Imp01 Chas 9

2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
CHASSIS SECTION
FRONT SUSPENSION FS
REAR SUSPENSION RS
WHEEL AND TIRE SYSTEM WT
DIFFERENTIALS DI
This service manual has been prepared
to provide SUBARU service personnel
TRANSFER CASE TC
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles. DRIVE SHAFT SYSTEM DS
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 ABS (DIAGNOSTICS) ABS
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
POWER ASSISTED SYSTEM PS

(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. G1830GE5

BRAKE
BR
Page
1. General Description ....................................................................................2
2. Front Brake Pad ........................................................................................23
3. Front Disc Rotor ........................................................................................26
4. Front Disc Brake Assembly.......................................................................28
5. Rear Brake Pad.........................................................................................34
6. Rear Disc Rotor.........................................................................................37
7. Rear Disc Brake Assembly .......................................................................39
8. Rear Drum Brake Shoe.............................................................................44
9. Rear Drum Brake Drum ............................................................................46
10. Rear Drum Brake Assembly......................................................................48
11. Master Cylinder .........................................................................................52
12. Brake Booster ...........................................................................................55
13. Proportioning Valve...................................................................................60
14. Brake Fluid ................................................................................................62
15. Air Bleeding...............................................................................................64
16. Brake Hose ...............................................................................................66
17. Brake Pipe.................................................................................................68
18. Hill Holder..................................................................................................70
19. Brake Pedal...............................................................................................73
20. Stop Light Switch ......................................................................................77
21. General Diagnostics..................................................................................79
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)
Front Disc thickness × Outer diame- 24 × 260 mm 24 × 277 mm 24 × 294 mm
disc ter (0.94 × 10.24 in) (0.94 × 10.91 in) (0.94 × 11.57 in)
brake Effective cylinder diameter 57.2 mm (2.252 in) 42.8 mm (1.685 in) × 2 40.4 mm (1.591 in) × 4
Pad dimensions 112.4 × 44.3 × 11.0 mm 112.3 × 50.0 × 11.0 mm 116.0 × 48.3 × 10.0 mm
(length × width × thickness) (4.425 × 1.744 × 0.433 in) (4.421 × 1.969 × 0.433 in) (4.567 × 1.902 × 0.344 in)
Clearance adjustment Automatic adjustment
Type — Disc (Floating type)
Effective disc diameter — 230 mm (9.06 in) 261 mm (10.28 in)
Disc thickness × Outer diame- 10 × 266 mm 18 × 290 mm
Rear —
ter (0.39 × 10.47 in) (0.71 × 11.42 in)
disc
brake Effective cylinder diameter — 38.1 mm (1.500 in)
Pad dimensions 82.4 × 33.7 × 9.0 mm 71.8 × 35.0 × 11.5 mm
—
(length × width × thickness) (3.244 × 1.327 × 0.354 in) (2.827 × 1.378 × 0.453 in)
Clearance adjustment — Automatic adjustment
Drum
Type — —
(Leading-Trailing type)
Rear Effective drum diameter 228.6 mm (9 in) — —
drum Effective cylinder diameter 17.5 mm (0.689 in) — —
brake Lining dimensions 218.8 × 35.0 × 4.1 mm
— —
(length × width × thickness) (8.61 × 1.378 × 0.161 in)
Clearance adjustment Automatic adjustment — —
Type Tandem
23.81 mm (0.9374 in)
Master Effective diameter 26.99 mm (1-1/16 in)
[25.4 mm (1 in)]
cylinder
Reservoir type Sealed type
Brake fluid reservoir capacity 205 cm3 (12.51 cu in)
Type Vacuum suspended
Brake 230 mm (9.06 in)
205 + 230 mm
booster Effective diameter [180 + 205 mm
(8.07 + 9.06 in)
(7.09 + 8.07 in)]
Propor- 1,961 kPa
Split point
tioning (20 kg/cm2, 285 psi)
valve Reducing ratio 0.3
Brake line Dual circuit system
Brake fluid
CAUTION:
• Avoid mixing brake fluid of different
brands to prevent the fluid perfor-
mance from degrading.
FMVSS No. 116, DOT3 or DOT4
• When brake fluid is supplemented,
be careful not to allow any dust into
the reservoir.
• Use fresh DOT3 or 4 brake fluid
when replacing or refilling the fluid.
[ ] : ABS equipped vehicle.
NOTE:
Refer to “PB section” for parking brake SPECIFICATIONS. <Ref. to PB-2, SPECIFICATIONS, General De-
scription.>
BR-2
GENERAL DESCRIPTION
BRAKE
ITEM STANDARD SERVICE LIMIT

Pad thickness 14”,15” 17 mm (0.571 in) 7.5 mm (0.295 in)
(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 — 0.075 mm (0.0030 in)
Pad thickness 14” 14 mm (0.55 in) 6.5 mm (0.256 in)
(including back metal) 15” 16 mm (0.63 in) 6.0 mm (0.236 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) 10.0 mm (0.63 in)
Disc runout — 0.07 mm (0.0028 in)
Inside diameter 228.6 mm (9 in) 230.6 mm (9.08 in)
Rear brake (Drum type)
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 lb)
Fluid pressure
Brake pedal
14 inch type
force 15 inch type 16 inch type
Without ABS With ABS
686 kPa 686 kPa
147 N 588 kPa
(7 kg/cm2, (7 kg/cm2,
(15 kgf, 33 lb) (6 kg/cm2, 85 psi)
Brake fluid pressure 100 psi) 100 psi)
without engine running 1,961 kPa 1,961 kPa
294 N 1,471 kPa
(20 kg/cm2, (20 kg/cm2,
(30 kgf, 66 lb) (15 kg/cm2, 213 psi)
Brake 284 psi) 284 psi)
booster 5,982 kPa 5,982 kPa 5,296 kPa 4,707 kPa
Brake fluid pressure 147 N
(61 kg/cm2, (61 kg/cm2, (54 kg/cm2, (48 kg/cm2,
with engine running (15 kgf, 33 lb)
868 psi) 868 psi) 768 psi) 683 psi)
and vacuum at 66.7
kPa (500 mmHg, 19.69 7,649 kPa 8,434 kPa
294 N 9,120 kPa
inHg) (78 kg/cm2, (86 kg/cm2,
(30 kgf, 66 lb) (93 kg/cm2, 1,323 psi)
1,109 psi) 1,223 psi)
1 — 3 mm (0.04 — 0.12 in)

Brake pedal Free play
[Depress brake pedal pad with a force of less than 10 N (1 kgf, 2 lb).]
BR-3
GENERAL DESCRIPTION
BRAKE
B: COMPONENT
1. 14 INCH TYPE
B4M1208C
(1) Caliper body (9) Support Tightening torque: N·m (kgf-m, ft-lb)
(2) Air bleeder screw (10) Pad clip T1: 8 (0.8, 5.8)
(3) Guide pin (Green) (11) Outer shim T2: 18 (1.8, 13.0)
(4) Pin boot (12) Inner shim T3: 37 (3.8, 27.5)
(5) Piston seal (13) Pad (Outside) T4: 80 (8.2, 59)
(6) Piston (14) Pad (Inside)
(7) Piston boot (15) Disc rotor
(8) Lock pin (Yellow) (16) Disc cover
BR-4
GENERAL DESCRIPTION
BRAKE
2. 15 INCH TYPE
B4M1151C
(1) Caliper body (9) Lock pin (Yellow) (17) Disc cover
(2) Air bleeder screw (10) Support
(3) Guide pin (Green) (11) Pad clip Tightening torque: N·m (kgf-m, ft-lb)
(4) Pin boot (12) Outer shim T1: 8 (0.8, 5.8)
(5) Piston seal (13) Inner shim T2: 18 (1.8, 13.0)
(6) Piston (14) Pad (Outside) T3: 37 (3.8, 27.5)
(7) Piston boot (15) Pad (Inside) T4: 80 (8.2, 59)
(8) Boot ring (16) Disc rotor
BR-5
GENERAL DESCRIPTION
BRAKE
3. 16 INCH TYPE
BR0003
(1) Housing (9) Piston boot Tightening torque: N·m (kgf-m, ft-lb)
(2) Air bleeder screw (10) Boot ring T1: 8 (0.8, 5.8)
(3) Caliper body (11) Shim A T2: 18 (1.8, 13.0)
(4) M clip (12) Shim B T3: 80 (8.2, 59)
(5) Cross spring (13) Pad (Outside)
(6) Pad pin (14) Pad (Inside)
(7) Piston seal (15) Disc rotor
(8) Piston (16) Disc cover
BR-6
GENERAL DESCRIPTION
BRAKE
4. REAR DISC BRAKE (14 INCH TYPE)
H4M1355A
(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
(8) Boot ring (21) Parking brake shoe (Secondary) Tightening torque: N·m (kgf-m, ft-lb)
(9) Lock pin (Yellow) (22) Parking brake shoe (Primary) T1: 8 (0.8, 5.8)
(10) Support (23) Strut T2: 37 (3.8, 27.5)
(11) Pad clip (24) Strut shoe spring T3: 52 (5.3, 38.3)
(12) Inner pad (25) Shoe guide plate
(13) Outer pad (26) Secondary shoe return spring
BR-7
GENERAL DESCRIPTION
BRAKE
5. REAR DISC BRAKE (15 INCH TYPE)
BR0004
(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-lb)
(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-8
GENERAL DESCRIPTION
BRAKE
6. REAR DRUM BRAKE
(8) (1) (2)

T2 (3)
T1
(4)
(5)
(6)
(9)
(12) (7)
(13) (5)
(14) (4)
(8)
(3)
(15) (17)
(24) (18)
(10) (11) (19)
(22)
(16)
(20)
T3 (21)
(23)
B4M1120A
(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
(5) Cup (15) Brake shoe (Trailing) Tightening torque: N·m (kgf-m, ft-lb)
(6) Spring (16) Brake shoe (Leading) T1: 8 (0.8, 5.8)
(7) Wheel cylinder body (17) Shoe hold-down spring T2: 10 (1.0, 7.2)
(8) Pin (18) Cup T3: 52 (5.3, 38.3)
(9) Plug (19) Adjusting lever
(10) Back plate (20) Adjuster
BR-9
GENERAL DESCRIPTION
BRAKE
7. MASTER CYLINDER
• LHD models
(1)
(2)
(11) (3)
(4)
(10)
(9) T1
(5)
(6)
(7)
(8)
S4M0186A
(1) Cap (7) Secondary piston Tightening torque: N·m (kgf-m, ft-lb)
(2) Filter (8) Cylinder body T1: 14 (1.4, 10.1)
(3) Reservoir tank (9) Cylinder pin (with ABS)
(4) Bracket (10) Seal
(5) Piston retainer (11) Pin
(6) Primary piston
BR-10
GENERAL DESCRIPTION
BRAKE
• RHD models
(1)
(2)
(11) (3)
(4)
(10)
(9) T1
(5)
(6)
(7)
(8)
B4M1155C
(1) Cap (6) Primary piston (11) Pin

(2) Filter (7) Secondary piston
(3) Reservoir tank (8) Cylinder body Tightening torque: N·m (kgf-m, ft-lb)
(4) Bracket (9) Cylinder pin (with ABS) T1: 14 (1.4, 10.1)
(5) Piston retainer (10) Seal
BR-11
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
GENERAL DESCRIPTION
BRAKE
(1) Front brake pipe assembly (12) Two-way connector (19) Rear brake hose LH (FWD drum
(2) Proportioning valve (13) Rear brake pipe assembly brake model)
(3) Front brake hose RH (14) Rear brake hose RH (Disc brake (20) Rear brake pipe LH (FWD drum
(4) Front brake hose LH model) brake model)
(5) Clamp (15) Rear brake pipe RH (FWD drum (21) Rear brake hose LH (AWD drum
(6) Gasket brake model) brake model)
(7) ABS control module and hydraulic (16) Rear brake hose RH (FWD drum (22) Adapter pipe
control unit brake model)
(8) Bracket (17) Rear brake hose (AWD drum Tightening torque: N·m (kgf-m, ft-lb)
(9) Master Cylinder brake model) T1: 15 (1.5, 10.8)
(10) Hill holder (18) Rear brake hose LH (Disc brake T2: 18 (1.8, 13.0)
(11) Center brake pipe assembly model) T3: 32 (3.3, 23.6)
BR-13
GENERAL DESCRIPTION
BRAKE
• RHD model
AT MODEL MT MODEL WITH HILL HOLDER

MT MODEL WITHOUT HILL HOLDER
WITHOUT ABS
BR0074
BR-14
GENERAL DESCRIPTION
BRAKE
(1) Front brake pipe assembly (12) Two-way connector (19) Rear brake hose LH (FWD drum
(2) Proportioning valve (13) Rear brake pipe assembly brake model)
(3) Front brake hose RH (14) Rear brake hose RH (Disc brake (20) Rear brake pipe LH (FWD drum
(4) Front brake hose LH model) brake model)
(5) Clamp (15) Rear brake pipe RH (FWD drum (21) Rear brake hose LH (AWD drum
(6) Gasket brake model) brake model)
(7) ABS control module and hydraulic (16) Rear brake hose RH (FWD drum (22) Adapter pipe
control unit brake model)
(8) Bracket (17) Rear brake hose (AWD drum Tightening torque: N·m (kgf-m, ft-lb)
(9) Master Cylinder brake model) T1: 15 (1.5, 10.8)
(10) Hill holder (18) Rear brake hose LH (Disc brake T2: 18 (1.8, 13.0)
(11) Center brake pipe assembly model) T3: 32 (3.3, 23.6)
BR-15
GENERAL DESCRIPTION
BRAKE
9. BRAKE BOOSTER
• Models with ABS
B4M1974A
(1) Push rod (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
• Models without ABS
BR0059
(1) Push rod (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-16
GENERAL DESCRIPTION
BRAKE
10.HILL HOLDER
S4M0240B
(1) Clamp (5) Lock nut Tightening torque: N·m (kgf-m, ft-lb)
(2) PHV cable (6) To clutch pedal T1: 3.5 (0.35, 2.5)
(3) PHV (Pressure hold valve) T2: 18 (1.8, 13.0)
(4) Adjusting nut
BR-17
GENERAL DESCRIPTION
BRAKE
11.BRAKE PEDAL
• 1.6 L Model
RHD
LHD
BR0060
(1) Stopper (8) Spring (15) Stop light switch

(2) Bushing (9) Clutch pedal pad
(3) Clutch pedal bracket (10) Clutch pedal Tightening torque: N·m (kgf-m, ft-lb)
(4) Snap pin (11) Clutch cable T1: 5.9 (0.6, 4.3)
(5) Brake pedal pad (12) Clutch cable clamp T2: 8 (0.8, 5.8)
(6) Brake pedal (13) Clip T3: 18 (1.8, 13.0)
(7) Clevis pin (14) Spring assist T4: 30 (3.1, 22.4)
BR-18
GENERAL DESCRIPTION
BRAKE
• 2.0 L Model
LHD
RHD
BR0061
(1) Stopper (12) Clutch clevis pin (23) Clutch switch (With cruise control)
(2) Bushing (13) Assist rod A (24) Stop light switch
(3) Spring pin (14) Clip (25) Pedal bracket
(4) Snap pin (15) Assist spring (26) Clutch master cylinder bracket
(5) Brake pedal pad (16) Assist bushing (27) Lever
(6) Brake pedal (17) Assist rod B (28) Brake pedal bracket
(7) Clevis pin (18) Spring S
(8) Brake pedal spring (19) Rod S Tightening torque: N·m (kgf-m, ft-lb)
(9) Clutch pedal pad (20) Bushing S T1: 8 (0.8, 5.8)
(10) Clutch pedal (21) O-ring T2: 18 (1.8, 13.0)
(11) Bushing C (22) Clip T3: 30 (3.1, 22.4)
BR-19
GENERAL DESCRIPTION
BRAKE
12.BRAKE PEDAL FOR AT MODEL
BR0007
(1) Stopper (6) Brake pedal pad Tightening torque: N·m (kgf-m, ft-lb)
(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 T3: 29 (3.0, 21.7)
(5) Snap pin
BR-20
GENERAL DESCRIPTION
BRAKE
C: CAUTION
• Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
• Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
• Keep the disassembled parts in order and pro-
tect them from dust or dirt.
• 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 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.
• Be sure to tighten fasteners including bolts and
nuts to the specified torque.
• Place shop jacks or safety stands at the specified
points.
• Apply grease onto sliding or revolution surfaces
before installation.
• Before installing O-rings or snap rings, apply suf-
ficient amount of grease to avoid damage and de-
formation.
• Before securing a part on a vice, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vice.
• Do not put fluid on body. If the body is tainted,
wash away with water.
BR-21
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.
BR-22
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.
1. 14 INCH AND 15 INCH TYPE
1) Set the vehicle on the lift.
2) Disconnect ground terminal from battery.
3) Loosen wheel nuts.
4) Jack-up the vehicle, and remove front wheel.
5) Remove lock pin.
6) Raise caliper body.
7) Remove pad.
B4M2231
2. 16 INCH TYPE
5) Remove M clip.
B4M1167
NOTE:
If brake pad is difficult to remove, proceed as fol-
lows:
(1) Remove caliper body and fasten it provi-
sionally to coil spring.
(2) Remove support.
(3) Place a support in a vise between wooden
blocks.
H4M1367A
6) Remove cross spring.
B4M2230B
(1) Support H4M1368
(2) Wooden blocks

7) Remove pad pins.
H4M1369
BR-23
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.
BR0008
2) Install pads on caliper body.
3) Install pad pins on caliper body.
4) Install M clip.
5) Install cross spring.
C: INSPECTION
H4M1371 Check pad thickness A.
B: INSTALLATION
1) Apply thin coat of Molykote AS880N (Part No.
26298AC000) to the frictional portion between pad
and pad clip.
and pad inner shim. A
BR0009
Pad thickness Standard value 17 mm (0.67 in)

(including back
Wear limit 7.5 mm (0.295 in)
metal)
CAUTION:
• Always replace the pads for both the left and
right wheels at the same time. Also replace pad
clips if they are twisted or worn.
• A wear indicator is provided on the inner disc
BR0008 brake pad. If the pad wears down to such an ex-
3) Install pads on support. tent that the end of the wear indicator contacts
4) Install caliper body on support. the disc rotor, a squeaking sound is produced
Tightening torque: as the wheel rotates. If this sound is heard, re-
37 N·m (3.8 kgf-m, 27.5 ft-lb) place the pad.
• Replace pad if there is oil or grease on it.
NOTE:
If it is difficult to push piston during pad replace-
ment, loosen air bleeder to facilitate work.
BR-24
FRONT BRAKE PAD
BRAKE
2. 16 INCH TYPE
Check pad thickness A.
A
BR0009
Pad thickness Standard value 14.5 mm (0.571 in)

(including back
metal) Wear limit 6.0 mm (0.236 in)
CAUTION:
brake pad. If the pad wears down to such an ex-
tent that the end of the wear indicator contacts
the disc rotor, a squeaking sound is produced
as the wheel rotates. If this sound is heard, re-
place the pad.
BR-25
FRONT DISC ROTOR
BRAKE
3. Front Disc Rotor 5) Remove caliper body from housing and suspend
from strut using a wire.
A: REMOVAL
5) Remove caliper body from housing, and sus-
pend it from struct using a wire.
BR0010
6) Remove disc rotor from hub.
NOTE:
If disc rotor seizes up within the hub, drive disc rotor
out by installing an 8-mm bolt in holes B on the ro-
tor.
BR0076
6) Remove the disc rotor.
NOTE:
If disc rotor seizes up within the hub, drive disc rotor
out by installing an 8-mm bolt in holes B on the ro-
tor.
G4M0365
7) Clean mud and foreign particles from caliper
body assembly and support.
G4M0365
2. 16 INCH TYPE
3) Loosen wheel nut.
4) Jack-up vehicle, and remove front wheel.
BR-26
FRONT DISC ROTOR
BRAKE
B: INSTALLATION C: INSPECTION
1) Install the disc rotor. 1) Install disc rotor by tightening the five wheel
2) Install caliper body on housing. nuts.
2) Set a dial gauge on the disc rotor. Turn disc rotor
Tightening torque:
to check runout.
80 N·m (8.2 kgf-m, 59 ft-lb)
CAUTION:
place the pad. B4M2353
• When replacing the pad, replace pads of the NOTE:

left and right wheels at the same time. Make sure that dial gauge is set 5 mm (0.20 in) in-
3) Install the wheel. ward of rotor outer perimeter.
Disc rotor runout limit:
0.075 mm (0.0030 in)
3) Measure disc rotor thickness.
G4M0365
NOTE:
Make sure that micrometer is set 5 mm (0.20 in) in-
ward of rotor outer perimeter.
Standard Service Disc outer
value limit dia.
24.0 mm 22.0 mm 260 mm
14″
(0.945 in) (0.866 in) (10.24 in)
Disc rotor 24.0 mm 22.0 mm 277 mm
15″
thickness A (0.945 in) (0.866 in) (10.91 in)
24.0 mm 22.0 mm 294 mm
16″
(0.945 in) (0.866 in) (11.57 in)
BR-27
FRONT DISC BRAKE ASSEMBLY
BRAKE
4. Front Disc Brake Assembly 2. 16 INCH TYPE

A: REMOVAL 2) Disconnect ground terminal from battery.
1. 14 INCH AND 15 INCH TYPE 3) Loosen wheel nuts.
1) Set the vehicle on the lift. 5) Remove union bolt and disconnect brake hose
2) Disconnect ground terminal from battery. from caliper body assembly.
3) Loosen wheel nuts. 6) Remove caliper body from housing.
5) Remove union bolt and disconnect brake hose
from caliper body assembly.
BR0011
B4M1844
6) Remove bolt securing lock pin to caliper body.
B4M1845
7) Raise caliper body and move it toward vehicle
center to separate it from support.
8) Remove support from housing.
NOTE:
Remove support only when replacing it or the rotor.
It need not be removed when servicing caliper body
assembly.
B4M1192
BR-28
BRAKE
B: INSTALLATION 2. 16 INCH TYPE

1. 14 INCH AND 15 INCH TYPE 1) Install caliper body on housing.
1) Install support on housing. Tightening torque:
80 N·m (8.2 kgf-m, 59 ft-lb)
Tightening torque:
80 N·m (8.2 kgf-m, 59 ft-lb) CAUTION:
CAUTION: right wheels at the same time. Also replace pad
• Always replace the pads for both the left and clips if they are twisted or worn.
right wheels at the same time. Also replace pad • A wear indicator is provided on the inner disc
clips if they are twisted or worn. brake pad. If the pad wears down to such an ex-
• A wear indicator is provided on the inner disc tent that the end of the wear indicator contacts
brake pad. If the pad wears down to such an ex- the disc rotor, a squeaking sound is produced
tent that the end of the wear indicator contacts as the wheel rotates. If this sound is heard, re-
the disc rotor, a squeaking sound is produced place the pad.
as the wheel rotates. If this sound is heard, re- • When replacing the pads, replace pads of the
place the pad. right and left wheels at the same time.
• When replacing the pads, replace pads of the 2) Apply thin coat of Molykote AS880N (Part No.
right and left wheels at the same time. 26298AC000) to the frictional portion between pad
2) Apply thin coat of Molykote AS880N (Part No. and pad inner shim.
and pad clip.
and inner shim.
BR0008
3) Install pads on caliper body.
4) Install pad pins on caliper body.
5) Install M clip.
6) Install cross spring.
B4M1169A 7) Install caliper body on housing.
4) Install pads on support.
5) Install caliper body on support. Tightening torque:
52 N·m (5.3 kgf-m, 38.3 ft-lb)
Tightening torque:
8) Connect brake hose.
37 N·m (3.8 kgf-m, 27.5 ft-lb)
6) Connect brake hose. Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb) CAUTION:
Replace brake hose gaskets with new ones.
CAUTION:
9) Bleed air from brake system.
Replace brake hose gaskets with new ones.
BR-29
BRAKE
C: DISASSEMBLY
1. 14 INCH TYPE
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. B4M1164C
CAUTION: (1) Boot ring

• Place a wooden block as shown in Figure to
prevent damage to piston. 3) Remove boot from piston end.
• Do not apply excessively high-pressure. 4) Gradually supply compressed air via caliper
body brake hose to force piston out.
CAUTION:
Place a wooden block as shown in Figure to
prevent damage to piston.
B4M1174C
(1) Place a 30 mm (1.18 in) wide wooden block

here.
3) Remove piston boot. B4M1165C

4) Remove piston seal from caliper body cylinder.
here.
B4M1173
5) Remove guide pin and boot from caliper body.
2. 15 INCH TYPE
1) Clean mud and foreign particles from caliper B4M1172B
body assembly and support. (1) Piston pin
CAUTION:
Be careful not to allow foreign particles to enter 6) Remove lock pin boot and guide pin boot.
inlet (at brake hose connector). 3. 16 INCH TYPE
2) Using a standard screwdriver, remove boot ring 1) Clean mud and foreign particles from caliper
from piston. body assembly.
CAUTION:
BR-30
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.
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 boot and fit in
groove on ends of cylinder and install piston boot
Boot ring onto cylinder.
BR0012
Grease:
3) Remove boot from piston end. NIGLUBE RX-2 (Part No. 003606000)
5) Insert piston into cylinder.
CAUTION:
Do not force piston into cylinder.
BR0013
4) Gradually supply compressed air via caliper
body brake hose to force piston out.
CAUTION:
Place a wooden block as shown in figure to pre- B4M1175B
vent damage to piston.
(1) Piston
(2) Piston boot
6) Position boot in grooves on cylinder and piston.
Place a 30 mm (1.18 in)

wide wood block here.
BR0014
Piston seal
B4M0072B
(1) Piston
(2) Piston boot
(3) Caliper body
(4) Piston seal
7) Apply a coat of specified grease to lock pin and

BR0015
guide pin outer surface, cylinder inner surface, and
boot grooves.
Grease:
NIGLUBE RX-2 (Part No. 003606000)
BR-31
BRAKE
8) Install lock and guide pin boot on support.
S4M0448A
B4M1176B
(1) Piston boot
(1) Pin boot (2) Boot ring
(2) Lock pin or guide pin (3) Piston seal
(3) Apply grease. (4) Caliper body
2. 15 INCH TYPE 6) Position boot in grooves on cylinder and piston.

7) Install boot ring. Be careful not scratch boot.
1) Clean caliper body interior using brake fluid. 8) Apply a coat of specified grease to lock pin and
2) Apply a coat of brake fluid to piston seal and fit guide pin, outer surface, cylinder inner surface, and
piston seal in groove on caliper body. boot grooves.
face of cylinder and outer surface of piston. Grease:
4) Insert piston into cylinder. NIGLUBE RX-2 (Part No. 003606000)
CAUTION:
B4M1176B
(1) Pin boot

B4M0771
(2) Lock pin or guide pin
5) Apply a coat of specified grease to boot and fit in (3) Apply grease.
groove on ends of cylinder and piston.
Grease: 9) Install lock pin boot and guide pin boot on sup-
NIGLUBE RX-2 (Part No. 003606000) port.
To facilitate installation, fit boot starting with piston
end.
BR-32
BRAKE
3. 16 INCH TYPE E: INSPECTION

1) Clean caliper body interior using brake fluid. 1) Repair or replace faulty parts.
2) Apply a coat of brake fluid to piston seal and fit 2) Check caliper body and piston for uneven wear,
piston seal in groove on caliper body. damage or rust.
3) Apply a coat of brake fluid to the entire inner sur- 3) Check rubber parts for damage or deterioration.
CAUTION:
BR0016

Grease:
To facilitate installation, fit boot starting with piston
end.
Piston
Piston boot
Boot ring BR0017

Piston seal
6) Position boot in grooves on cylinder and piston.
7) Install boot ring. Be careful not scratch boot.
BR-33
REAR BRAKE PAD
BRAKE
5. Rear Brake Pad 2. 15 INCH TYPE

A: REMOVAL 2) Disconnect ground terminal from battery.
1. 14 INCH TYPE 3) Loosen wheel nuts.
1) Set the vehicle on the lift. 5) Remove M clip.
4) Jack-up the vehicle, and remove rear wheel.
5) Remove lock pin.
BR0018
(1) M clip
(2) Caliper
S4M0115
6) Raise caliper body. 6) Remove two pad pins.
7) Remove pad from support. 7) Remove cross spring.
NOTE:
If brake pad is difficult to remove, use the same pro-
cedure as for front disc brake pad.
<Ref. to BR-23, REMOVAL, Front Brake Pad.>
BR0019
(1) Cross spring

(2) Pad pin
B4M1770
8) Expand the pads and push the piston back.
9) Remove pad and shim.
BR0020
(1) Brake pad
BR-34
REAR BRAKE PAD
BRAKE
1. 14 INCH TYPE 1. 14 INCH TYPE
1) Apply thin coat of Molykote AS880N (Part No. Check pad thickness A.
and pad clip.
2) Install pad on support.
3) Install caliper body on support.
Tightening torque:
39 N·m (4.0 kgf-m, 28.9 ft-lb)
NOTE:
If it is difficult to push piston during pad replace-
ment, loosen air bleeder to facilitate work.
S4M0187A
2. 15 INCH TYPE
Pad thickness Standard value 14.0 mm (0.551 in)
1) Apply thin coat of Molykote AS880N (Part No. (including back
26298AC000) to frictional portion between pad and metal)
pad inner shim.
2) Install pads on caliper body. CAUTION:
3) Install cross spring. • Always replace the pads for both the left and
4) Install pad pins on caliper body. right wheels at the same time. Also replace pad
5) Install M clip. clips if they are twisted or worn.
place the pad.
2. 15 INCH TYPE
Check pad thickness A.
BR0021
Pad thickness Standard value 16 mm (0.63 in)

(including back
metal)
CAUTION:
BR-35
REAR BRAKE PAD
BRAKE

place the pad.
BR-36
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.
G4M0383
G4M0412
3) Suspend the disc brake assembly so that the
hose is not stretched.
4) Pull down and release parking brake.
5) Remove the disc rotor.
NOTE:
If the disc rotor is difficult to remove try the following
two methods in order.
(1) Turn adjusting screw using a slot-type
screwdriver until brake shoe gets away enough
from the disc rotor.
S4M0463A
(1) Adjusting screw

(2) Cover
(3) Slot-type screwdriver
(4) Back plate
BR-37
REAR DISC ROTOR
BRAKE
1) Install in the reverse order of removal. 1) Set a dial gauge on the disc rotor. Turn disc rotor
2) Adjust parking brake. <Ref. to PB-11, ADJUST- to check runout.
MENT, Parking Brake Assembly (Rear Disc CAUTION:
Brake).> Securely adjust disc rotor to hub.
B4M1771
NOTE:
Make sure that dial gauge is set 5 mm (0.20 in) in-
Disc rotor runout limit:
0.075 mm (0.0030 in)
2) Measure disc rotor thickness.
G4M0383
NOTE:
Make sure that micrometer is set 5 mm (0.20 in) in-
Disc rotor thickness: A (14inch type)
Standard value
10 mm (0.39 in)
Service limit
8.5 mm (0.335 in)
Disc rotor thickness: A (15inch type)
Standard value
18 mm (0.71 in)
Service limit
16 mm (0.63 in)
BR-38
REAR DISC BRAKE ASSEMBLY
BRAKE
7. Rear Disc Brake Assembly 2. 15 INCH TYPE
A: REMOVAL CAUTION:
Do not allow brake fluid to come in contact with
1. 14 INCH TYPE vehicle body; wipe off completely if spilled.
CAUTION:
Do not allow brake fluid to come in contact with
vehicle body; wipe off completely if spilled. 3) Loosen wheel nuts.
4) Lift-up vehicle and remove wheels.
1) Set the vehicle on the lift. 5) Remove pads from caliper body. <Ref. to BR-34,
2) Disconnect ground terminal from battery. REMOVAL, Rear Brake Pad.>
3) Loosen wheel nuts. 6) Disconnect brake hose from caliper body as-
4) Lift-up vehicle and remove wheels. sembly.
5) Disconnect brake hose from caliper body as- 7) Remove caliper body from housing.
sembly.
6) Remove lock pin.
BR0063
8) Remove disc rotor from hub.
S4M0119
7) Raise caliper body and move it toward vehicle body assembly and support.
center to separate it from support.
8) Remove support from back plate. CAUTION:
NOTE: inlet (at brake hose connector).
Remove support only when replacing it or the rotor.
It need not be removed when servicing caliper body
assembly.
CAUTION:
BR-39
BRAKE
B: INSTALLATION 3) Apply thin coat of Molykote AS880N (Part No.

1. 14 INCH TYPE and pad clip.
1) Install disc rotor on hub. 4) Install pads on caliper body.
2) Install support on back plate. 5) Connect brake hose.
Tightening torque: Tightening torque:
52 N·m (5.3 kgf-m, 38.3 ft-lb) 18 N·m (1.8 kgf-m, 13.0 ft-lb)
CAUTION: CAUTION:
• Always replace the pads for both the left and • The brake hose must be connected without
right wheels at the same time. Also replace pad any twist.
clips if they are twisted or worn. • Replace brake hose gaskets with new ones.
• A wear indicator is provided on the inner disc 6) Bleed air from brake system.
place the pad.
• Replace pads if there is oil or grease on them.
and pad clip.
4) Install pads on support.
5) Install caliper body on support.
Tightening torque:
37 N·m (3.8 kgf-m, 27.5 ft-lb)
6) Connect brake hose.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
CAUTION:
• The brake hose must be connected without
any twist.
• Replace brake hose gaskets with new ones.
2. 15 INCH TYPE
1) Install disc rotor on hub.
2) Install caliper body on housing.
Tightening torque:
52 N·m (5.3 kgf-m, 38.3 ft-lb)
CAUTION:
place the pad.
• Replace pads if there is oil or grease on them.
BR-40
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. 15 INCH TYPE
(1) Boot ring
1) Remove the boot ring.
2) Remove the piston boot.
BR0023
S4M0121
3) Gradually supply compressed air via inlet of cal- (1) Boot ring
iper body to force piston out.
2) Remove the piston boot.
CAUTION:
• Place a wooden block as shown in Figure to
prevent damage to piston.
• Do not apply excessively high-pressure.
BR0064
B4M1174C

here.
BR-41
BRAKE
3) Gradually supply compressed air via inlet of cal- D: ASSEMBLY

iper body to force piston out.
1. 14 INCH TYPE
CAUTION:
• Place a wooden block as shown in figure to 1) Clean caliper body interior using brake fluid.
prevent damage to piston. 2) Apply a coat of brake fluid to piston seal and fit
• Do not apply excessively high-pressure. piston seal in groove on caliper body.
CAUTION:
Grease:
BR0025 6) Install the piston boot to the caliper body, and at-
tach boot ring.
here.
S4M0448A
(1) Piston boot

BR0065 (2) Boot ring
(3) Piston seal
(4) Caliper body
7) Apply a coat of specified grease to guide pin,

outer surface, sleeve outer surface, cylinder inner
surface, and boot grooves.
Grease:
B4M1176B
(1) Pin boot

(2) Lock pin or guide pin
(3) Apply grease.
8) Install guide pin boot on caliper body.
BR-42
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. 15 INCH TYPE 2) Check caliper body and piston for uneven wear,
damage or rust.
1) Clean caliper body interior using brake fluid. 3) Check rubber parts for damage or deterioration.
2) Apply a coat of brake fluid to piston seal and fit
piston seal in groove on caliper body.
CAUTION:
Grease:
6) Install the piston boot to the caliper body, and at-
tach boot ring.
BR0027
(1) Piston
(2) Piston boot
(3) Piston seal
(4) Boot ring
7) Install shim and brake pad.

8) Install pad pin, cross spring, and M clip.
BR-43
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:
• If it is difficult to remove brake drum, remove ad-
justing hole cover from back plate, and then turn
adjuster assembly pawls using a slot-type screw- S4M0452
driver until brake shoe separates from the drum. 7) Remove shoes one by one from back plate with
adjuster.
CAUTION:
Be careful not to bend parking brake cable ex-
cessively when removing brake shoes.
G4M0242
• If brake drum is difficult to remove, drive it out by
installing an 8-mm bolt into bolt hole in brake drum.
G4M0397
8) Disconnect parking brake cable from parking le-
ver.
B4M0243
4) Hold hold-down pin by securing rear of back
plate with your hand.
S4M0451A
(1) Hold-down cup

(2) Hold-down pin
5) Disconnect hold-down cup from hold-down pin

by rotating hold-down cup.
BR-44
REAR DRUM BRAKE SHOE
BRAKE
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. 7439 (Part No. 2) If the deformation or wear of back plate, shoe,
725191460) etc. are notable, replace them.
3) When the shoe return spring tension is exces-
sively weakened, replace it, taking care to identify
upper and lower springs.
G4M0407
3) Apply grease to adjusting screw and both ends
of adjuster.
Brake grease:
Dow Corning Molykote No. 7439 (Part No.
725191460)
S4M0457B
4) Connect upper shoe return spring to shoes.
5) Connect parking brake cable to parking lever.
6) While positioning shoes (one at a time) in groove
on wheel cylinder, secure shoes.
G4M0409
7) Fix shoes by connecting hold-down cup to hold-
down pin.
8) Connect 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 the inside diameter of brake drum.
BR-45
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.
NOTE:
adjuster assembly pawls using a slot-type screw-
driver until brake shoe separates from the drum.
G4M0242
B4M0243
BR-46
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.
Drum inner diameter: “L”
Standard 228 mm (9 in)
Service limit 230.6 mm (9.08 in)
G4M0403
BR-47
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
NOTE:
adjuster assembly pawls using a slot-type screw- S4M0452
driver until brake shoe separates from the drum. 7) Remove shoes one by one from back plate with
adjuster.
CAUTION:
Be careful not to bend parking brake cable ex-
cessively when removing brake shoes.
G4M0242
G4M0409
8) Disconnect parking brake cable from parking le-
ver.
9) Unscrew the brake pipe flare nut and disconnect
brake pipe.
G4M0243
4) Hold hold-down pin by securing rear of back
plate with your hand.
G4M0399
10) Remove hub.
<Ref. to DS-24, REMOVAL, Rear Axle.>
11) Remove brake assembly.
S4M0451A
(1) Hold-down cup

(2) Hold-down pin
5) Disconnect hold-down cup from hold-down pin

by rotating hold-down cup.
G4M0400
BR-48
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.
3) Apply grease to portions indicated by arrows in
Figure.
Brake grease:
725191460)
G4M0407
4) Apply grease to adjusting screw and both ends
of adjuster.
Brake grease:
725191460)
S4M0457B
5) Connect upper shoe return spring to shoes.
BR-49
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.
G4M0409
8) Fix shoes by connecting hold-down cup to hold- B4M1126B
down pin. (1) Bleeder cap
9) Connect lower shoe return spring. (2) Bleeder screw
10) Set the outside diameter of brake shoes less (3) Spring
than 0.5 to 0.8 mm (0.020 to 0.031 in) in compari-
(4) Cylinder
son with the inside diameter of brake drum.
(5) Cup
11) Install hub.
(6) Piston
<Ref. to DS-27, INSTALLATION, Rear Axle.>
(7) Boot
12) Connect brake pipe, and tighten brake pipe
flange nut. 2) Remove piston, cup, spring and air bleeder
Tightening torque: screw and cap.
15 N·m (1.5 kgf-m, 10.8 ft-lb)
G4M0399
13) Install brake drum.
14) After installing brake assembly, bleed air from
brake line.
BR-50
BRAKE
D: ASSEMBLY 3) Apply rubber grease to the boot inside as shown

1) Clean all parts in brake fluid. Check and replace in Figure.
faulty parts. CAUTION:
• Cup and boot for damage or fatigue Never use brake grease.
• Cylinder, piston and spring or damage or rust for-
Grease:
mation
2) Assembly is 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 the same as
those which were replaced.
• Use only the tool of the correct size.
S4M0456B
ST: ADAPTER
Applicable size Part No.
E: INSPECTION
1) If the deformation or wear of back plate, shoe,
17.5 mm (11/16 in) 925460000
etc. are notable, replace them.
CAUTION:
While assembling, be careful to prevent any
metal chip, dust or dirt from entering the wheel
cylinder.
S4M0455A
(1) Cup
(2) Piston
BR-51
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.
2) Disconnect fluid level indicator harness connec- Tightening torque:
tor. Master cylinder mounting nut
3) Remove brake pipes from master cylinder. 14 N·m (1.4 kgf-m, 10.1 ft-lb)
4) Remove master cylinder mounting nuts, and Piping flare nut
take out master cylinder from brake booster. 15 N·m (1.5 kgf-m, 10.8 ft-lb)
CAUTION: CAUTION:
Be extremely careful not to spill brake fluid. Be sure to use recommended brake fluid.
Brake fluid spilt on the vehicle body will harm 2) Bleed air from brake system. <Ref. to BR-64,
the painted surface; wipe it off quickly if spilt. PROCEDURE, Air Bleeding.>
BR-52
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. and piston cups are free from dirt when assem-
3) Clean work bench. bling.
3) Be extremely careful not to damage, scratch, or
2. DISASSEMBLING PROCEDURE dent cylinder inside wall, pistons, and piston cups.
1) Remove pin with drift pin which secures reserve 4) Do not drop parts. Never attempt to use any part
tank to master cylinder. that has been dropped accidentally.
2) Remove cylinder pin with magnetic pick-up tool
while pushing in primary piston. (with ABS) 2. ASSEMBLING PROCEDURE
1) Assembling piston assembly:
Apply recommended brake fluid to inside wall of
cylinder, and to outer surface of piston assembly,
and install piston assemblies carefully into cylinder.
2) Assembling cylinder pin:
3) Press the pawl and install the piston retainer into
the master cylinder.
S4M0123B
(1) Cylinder pin
3) Pry up the pawl and remove the piston retainer.

NOTE:
Piston may jump out from master cylinder.
S4M0124
4) Install seal to reservoir tank.
S4M0124
4) Extract primary piston assembly and secondary
piston assembly. B4M1450C
CAUTION:
(1) Seal
• Do not disassemble the piston assembly;
otherwise, the spring set value may be 5) Install pin with drift pins which secures reservoir
changed. tank to master cylinder.
• Use brake fluid or methanol to wash inside
wall of cylinder, pistons and piston cups. Be
careful not to damage parts when washing. If
methanol is used for washing, do not dip rub-
ber parts, such as piston cups, in it for more
than 30 seconds; otherwise, they may become
swelled.
BR-53
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.
• The service limit of the clearance between
each piston and the master cylinder inner dia.
is 0.11 mm (0.0043 in).
• When handling parts, be extremely careful
not to damage or scratch the parts, or let any
foreign matter get on them.
BR-54
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
er.
2) Remove the following parts from the pedal (1) Force
bracket.
(1) Snap pin and clevis pin
(2) Four brake booster installing nuts
3) Remove brake booster while shunning brake
pipes.
NOTE:
• Be careful not to drop brake booster. Brake
booster should be discarded if it has been dropped.
• Use special care when handling operating rod.
If excessive force is applied to operating rod, suffi-
cient to cause a change in the angle in excess of
±3°, it may result in damage to the power piston cyl-
inder.
• Use care when placing brake booster on the
floor.
• Do not change the push rod length. If it has been
changed, reset the projected length “L” to the stan-
dard length.
Standard:
L = 10.4 mm (0.41 in)
G4M0424
CAUTION:
If external force is applied from above when
brake booster is placed in this position, the res-
in portion as indicated by “P”, may be dam-
aged.
BR-55
BRAKE BOOSTER
BRAKE
B: INSTALLATION If it is not in specified value, adjust it by adjusting

1) Mount brake booster in position. brake booster operating rod.
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.
If it is not in specified value, adjust it by adjusting
position of stop light switch.
CAUTION:
Be careful not to rotate stop light switch.
Stop light switch clearance: A
0.3 mm (0.012 in)
B4M0117C
(1) Nuts
(2) Clevis pin
(3) Snap pin
(4) Operating rod
B4M0617H
3) Connect vacuum hose to brake booster. 9) Apply grease to operating rod connecting pin to
prevent it from wearing.
Tightening torque (Air bleeder screw):
8 N·m (0.8 kgf-m, 5.8 ft-lb)
11) Conduct road tests to ensure brakes do not
drag.
S4M0125
4) Mount master cylinder onto brake booster.
5) Connect brake pipes to master cylinder.
6) Connect electric connector for brake fluid level
indicator.
7) Adjust operating rod of brake booster.
Standard: L
LHD model:
144.6 mm (5.69 in)
RHD model:
173.2 mm (6.82 in)
BR-56
BRAKE BOOSTER
BRAKE
C: INSPECTION • Operation check
1. OPERATION CHECK (WITHOUT GAUG- 1) With engine off, depress brake pedal several
times applying the same pedal force and make
ES) sure that the pedal height does not vary with each
CAUTION: depression of the pedal.
When checking operation, be sure to securely
apply the hand brake.
• Checking without gauges
This method cannot determine the exact portion
which has failed, but it can provide a rough under-
standing of the nature of the failure if checking is
conducted in accordance with the following proce-
dures.
• Air tightness check
Start engine, and run it for 1 to 2 minutes, then turn S4M0466A
it off. Depress brake pedal several times applying
(1) When engine is stopped
the same pedal force as that used in ordinary brak-
(2) When engine is started
ing operations. The pedal stroke should be greatest
on the 1st depression, and it should become small- 2) With brake pedal depressed, start engine.
er with each successive depression. If no change 3) As engine starts, brake pedal should move
occurs in the pedal height while in a depressed slightly toward the floor. If no change occurs in the
state, brake booster is faulty. pedal height, brake booster is faulty.
NOTE:
If faulty, check precisely with gauges.
• Loaded air tightness check
Depress brake pedal while engine is running, and
turn off engine while the pedal is still depressed.
Keep the pedal depressed for 30 seconds; if no
change occurs in the pedal height, brake booster is
functioning normally; if the pedal height increases,
it is faulty.
S4M0465A
NOTE:
(1) OK If faulty, check precisely with gauges.
(2) NOT OK
(3) 1st
(4) 2nd
(5) 3rd
NOTE:
• In the event of defective operation, inspect the
condition of the check valve and vacuum hose.
• Replace them if faulty and conduct the test
again.
• If no improvement is observed, check precisely
with gauges.
BR-57
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 • Loaded air tightness check
apply the hand brake.
• Checking with gauges 1) Start engine and depress brake pedal with pedal
force of 196 N (20 kgf, 44 lb). Keep engine running
Connect gauges as shown in Figure. After bleeding until a vacuum of 66.7 kPa (500 mmHg, 19.69 in-
air from pressure gauges, proceed to each check. Hg) = point B is indicated on vacuum gauge while
the pedal is still depressed.
S4M0467A
(1) Pressure gauge S4M0469A
(2) Vacuum gauge (1) Pressure gauge

(3) Adapter hose (2) Vacuum gauge
(4) Vacuum hose (3) Pedal force gauge
(5) Pedal force gauge (4) Depress
• Air tightness check 2) Stop engine and watch vacuum gauge.

1) Start engine and keep it running until a vacuum If the vacuum drop range is less than 3.3 kPa (25
of 66.7 kPa (500 mmHg, 19.69 inHg) = point A is in- mmHg, 0.98 inHg) within 15 seconds after stopping
dicated on vacuum gauge. Do not depress brake engine, brake booster is functioning properly.
pedal. If defective, refer to “AIR TIGHTNESS CHECK”.
<Ref. to BR-57, INSPECTION, Brake Booster.>
S4M0468A
(1) Pressure gauge

(2) Vacuum gauge
2) Stop engine and watch the gauge. If the vacuum

drop range is less than 3.3 kPa (25 mmHg, 0.98 in-
Hg) within 15 seconds after stopping engine, 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
BR-58
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
force (15 kgf, 33 lb) (30 kgf, 66 lb)
686 kPa 1,961 kPa
(7 kg/cm2, 100 psi) (20 kg/cm2, 284 psi)
Fluid 14″
[ 588 kPa [ 1,667 kPa
pres-
(6 kg/cm2, 85 psi) ] (17 kg/cm2, 242 psi) ]
sure
15″ 686 kPa 1,715 kPa
16″ (6 kg/cm2, 100 psi) (15 kg/cm2, 250 psi)
[ ]: ABS equipped vehicle.

• Boosting action check
Set the vacuum gauge 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 147 N 294 N
force (15 kgf, 33 lb) (30 kgf, 66 lb)
5,982 kPa 7,649 kPa
(61 kg/cm2, 868 psi) (78 kg/cm2, 1,109 psi)
14″
[7,061 kPa (72 kg/ [8,434 kPa (86 kg/
Fluid cm2, 1,024 psi)] cm2, 1,223 psi)
pres- 5,296 kPa
sure 15″ (54 kg/cm2,
9,120 kPa
768 psi)
(93 kg/cm2, 1,323 psi)
4,707 kPa
16″
(48 kg/cm2, 683psi)
[ ]: ABS equipped vehicle.
BR-59
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)
BR0066
1) Remove brake pipe from proportioning valve at
four places.
2) Remove proportioning valve from its bracket.
CAUTION:
Do not disassemble or adjust the proportioning
valve. (The proportioning valve must be re-
placed as an assembly.)
BR-60
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.
The standard values are shown in Figure.
Rear wheel cylinder
fluid pressure: P 3
When both circuits

are normal
Master cylinder fluid pressure: P 2

BR0067
4) For the oil pressure in case of split point, refer to
“SPECIFICATIONS”.
<Ref. to BR-2, SPECIFICATIONS, General De-
scription.>
BR-61
BRAKE FLUID
BRAKE
14.Brake Fluid B: REPLACEMENT

A: INSPECTION CAUTION:
• 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. If fluid level becomes close to “MIN”, used in severe condition.
refill fluid.
• The FMVSS No. 116, fresh DOT3 or 4 brake
2) Check fluid for discoloration. If fluid color has ex- fluid must be used.
cessively changed, drain the fluid and refill with
• Cover bleeder with waste cloth, when loosen-
new fluid.
ing it, to prevent brake fluid from being
splashed over surrounding parts.
• 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.
NOTE:
• During bleeding operation, keep the brake reser-
voir tank filled with brake fluid to eliminate entry of
air.
• Brake pedal operating must be very slow.
• For convenience and safety, two people should
do the work.
• The amount of brake fluid required is approxi-
mately 500 m2 (16.9 US fl oz, 17.6 Imp fl oz) for to-
tal brake system.
1) Either jack-up vehicle and place a safety stand
under it, or left up vehicle.
2) Remove both front and rear wheels.
3) Draw out the brake fluid from master cylinder
with syringe.
4) Refill reservoir tank with recommended brake
fluid.
Recommended brake fluid:
FMVSS No. 116, fresh DOT3 or 4 brake fluid
BR-62
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.
9) After completing the bleeding operation, hold
brake pedal depressed and tighten screw and in-
stall bleeder cap.
Tightening torque (Bleeder screw):
8 N·m (0.8 kgf-m, 5.8 ft-lb)
10) Bleed air from each wheel cylinder using the
same procedures as described in steps 6) through
7) above.
S4M0246
11) Depress brake pedal with a force of approxi-
mately 294 N (30 kgf, 66 lb) and hold it there for ap-
proximately 20 seconds. At this time check pedal to
see if it shows any unusual movement.
Visually inspect bleeder screws and brake pipe
joints to make sure that there is no fluid leakage.
12) Install wheels, and drive vehicle for a short dis-
tance between 2 to 3 km (1 to 2 miles) to make sure
that brakes are operating properly.
G4N0438
CAUTION:
Brake fluid replacement sequence; (A) Front
right → (B) Rear left → (C) Front left → (D) Rear
right
S4M0475A
(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 bleeder screw approximately 1/4 turn
until a small amount of brake fluid drains into con-
tainer, and then quickly tighten screw.
8) Repeat steps 6) and 7) above until there are no
air bubbles in drained brake fluid and new fluid
flows through vinyl tube.
BR-63
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.>
fluid must be used.
• Cover bleeder with waste cloth when loosen- 2. BRAKE LINE
ing it to prevent brake fluid from being NOTE:
splashed over surrounding parts. • During bleeding operation, keep the brake reser-
• Avoid mixing different brands of brake fluid voir tank filled with brake fluid to eliminate entry of
to prevent degrading the quality of the fluid. air.
• Be careful not to allow dirt or dust to get into • Brake pedal operating must be very slow.
the reservoir tank. • For convenience and safety, two people should
NOTE: do the work.
• Start with the brakes (wheels) connected to the 1) Make sure that there is no leak from joints and
secondary chamber of the master cylinder. connections of the brake system.
• The time interval between two brake pedal oper- 2) Fit one end of vinyl tube into the air bleeder and
ations (from the time when the pedal is released to put the other end into a brake fluid container.
the time when it is depressed another time) shall be
approximately 3 seconds.
• The air bleeder on each brake shall be released
for 1 to 2 seconds.
1. MASTER CYLINDER
NOTE:
If master cylinder is disassembled or reservoir tank
is empty, bleed master cylinder.
1) Disconnect brake line at primary and secondary S4M0246
sides.
2) Carefully depress and hold brake pedal. CAUTION:
Brake fluid replacement sequence; (A) Front
right → (B) Rear left → (C) Front left → (D) Rear
right
B4M2351
3) Close outlet plug with your finger, and release
brake pedal.
S4M0475A
(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 air bleeder for 1 to 2 seconds.
B4M2352 Next, with the bleeder closed, slowly release the
4) Repeat above step2) and 3) until brake fluid is brake pedal.
completey bled from outlet plug.
BR-64
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. to ABS-11, ABS Sequence Control.>
erations. 9) Recheck the brake stroke.
CAUTION: 10) If the distance is more than specifications, there
Cover bleeder with waste cloth, when loosen- is a possibility air is in the inside of the hydraulic
ing it, to prevent brake fluid from being unit. Repeat above steps 2) to 9) above until pedal
splashed over surrounding parts. stroke meets the specification.
11) Add brake fluid to the required level (MAX. lev-
NOTE: el) of reservoir tank.
Brake pedal operating must be very slow. 12) As a final step, test run the vehicle at low speed
4) Tighten air bleeder securely when no air bubbles and apply brakes relatively hard 2 to 3 times to en-
are visible. sure that brakes provide normal braking action on
Air bleeder tightening torque: all four wheels without dragging and uneven brak-
8 N·m (0.8 kgf-m, 5.8 ft-lb) ing.
5) Perform these steps for the brakes connecting to
the secondary chamber of master cylinder, first,
and then for the ones connecting to primary cham-
ber. With all procedures completed, fully depress
the brake pedal and keep it in that position for ap-
proximately 20 seconds to make sure that there is
no leak evident in the entire system.
6) Check the pedal stroke.
While the engine is idling, depress the brake pedal
with a 490 N (50 kgf, 110 lb) load and measure the
distance between the brake pedal and steering
wheel. With the brake pedal released, measure the
distance between the pedal and steering wheel
again. The difference between the two measure-
ments must be more than specified.
S4M0476A
(1) Steering wheel

(2) Toe board
Specified pedal stroke:

Without ABS
90 mm (3.54 in)
With ABS
95 mm (3.74 in)
When depressing brake pedal with a 490 N
(50 kg, 110 lb) load.
7) If the distance is more than specifications, there
is a possibility that air is in the brake line. Bleed
brake line until pedal stroke meets the specifica-
tion.
BR-65
BRAKE HOSE
BRAKE
16.Brake Hose B: INSTALLATION

A: REMOVAL 1. FRONT BRAKE HOSE
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.
deform flare nut.)
Tightening torque (Union bolt):
18 N·m (1.8 kgf-m, 13.0 ft-lb)
B4M1843B
B4M1844
(1) Brake hose
(2) Brake pipe 3) Secure middle fitting of brake hose to bracket at
strut location using a clamp.
2) Pull out clamp to remove brake hose. 4) Position disc in straight-forward direction and
3) Remove bolt at strut and union bolt. route brake hose through hole in bracket on wheel
apron side.
2. REAR BRAKE HOSE
CAUTION:
1) Separate brake pipe from brake hose. Be sure brake hose is not twisted.
NOTE: 5) Temporarily tighten flare nut to connect brake
Always use flare nut wrench and be careful not to pipe and hose.
deform flare nut. 6) Fix brake hose with clamp at wheel apron brack-
et.
7) While holding hexagonal part of brake hose fit-
ting with a wrench, tighten flare nut to the specified
torque.
Tightening torque (Brake pipe flare nut):
15 N·m (1.5 kgf-m, 10.8 ft-lb)
8) Bleed air from the brake system.
BR0068
(1) Brake hose clip

(2) Brake hose
(3) Brake pipe
2) Pull out clamp to remove brake hose.
BR-66
BRAKE HOSE
BRAKE
2. REAR BRAKE HOSE C: INSPECTION

1) Pass brake hose through the hole of bracket, Ensure there are no cracks, breakage, or damage
and lightly tighten flare nut to connect brake pipe. on hoses. Check joints for fluid leakage. If any
2) Insert clamp upward to fix brake hose. cracks, breakage, damage or leakage is found, re-
3) While holding hexagonal part of brake hose fit- pair or replace hose.
ting with a wrench, tighten flare nut to the specified
torque.
Tightening torque (Brake pipe flare nut):
15 N·m (1.5 kgf-m, 10.8 ft-lb)
BR0068
(1) Brake hose clip

(2) Brake hose
(2) Brake pipe
4) Bleed air from the brake system.
BR-67
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. Do not use electri-
• All Airbag system wiring harness and con- cal test equipment on these circuits.
nectors are colored yellow. Do not use electri- • Be careful not to damage Airbag system wir-
cal test equipment on these circuits. ing harness when servicing the center brake
• Be careful not to damage Airbag system wir- pipe.
ing harness when servicing the center brake • When installing the brake pipe, make sure
pipe. that it is not bent.
• When removing the brake pipe, make sure • After installing the brake pipe and hose,
that it is not bent. bleed the air.
• After installing the brake hose, make sure
that it does not touch the tire or suspension as-
sembly, etc.
Brake pipe tightening torque:
15 N·m (1.5 kgf-m, 10.8 ft-lb)
BR-68
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.
BR-69
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
(3) PHV
3) Remove cable clamp, and disconnect PHV cable

from PHV.
CAUTION: S4M0241C
Carefully protect boots and inner cable from (1) Adjusting nut
damage when disconnecting PHV cable.
(2) Lock nut
(3) PHV
2) Remove cable clamp, and disconnect PHV cable

from PHV.
CAUTION:
Carefully protect boot and inner cable from
damage when disconnecting PHV cable.
S4M0242C
(1) PHV cable

(2) Clamp
4) Disconnect brake pipes from PHV.

CAUTION:
• Pay attention not to drop brake fluid onto
body painting since it may dissolve paint. S4M0242C
• Pay attention not to damage hexagonal head
(1) PHV cable
of flare nut by using pipe wrench without fail.
(2) Clamp
5) Detach PHV along with support from side frame.
CAUTION:
Exercise utmost care to prevent foreign matter
from entering into PHV when removing it.
BR-70
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:
S4M0244B Confirm that brake pipes are not deformed and/
or damaged. Replace them with new ones if
(1) Clamp necessary.
(2) PHV cable 3) Install PHV cable to PHV.
(3) Clutch pedal
CAUTION:
RHD model If cable clamp (and clips) is damaged, replace it
with a new one.
4) Connect PHV cable with clips.
NOTE:
Avoid sharp bending of PHV cable as it may cause
breakage.
5) Apply grease to the following points.
• Hook portion of return spring
• Cable end portion of lever
Grease:
S4M0245B SUNLIGHT 2 (Part No. 003602010)
(1) Clamp 6) Be sure to bleed air from the brake system.
(2) PHV cable 7) Adjust PHV cable. <Ref. to BR-71, PHV CABLE,
(3) Clutch pedal INSTALLATION, Hill Holder.>
CAUTION:
4) Remove PHV cable.
After replacing PHV cable with new one, oper-
B: INSPECTION ate clutch pedal about 30 times as a running-in
Check up removed parts as follows, and replace operation prior to adjustment.
defective ones. 2. PHV CABLE
1) Check if boots of PHV cable are damaged or de-
graded, and inner cable is damaged or corroded. 1) Install PHV cable in the reverse order of remov-
2) Check if return spring is worn out, damaged or al.
corroded. CAUTION:
3) Confirm that rolling sound of ball is heard with • If cable clamp is damaged, replace it with a
PHV inclined and lever rotates smoothly. new one.
CAUTION: • Avoid sharp bending of PHV cable as it may
Never disassemble PHV. Replace entire PHV cause breakage.
assembly if necessary. 2) Apply grease to the following points.
• Hook portion of return spring
• Cable end portion of lever
Grease:
SUNLIGHT 2 (Part No. 003602010)
BR-71
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° or higher
inclination.
1) If vehicle does not stop;
Tighten adjusting nut of PHV cable.
2) If vehicle does not start properly;
• Case A — When 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 hill holder is released earlier
than engagement of clutch pedal (Vehicle slips
down slightly.):
Tighten adjusting nut so that hill holder is released
later than engagement of clutch pedal (status in
Case A). Then make adjustment the same as in
Case A.
CAUTION:
Whenever turning adjusting nut, prevent PHV
cable from revolving.
S4M0241C
(1) Adjusting nut

(2) Lock nut
(3) PHV
3) Tighten lock nut.

Tightening torque:
3.4 N·m (0.35 kgf-m, 2.5 ft-lb)
BR-72
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-
et.
1. LHD 1.6 L MT MODEL • Operating rod of brake booster
1) Disconnect ground cable from battery. • Electrical connectors (for stop light switch, etc.)
2) Disconnect clutch cable from release lever. 6) Remove clevis pin which secures lever to push
3) Remove instrument panel lower cover from in- rod.
strument panel. 7) Remove nut which secures clutch master cylin-
4) Disconnect the following parts from pedal brack- der.
et. 8) Remove steering assembly.
• Operating rod of brake booster 9) Remove accelerator pedal.
• Electrical connectors (for stop light switch, etc.) 10) Remove bolts and nuts which secure pedal
5) Remove clevis pin which secures pedal to push bracket.
rod.
6) Remove bolts and nuts which secure brake and
clutch pedals, and remove pedal bracket and clutch
cable as a unit.
CAUTION:
Before removing clutch cable from toe board,
remove grommet. Slowly remove clutch cable,
being careful not to scratch it.
BR0075
3. AT MODEL AND RHD MT MODEL

1) Disconnect ground cable from battery.
2) Remove instrument panel lower cover from in-
strument panel.
3) Remove clevis pin which secures brake pedal to
brake booster operating rod. Also disconnect stop
light switch connector.
4) Remove two bolts and four nuts which secure
brake pedal to pedal.
(A) (B)
TR0494 G4M0324
(1) Clutch pedal

(2) Brake pedal
7) Depress clutch pedal, disconnect clutch cable

from clutch pedal.
2. LHD 2.0 L MT MODEL
1) Remove steering bolts.
2) Raise vehicle on hoist and remove the two bolts
which secure steering unit to underside of body.
3) Lower vehicle to floor.
BR-73
BRAKE PEDAL
BRAKE
B: INSTALLATION C: DISASSEMBLY
1) Install in the reverse order of removal.
CAUTION:
• If cable clamp is damaged, replace it with a 1) Remove the stop light switch.
new one. <Ref. to BR-77, REMOVAL, Stop Light Switch.>
• Never fail to cover outer cable end with boot. 2) Remove nut and pull out the bolt until brake ped-
• Be careful not to kink accelerator cable. al is able to remove, then remove brake pedal.
• Always use new clevis pins.
2) Adjustment of clutch pedal <Ref. to CL-36, AD-
JUSTMENT, Clutch Pedal.>
3) Inspect after pedal installation <Ref. to BR-76,
INSPECTION, Brake Pedal.>
BR0069
3) Remove bush, spring and stopper.
BR0070
(1) Stopper
(2) Bushing
(3) Brake pedal
(4) Brake pedal spring
4) Remove the brake pad.

1) Remove the brake switch.
<Ref. to BR-77, REMOVAL, Stop Light Switch.>
2) Remove the clutch pedal.
<Ref. to CL-34, DISASSEMBLY, Clutch Pedal.>
3) Remove the clutch master cylinder bracket.
B4M2349
BR-74
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.
NOTE:
B4M2350A
Clean up inside of bushings and apply grease be-
fore installing spacer.
(1) Stopper
Tightening torque:
(2) Bushing
T: 29 N·m (3.0 kgf-m, 21.7 ft-lb)
(3) Brake pedal
5) Remove the brake pedal pad.

3. AT MODEL AND RHD MT MODEL
1) Remove the brake switch.
2) Unbolt, and then remove the brake pedal.
B4M1753C
4) Set brake pedal position by adjusting position of
stop light switch.
Pedal position: L
125.9 mm (4.96 in)
Tightening torque:
B4M2347 T: 8 N·m (0.8 kgf-m, 5.8 ft-lb)
3) Remove bush, spacer and spring.
B4M1754B
BR0028
(1) Plug
(2) Stopper
(3) Brake pedal
4) Remove the brake pedal pad.
BR-75
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.
Deflection of brake and clutch pedal:
Service limit B4M0366B
5.0 mm (0.197 in) or less (1) Stop light switch
(2) Mat
(3) Toe board
(4) Brake booster operating rod
3) If it is not in specified value, adjust it by adjusting

brake booster operating rod length.
S4M0135B
(1) Clutch pedal

(2) Brake pedal
G4M0326
2) Check position of pedal pad.
Pedal height: L
148 mm (5.83 in)
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-76
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. the nut.
3) Loosen nuts, and unscrew stop light switch to re- <Ref. to BR-78, ADJUSTMENT, Stop Light
move. Switch.>
Tightening torque:
8 N·m (0.8 kgf-m, 5.8 ft-lb)
B4M1753D
(1) Stop light switch

B4M1753E
BR-77
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. the stop light switch and the stopper becomes 0.3
mm (0.012 in). Then, tighten the lock nut.
Specified position: L
2 mm (0.079 in)
B4M0617E
G4M0327
2) Measure the clearance between threaded end of
stop light switch and stopper.
CAUTION:
Stop light switch clearance: A
0.3 mm (0.012 in)
B4M0617E
(1) Stop light switch

(2) Stopper
(3) Brake pedal
3) If it is not in specified value, adjust it by adjusting

position of stop light switch.
CAUTION:
BR-78
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.
(3) Excessively wide shoe clearance Adjust the clearance.
(4) Wear, deteriorated surface material, adhering Replace, grind or clean.
water or fluid on the lining
(5) Improper operation of master cylinder, disc cal- Correct or replace.
iper, brake booster or check valve
2. Unstable or uneven (1) Fluid on the lining, drum or rotor Eliminate cause of fluid leakage, clean, or replace.
braking (2) Drum or rotor eccentricity Correct or replace the drum or rotor.
(3) Worn brake drum, or damage to the drum Correct by grinding, or replace.
caused by sand
(4) Improper lining contact, deteriorated surface Correct by grinding, or replace.
material, improper inferior material, or wear
(5) 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 Retighten.
bolts
(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. Excessive pedal (1) Entry of air into the hydraulic mechanism Bleed the air.
stroke (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.
(5) Improper lining contact or worn lining Correct or replace.
4. Brake dragging or (1) Insufficient pedal play Adjust play.
improper brake return (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.
(5) Weakened spring tension or breakage of shoe Replace the spring.
return spring
(6) Excessively narrow shoe clearance Adjust the clearance.
(7) Improper disc caliper operation Correct or replace.
(8) Improper adjusted wheel bearing Adjust or replace.
5. Brake noise (1) (1) Hardened or deteriorated lining Replace the shoe assembly or pad.
(creak sound) (2) Worn lining Replace the shoe assembly or pad.
(3) Loosened back plate or the support installing Retighten.
bolts
(4) Loose wheel bearing Retighten to normal tightening torque.
(5) Dirty drum or rotor Clean the drum or rotor, or clean and replace the
brake assembly.
6. Brake noise (2) (1) Worn lining Replace the shoe assembly or pad.
(hissing sound) (2) Improper installed shoe or pad Correct or replace the shoe assembly or pad.
(3) Loose or bent drum or rotor Retighten or replace.
BR-79
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.
(2) Lack of oil on the shoe ridge surface and Add more grease.
anchor
BR-80

Imp01 Chas 9

Uploaded by

Copyright:

Available Formats

Imp01 Chas 9

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Imp01 Chas 9

Uploaded by

Copyright:

Available Formats

2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

WHEEL AND TIRE SYSTEM WT

POWER ASSISTED SYSTEM PS

All information, illustration and specifi-

FUJI HEAVY INDUSTRIES LTD. G1830GE5

ITEM STANDARD SERVICE LIMIT

1 — 3 mm (0.04 — 0.12 in)

4. REAR DISC BRAKE (14 INCH TYPE)

5. REAR DISC BRAKE (15 INCH TYPE)

6. REAR DRUM BRAKE

(8) (1) (2)

(10) (11) (19)

(1) Cap (6) Primary piston (11) Pin

8. BRAKE PIPES AND HOSE

AT MODEL MT MODEL WITH HILL HOLDER

AT MODEL MT MODEL WITH HILL HOLDER

(1) Push rod (5) Filter (9) Valve body

(1) Push rod (5) Plunger valve (9) Operating rod

(1) Stopper (8) Spring (15) Stop light switch

12.BRAKE PEDAL FOR AT MODEL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS

(1) Support H4M1368

(2) Wooden blocks

Pad thickness Standard value 17 mm (0.67 in)

Pad thickness Standard value 14.5 mm (0.571 in)

• When replacing the pad, replace pads of the NOTE:

4. Front Disc Brake Assembly 2. 16 INCH TYPE

B: INSTALLATION 2. 16 INCH TYPE

CAUTION: (1) Boot ring

(1) Place a 30 mm (1.18 in) wide wooden block

3) Remove piston boot. B4M1165C

5) Remove piston seal from caliper body cylinder.

2) Using a standard screwdriver, remove boot ring D: ASSEMBLY

6) Position boot in grooves on cylinder and piston.

Place a 30 mm (1.18 in)

5) Remove piston seal from caliper body cylinder.

7) Apply a coat of specified grease to lock pin and

8) Install lock and guide pin boot on support.

2. 15 INCH TYPE 6) Position boot in grooves on cylinder and piston.

(1) Pin boot

3. 16 INCH TYPE E: INSPECTION

5) Apply a coat of specified grease to boot and fit in

Boot ring BR0017

5. Rear Brake Pad 2. 15 INCH TYPE

(1) Cross spring

(1) Brake pad

Pad thickness Standard value 16 mm (0.63 in)

as the wheel rotates. If this sound is heard, re-

(1) Adjusting screw

7. Rear Disc Brake Assembly 2. 15 INCH TYPE

B: INSTALLATION 3) Apply thin coat of Molykote AS880N (Part No.

C: DISASSEMBLY 4) Remove piston seal from caliper body cylinder.

(1) Place a 30 mm (1.18 in) wide wooden block

3) Gradually supply compressed air via inlet of cal- D: ASSEMBLY

4) Remove piston seal from caliper body cylinder.

(1) Piston boot

7) Apply a coat of specified grease to guide pin,

(1) Pin boot