FRONT DISC BRAKE ASSEMBLY BRAKE 2) Using a standard screwdriver, remove boot ring D: ASSEMBLY from piston. 1. 14 INCH TYPE 1) Clean caliper body interior using brake fluid. 2) Apply a coat of brake fluid to piston seal and fit piston seal in groove on caliper body.
  • Page 33 FRONT DISC BRAKE ASSEMBLY BRAKE 8) Install lock and guide pin boot on support. S4M0448A B4M1176B (1) Piston boot (2) Boot ring (1) Pin boot (3) Piston seal (2) Lock pin or guide pin (4) Caliper body (3) Apply grease. 6) Position boot in grooves on cylinder and piston.
  • Page 34 FRONT DISC BRAKE ASSEMBLY BRAKE 3. 16 INCH TYPE E: INSPECTION 1) Repair or replace faulty parts. 1) Clean caliper body interior using brake fluid. 2) Check caliper body and piston for uneven wear, 2) Apply a coat of brake fluid to piston seal and fit damage or rust.

  • Page 35: Rear Brake Pad

    REAR BRAKE PAD BRAKE 5. Rear Brake Pad 2. 15 INCH TYPE 1) Set the vehicle on the lift. A: REMOVAL 2) Disconnect ground terminal from battery. 3) Loosen wheel nuts. 1. 14 INCH TYPE 4) Jack-up the vehicle, and remove front wheel. 1) Set the vehicle on the lift.
  • Page 36 REAR BRAKE PAD BRAKE B: INSTALLATION C: INSPECTION 1. 14 INCH TYPE 1. 14 INCH TYPE 1) Apply thin coat of Molykote AS880N (Part No. Check pad thickness A. 26298AC000) to the frictional portion between pad and pad clip. 2) Install pad on support. 3) Install caliper body on support.
  • Page 37 REAR BRAKE PAD BRAKE as the wheel rotates. If this sound is heard, re- place the pad. • Replace pad if there is oil or grease on it. BR-36...

  • Page 38: Rear Disc Rotor

    REAR DISC ROTOR BRAKE 6. Rear Disc Rotor (2) If disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in holes B on A: REMOVAL the rotor. 1) Lift-up vehicle and remove wheels. 2) Remove the two mounting bolts and remove the disc brake assembly.
  • Page 39 REAR DISC ROTOR BRAKE B: INSTALLATION C: INSPECTION 1) Install in the reverse order of removal. 1) Set a dial gauge on the disc rotor. Turn disc rotor to check runout. 2) Adjust parking brake. <Ref. to PB-11, ADJUST- MENT, Parking Brake Assembly (Rear Disc CAUTION: Brake).>...

  • Page 40: Rear Disc Brake Assembly

    REAR DISC BRAKE ASSEMBLY BRAKE 7. Rear Disc Brake Assembly 2. 15 INCH TYPE CAUTION: A: REMOVAL Do not allow brake fluid to come in contact with 1. 14 INCH TYPE vehicle body; wipe off completely if spilled. 1) Set the vehicle on the lift. CAUTION: 2) Disconnect ground terminal from battery.
  • Page 41 REAR DISC BRAKE ASSEMBLY BRAKE B: INSTALLATION 3) Apply thin coat of Molykote AS880N (Part No. 26298AC000) to the frictional portion between pad 1. 14 INCH TYPE and pad clip. 4) Install pads on caliper body. 1) Install disc rotor on hub. 5) Connect brake hose.
  • Page 42 REAR DISC BRAKE ASSEMBLY BRAKE C: DISASSEMBLY 4) Remove piston seal from caliper body cylinder. 1. 14 INCH TYPE 1) Remove the boot ring. S4M0122 5) Remove lock pin sleeve and boot from caliper body. 6) Remove guide pin boot. S4M0120B 2.
  • Page 43 REAR DISC BRAKE ASSEMBLY BRAKE 3) Gradually supply compressed air via inlet of cal- D: ASSEMBLY iper body to force piston out. 1. 14 INCH TYPE CAUTION: 1) Clean caliper body interior using brake fluid. • Place a wooden block as shown in figure to 2) Apply a coat of brake fluid to piston seal and fit prevent damage to piston.
  • Page 44 REAR DISC BRAKE ASSEMBLY BRAKE 9) Install lock pin boot on caliper body and insert E: INSPECTION lock pin sleeve into place. 1) Repair or replace faulty parts. 2) Check caliper body and piston for uneven wear, 2. 15 INCH TYPE damage or rust.

  • Page 45: Rear Drum Brake Shoe

    REAR DRUM BRAKE SHOE BRAKE 8. Rear Drum Brake Shoe 6) Disconnect lower shoe return spring from shoes. A: REMOVAL 1) Loosen wheel nuts, jack-up vehicle, support it with rigid racks, and remove wheel. 2) Release parking brake. 3) Remove brake drum from brake assembly. NOTE: •...
  • Page 46 REAR DRUM BRAKE SHOE BRAKE B: INSTALLATION C: INSPECTION 1) Clean back plate and wheel cylinder. 1) Measure the lining thickness. 2) Apply grease to portions indicated by arrows in Lining thickness: Figure. Standard 4.1 mm (0.161 in) Brake grease: Service limit 1.5 mm (0.059 in) Dow Corning Molykote No.

  • Page 47: Rear Drum Brake Drum

    REAR DRUM BRAKE DRUM BRAKE 9. Rear Drum Brake Drum B: INSTALLATION Set the outside diameter of brake shoes less than A: REMOVAL 0.5 to 0.8 mm (0.020 to 0.031 in) in comparison 1) Loosen wheel nuts, jack-up vehicle, support it with the inside diameter of brake drum.
  • Page 48 REAR DRUM BRAKE DRUM BRAKE 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.

  • Page 49: Rear Drum Brake Assembly

    REAR DRUM BRAKE ASSEMBLY BRAKE 10.Rear Drum Brake Assembly 6) Disconnect lower shoe return spring from shoes. A: REMOVAL 1) Loosen wheel nuts, jack-up vehicle, support it with rigid racks, and remove wheel. 2) Release parking brake. 3) Remove brake drum from brake assembly. NOTE: •...
  • Page 50 REAR DRUM BRAKE ASSEMBLY BRAKE 12) Remove the bolts installing wheel cylinder on B: INSTALLATION back plate, and remove it. 1) Install wheel cylinder on back plate, and tighten bolts. Tightening torque: 10 N·m (1.0 kgf-m, 7.2 ft-lb) S4M0454 S4M0454 2) Clean back plate and wheel cylinder.
  • Page 51 REAR DRUM BRAKE ASSEMBLY BRAKE 6) Connect parking brake cable to parking lever. C: DISASSEMBLY 7) While positioning shoes (one at a time) in groove 1) Remove right and left dust boots from wheel cyl- on wheel cylinder, secure shoes. inder.
  • Page 52 REAR DRUM BRAKE ASSEMBLY BRAKE D: ASSEMBLY 3) Apply rubber grease to the boot inside as shown in Figure. 1) Clean all parts in brake fluid. Check and replace faulty parts. CAUTION: • Cup and boot for damage or fatigue Never use brake grease.

  • Page 53: Master Cylinder

    MASTER CYLINDER BRAKE 11.Master Cylinder B: INSTALLATION 1) To install the master cylinder to the body, re- A: REMOVAL verse the sequence of removal procedure. 1) Thoroughly drain brake fluid from reservoir tank. Tightening torque: 2) Disconnect fluid level indicator harness connec- Master cylinder mounting nut tor.
  • Page 54 MASTER CYLINDER BRAKE C: DISASSEMBLY D: ASSEMBLY 1. PRECAUTIONS FOR DISASSEMBLING 1. PRECAUTIONS FOR ASSEMBLING 1) Remove mud and dirt from the surface of brake 1) When assembling, be sure to use recommended master cylinder. brake fluid. 2) Prepare tools necessary for disassembly opera- 2) Ensure that the inside wall of cylinder, pistons, tion, and arrange them neatly on work bench.
  • Page 55 MASTER CYLINDER BRAKE E: INSPECTION If any damage, deformation, wear, swelling, rust, and other faults are found on the primary piston as- sembly, secondary piston assembly, supply valve stopper, or gasket, replace the faulty part. CAUTION: • The primary and secondary pistons must be replaced as complete assemblies.

  • Page 56: Brake Booster

    BRAKE BOOSTER BRAKE 12.Brake Booster A: REMOVAL 1) Remove or disconnect the following parts at en- gine compartment. (1) Disconnect connector for brake fluid level in- dicator. (2) Remove brake pipes from master cylinder. (3) Remove master cylinder installing nuts. (4) Disconnect vacuum hose from brake boost- S4M0464A 2) Remove the following parts from the pedal...
  • Page 57 BRAKE BOOSTER BRAKE B: INSTALLATION If it is not in specified value, adjust it by adjusting brake booster operating rod. 1) Mount brake booster in position. 2) Connect operating rod to brake pedal with clevis pin and snap pin. B4M0616A 8) Measure the clearance between threaded end of stop light switch and stopper.
  • Page 58 BRAKE BOOSTER BRAKE C: INSPECTION • Operation check 1) With engine off, depress brake pedal several 1. OPERATION CHECK (WITHOUT GAUG- times applying the same pedal force and make sure that the pedal height does not vary with each depression of the pedal. CAUTION: When checking operation, be sure to securely apply the hand brake.
  • Page 59 BRAKE BOOSTER BRAKE 2. OPERATION CHECK (WITH GAUGES) • Leak from valve body seal and bearing portion • Leak from plate and seal assembly portion CAUTION: • Leak from poppet valve assembly portion When checking operation, be sure to securely •...
  • Page 60 BRAKE BOOSTER BRAKE • Lack of boosting action check Turn off 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. Brake pedal 147 N 294 N...

  • Page 61: Proportioning Valve

    PROPORTIONING VALVE BRAKE 13.Proportioning Valve B: INSTALLATION 1) Install proportioning valve to bracket. A: REMOVAL 2) Connect brake pipes correctly to proportioning valve. 3) Bleed air, then check each joint of brake pipe for oil leaks. Tightening torque: Proportioning valve to brake pipe flare nut: 15 N·m (1.5 kgf-m, 10.8 ft-lb) Proportioning valve to bracket 18 N·m (1.8 kgf-m, 13.0 ft-lb)
  • Page 62 PROPORTIONING VALVE BRAKE C: INSPECTION 1) Install the oil pressure gauges to measure the master cylinder fluid pressure (front wheel brake fluid pressure) 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.

  • Page 63: Brake Fluid

    BRAKE FLUID BRAKE 14.Brake Fluid B: REPLACEMENT CAUTION: A: INSPECTION • To always maintain the brake fluid character- 1) Check that brake fluid level remains between istics, replace the brake fluid according to “MIN” and “MAX”. If out of the specified range, refill maintenance schedule or earlier than that when or drain fluid.
  • Page 64 BRAKE FLUID BRAKE 5) Install one end of a vinyl tube onto the air bleeder NOTE: and insert the other end of the tube into a container Add brake fluid as necessary while performing the to collect the brake fluid. air bleed operation, in order to prevent the tank from running short of brake fluid.

  • Page 65: Air Bleeding

    AIR BLEEDING BRAKE 15.Air Bleeding 5) Install brake pipes to master cylinder. Tightening torque: A: PROCEDURE 8 N·m (0.8 kgf-m, 5.8 ft-lb) CAUTION: 6) Bleed air from brake line. <Ref. to BR-64, • The FMVSS No. 116, fresh DOT3 or 4 brake BRAKE LINE, PROCEDURE, Air Bleeding.>...
  • Page 66 AIR BLEEDING BRAKE Repeat these steps until there are no more air bub- 8) Operate hydraulic control unit in the sequence bles in the vinyl tube. control mode. (With ABS) Allow 3 to 4 seconds between two brake pedal op- <Ref.

  • Page 67: Brake Hose

    BRAKE HOSE BRAKE 16.Brake Hose B: INSTALLATION 1. FRONT BRAKE HOSE A: REMOVAL 1) Route end of brake hose (on caliper side) 1. FRONT BRAKE HOSE through hole in brake hose bracket at strut location. 1) Separate brake pipe from brake hose. 2) Tighten end of brake hose at caliper using a (Always use flare nut wrench and be careful not to union bolt.
  • Page 68 BRAKE HOSE BRAKE 2. REAR BRAKE HOSE C: INSPECTION Ensure there are no cracks, breakage, or damage 1) Pass brake hose through the hole of bracket, on hoses. Check joints for fluid leakage. If any and lightly tighten flare nut to connect brake pipe. cracks, breakage, damage or leakage is found, re- 2) Insert clamp upward to fix brake hose.

  • Page 69: Brake Pipe

    BRAKE PIPE BRAKE 17.Brake Pipe B: INSTALLATION NOTE: A: REMOVAL Airbag system wiring harness is routed near the NOTE: center brake pipe. Airbag system wiring harness is routed near the CAUTION: center brake pipe. • All Airbag system wiring harness and con- CAUTION: nectors are colored yellow.
  • Page 70 BRAKE PIPE BRAKE C: INSPECTION Ensure there are no cracks, breakage, or damage on pipes. Check joints for fluid leakage. If any cracks, breakage, damage or leakage is found, re- pair or replace pipe. NOTE: Use a mirror when inspecting low-visible part or back side.

  • Page 71: Hill Holder

    HILL HOLDER BRAKE 18.Hill Holder A: REMOVAL 1. PHV (PRESSURE HOLD VALVE) 1) Drain brake fluid from reservoir of master cylin- der. 2) Remove adjusting nut and lock nut. S4M0243B (1) PHV 2. PHV CABLE 1) Remove adjusting nut and lock nut. S4M0241C (1) Adjusting nut (2) Lock nut...
  • Page 72 HILL HOLDER BRAKE 3) Remove cable clamp from clutch pedal bracket. C: INSTALLATION LHD model 1. PHV (PRESSURE HOLD VALVE) 1) Install PHV onto side frame. Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb) 2) Connect brake pipes to PHV. Tightening torque: 15 N·m (1.5 kgf-m, 10.8 ft-lb) CAUTION:...
  • Page 73 HILL HOLDER BRAKE 3) Adjust PHV cable. <Ref. to BR-72, ADJUST- MENT, Hill Holder.> CAUTION: After replacing PHV cable with new one, oper- ate clutch pedal about 30 times as a running-in operation prior to adjustment. D: ADJUSTMENT Confirm stopping and starting performances by ac- tivating hill holder on an uphill road of 3°...

  • Page 74: Brake Pedal

    BRAKE PEDAL BRAKE 19.Brake Pedal 4) Remove instrument panel lower cover from in- strument panel. A: REMOVAL 5) Disconnect the following parts from pedal brack- 1. LHD 1.6 L MT MODEL • Operating rod of brake booster • Electrical connectors (for stop light switch, etc.) 1) Disconnect ground cable from battery.
  • Page 75 BRAKE PEDAL BRAKE B: INSTALLATION C: DISASSEMBLY 1) Install in the reverse order of removal. 1. LHD 1.6 L MT MODEL CAUTION: 1) Remove the stop light switch. • If cable clamp is damaged, replace it with a <Ref. to BR-77, REMOVAL, Stop Light Switch.> new one.
  • Page 76 BRAKE PEDAL BRAKE 4) Remove bush, spring and stopper. D: ASSEMBLY 1) Attach stop light switch, etc. to pedal bracket temporarily. 2) Clean inside of bores of clutch pedal and brake pedal, apply grease, and set bushings into bores. 3) Align bores of pedal bracket, clutch pedal and brake pedal, attach brake pedal return spring and clutch pedal effort reducing spring (vehicle with hill holder), and then install pedal bolt.
  • Page 77 BRAKE PEDAL BRAKE E: INSPECTION 1) Move brake and clutch pedal pads in the lateral direction with a force of approximately 10 N (1 kgf, 2 lb) to ensure pedal deflection is in specified range. CAUTION: If excessive deflection is noted, replace bush- ings with new ones.

  • Page 78: Stop Light Switch

    STOP LIGHT SWITCH BRAKE 20.Stop Light Switch B: INSTALLATION 1) Screw the stop light switch onto a bracket and A: REMOVAL secure it temporarily with a nut. 1) Disconnect ground terminal from battery. 2) Adjust stop light switch position, and then tighten 2) Disconnect stop light switch connector.
  • Page 79 STOP LIGHT SWITCH BRAKE C: INSPECTION D: ADJUSTMENT 1) If stop light switch does not operate properly (or Loosen the lock nut, and adjust stop light switch po- if it does not stop at the specified position), replace sition until the clearance between threaded end of with a new one.

  • Page 80: 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 81 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.

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