BRAKE
BR
  1. General Description
  2. Front Brake Pad
  3. Front Disc Rotor
  4. Front Disc Brake Assembly
  5. Rear Brake Pad
  6. Rear Disc Rotor
  7. Rear Disc Brake Assembly
  8. Master Cylinder
  9. Brake Booster
  10. Brake Fluid
  11. Air Bleeding
  12. Brake Hose
  13. Brake Pipe
  14. Brake Pedal
  15. Stop Light Switch
  16. Brake Vacuum Pump
  17. General Diagnostic Table
BRAKE > General Description　
SPECIFICATION
 

Refer to “PARKING BRAKE” for parking brake specifications. PARKING BRAKE>General Description>SPECIFICATION

1. FRONT DISC BRAKE

Item

Specification

Size

16-inch

17-inch

Type

Floating 2-POT piston type

Ventilated disc

Effective cylinder diameter

mm (in)

40.4 (1.591)

Pad dimension (Length × Width × Thickness)

mm (in)

117.8 × 50.5 × 11

(4.638 × 1.988 × 0.43)

Pad thickness

mm (in)

Standard

11 (0.43)

Limit

1.5 (0.059)

Effective disc diameter

mm (in)

244 (9.61)

265 (10.43)

Rotor dimension (O.D. × Thickness)

mm (in)

294 × 24 (11.57 × 0.94)

316 × 28 (12.44 × 1.1)

Disc thickness

mm (in)

Standard

24 (0.94)

28 (1.1)

Limit

22 (0.87)

26 (1.02)

Disc runout

mm (in)

Standard

−

Limit

0.05 (0.002)

Clearance adjustment

Automatic adjustment
2. REAR DISC BRAKE

Item

Specification

Size

16-inch

Type

Floating 1-POT piston type

(Caliper with electric parking)

Ventilated disc

Effective cylinder diameter

mm (in)

40 (1.575)

Pad dimension (Length × Width × Thickness)

mm (in)

86.8 × 43.5 × 9

(3.417 × 1.713 × 0.354)

Pad thickness

mm (in)

Standard

9 (0.354)

Limit

1.5 (0.059)

Effective disc diameter

mm (in)

240 (9.45)

Rotor dimension (O.D. × Thickness)

mm (in)

285 × 17

(11.22 × 0.67)

Disc thickness

mm (in)

Standard

17 (0.67)

Limit

15 (0.59)

Disc runout

mm (in)

Standard

−

Limit

0.05 (0.002)

Clearance adjustment

Automatic adjustment
3. MASTER CYLINDER

Item

Specification

Type

Tandem

Effective diameter

mm (in)

23.8 (0.94)

Reservoir type

Sealed type

BRAKE FLUID

reservoir capacity

cm3 (cu in)

240 (14.64)
4. BRAKE BOOSTER

Item

Specification

Type

Vacuum suspended

Effective diameter

mm (in)

208 + 229 (8.19 + 9.02)

Brake fluid pressure

Brake pedal force N (kgf, lbf)

Fluid pressure kPa (kgf/cm2, psi)

When engine is stopped

147 (15, 33)

512 (5.2, 74)

294 (30, 66)

1,530 (15.6, 222)

When engine is running and vacuum pressure is at 93 kPa (697 mmHg, 27.47inHg)

147 (15, 33)

7,468 (76.1, 1,083)

294 (30, 66)

14,808 (151, 2,148)
5. BRAKE LINE, BRAKE PEDAL AND BRAKE FLUID
 

  • Do not let brake fluid come into contact with the painted surface of the vehicle body. Wash away with water immediately and wipe off if it is spilled by accident.

  • Do not mix different kinds of brake fluid. Mixing different brands of fluid, or mixing different grades of fluid (even if they have the same brand name), may lead to severe accidents due to reduced brake fluid performance.

  • When refilling brake fluid, do not allow dirt or dust to get into the reservoir tank.

  • Always use new SUBARU genuine brake fluid when replacing or refilling the fluid. Do not reuse drained brake fluid.

Item

Specification

Brake line

Dual circuit system

Brake pedal

Type

Suspended type

Free play

mm (in)

0.5 — 2.7 (0.02 — 0.11)

[When pulling the brake pedal upward with a force of less than 10 N (1 kgf, 2 lbf)]

BRAKE FLUID

Refer to “RECOMMENDED MATERIALS” section for brake fluid. RECOMMENDED MATERIALS>GREASE>BRAKE FLUID
BRAKE > General Description　
COMPONENT
1. FRONT DISC BRAKE

  • 16-inch model

    (1)

    Mounting bolt

    (10)

    Pad clip

    Tightening torque: N·m (kgf-m, ft-lb)

    (2)

    Bleeder screw

    (11)

    Pad disc brake front outer

    T1:

    8 (0.8, 5.9)

    (3)

    Bleeder cap

    (12)

    Shim disc brake front outer

    T2:

    27 (2.8, 19.9)

    (4)

    Caliper body

    (13)

    Brake disc front

    T3:

    135 (13.8, 99.6)

    (5)

    Piston seal

    (14)

    Support front disc brake

    (6)

    Piston disc brake

    (15)

    Pin boot

    (7)

    Boot piston

    (16)

    Slide pin bushing

    (8)

    Shim disc brake front inner

    (17)

    Slide pin lock

    (9)

    Pad disc brake front inner

    (18)

    Slide pin

  • 17-inch model

    (1)

    Mounting bolt

    (10)

    Pad clip

    Tightening torque: N·m (kgf-m, ft-lb)

    (2)

    Bleeder screw

    (11)

    Pad disc brake front outer

    T1:

    8 (0.8, 5.9)

    (3)

    Bleeder cap

    (12)

    Shim disc brake front outer

    T2:

    27 (2.8, 19.9)

    (4)

    Caliper body

    (13)

    Brake disc front

    T3:

    135 (13.8, 99.6)

    (5)

    Piston seal

    (14)

    Support front disc brake

    (6)

    Piston disc brake

    (15)

    Pin boot

    (7)

    Boot piston

    (16)

    Slide pin bushing

    (8)

    Shim disc brake front inner

    (17)

    Slide pin lock

    (9)

    Pad disc brake front inner

    (18)

    Slide pin
2. REAR DISC BRAKE

(1)

Mounting bolt

(9)

Pin boot

Tightening torque: N·m (kgf-m, ft-lb)

(2)

Support rear disc brake

(10)

Guide pin rear brake

T1:

8 (0.8, 5.9)

(3)

Pad COMPL inner

(11)

Bleeder cap

T2:

17 (1.7, 12.5)

(4)

Pad COMPL outer

(12)

Bleeder screw

T3:

25 (2.5, 18.4)

(5)

Pad clip

(13)

Caliper body

T4:

73 (7.4, 53.8)

(6)

Parking brake actuator

(14)

Boot piston

(7)

O-ring

(15)

Brake disc rear

(8)

Cap

∗: The component cannot be reused when the emergency release of parking brake was performed or when the actuator has a malfunction.

3. MASTER CYLINDER

(1)

Cap reservoir COMPL

(6)

Cylinder seal ASSY

Tightening torque: N·m (kgf-m, ft-lb)

(2)

Filter

(7)

Master cylinder ASSY

T:

13 (1.3, 9.6)

(3)

Caution label (model with caution label)

(8)

Bracket harness

(4)

Oil reservoir COMPL

(9)

Pin

(5)

Seal reservoir

(10)

Level indicator
4. FRONT BRAKE PIPES AND HOSES

(1)

Connector 2 ‐ two-way

(7)

Gasket

∗1:

Models without EyeSight

(2)

Hydraulic unit ASSY VDC

(8)

Clamp brake hose

∗2:

Models with EyeSight

(3)

Clip

(9)

Brake hose front LH

Tightening torque: N·m (kgf-m, ft-lb)

(4)

Pipe ASSY front ABS

(10)

Brake hose front RH

T1:

15 (1.5, 11.1)

(5)

Vacuum sensor ASSY

(11)

Pipe clamp

T2:

18 (1.8, 13.3)

(6)

Master cylinder ASSY and vacuum booster ASSY

T3:

19 (1.9, 14.0)

T4:

26 (2.7, 19.2)

T5:

33 (3.4, 24.3)
5. CENTER BRAKE PIPES AND HOSES

(1)

Fuel pipe bracket A

(6)

Clamp brake hose

Tightening torque: N·m (kgf-m, ft-lb)

(2)

Fuel pipe bracket B

(7)

Gasket

T1:

15 (1.5, 11.1)

(3)

Pipe center brake rear RH

(8)

Brake hose rear RH

T2:

18 (1.8, 13.3)

(4)

Pipe center brake rear LH

(9)

Brake hose rear LH

T3:

26 (2.7, 19.2)

(5)

Fuel pipe bracket C

(10)

Pipe clamp

T4:

33 (3.4, 24.3)
6. BRAKE BOOSTER

(1)

Vacuum hose COMPL

(4)

Vacuum booster ASSY

Tightening torque: N·m (kgf-m, ft-lb)

(2)

Vacuum pipe ASSY

(5)

Gasket booster

T1:

7.5 (0.8, 5.5)

(3)

Vacuum sensor ASSY

(6)

Seal (damping seat) (model with EyeSight)

T2:

18 (1.8, 13.3)
7. BRAKE PEDAL

(1)

Bracket pedal COMPL

(6)

Stopper

Tightening torque: N·m (kgf-m, ft-lb)

(2)

Stop light switch ASSY

(7)

Clevis pin

T1:

8 (0.8, 5.9)

(3)

Pad (AT) pedal

(8)

Bushing

T2:

18 (1.8, 13.3)

(4)

Pedal COMPL brake

(9)

Spacer

T3:

30 (3.1, 22.1)

(5)

Snap pin

(10)

Shaft bolt
BRAKE > General Description　
CAUTION
BRAKE > General Description　
PREPARATION TOOL
1. SPECIAL TOOL

ILLUSTRATION

TOOL NUMBER

DESCRIPTION

REMARKS

99099AL000

PISTON BOOT INSTALLER

Used for installing the boot piston.

—

SUBARU SELECT MONITOR 4

Used for setting of each function and troubleshooting for electrical system.

 

For detailed operation procedures, refer to “Help” of application.
2. GENERAL TOOL

TOOL NAME

REMARKS

Cap

Used for brake hose installing portion of caliper body.

Circuit tester

Used for measuring resistance, voltage and current.

Dial gauge

Used for measuring brake disc run-out.

Magnet stand

Used for measuring brake disc run-out.

Micrometer

Used for measuring the brake disc thickness.

Disc brake piston tool

Used for pushing back the electronic parking brake piston.

  • KTC disc parking tool rotor

  • OTC brake caliper tool adapter

or equivalent

Disc brake piston tool

Used for pushing back the piston. (Except for electronic parking brake)

Vacuum gauge

Used for measuring the operation and airtightness of the brake booster.

Flare nut wrench

Used for removing and installing the brake pipe.

Pressure gauge

Used for measuring the operation and airtightness of the brake booster.

Hexagon wrench

Used for removing and installing the electronic parking brake caliper.

Width across flat 7 mm (0.28in)

DST-i

Used together with Subaru Select Monitor 4.
BRAKE > Front Brake Pad　
REMOVAL
1.

Lift up the vehicle, and then remove the front wheels.

2.

Remove the pad disc brake front.

(1)

Remove the caliper bolt on the lower side.

(2)

Raise the caliper body and remove the pad disc brake front.

 

Do not disconnect the brake hose from the caliper body.

BRAKE > Front Brake Pad　
INSTALLATION
 

Before installation, remove the pad clip and remove mud, foreign matter and rust from the caliper body and the support front disc brake.

1.

Apply a thin coat of grease to the support front disc brake.

Preparation items:

Grease: An item contained in the pad kit or equivalent

2.

Check the pad disc brake front. BRAKE>Front Brake Pad>INSPECTION

3.

Apply a thin coat of grease to the pad disc brake front.

Preparation items:

Grease: An item contained in the pad kit or equivalent

4.

Install the pad clip.

5.

Press back the piston disc brake with a tool as needed.

 

When pressing back the piston disc brake, the clearance between pad disc brake and brake disc becomes large, which makes the brake pedal effort softer.

After the installation of front wheel, be sure to perform the adjustment of the clearance and the pedal effort by depressing the brake pedal repeatedly.

Preparation tool:

Disc brake piston tool

6.

Install the pad disc brake front.

 

When installing, make sure that the pad wear indicator (a) comes on the lower side.

7.

Install the caliper body.

Tightening torque:

27 N·m (2.8kgf-m, 19.9ft-lb)

8.

Install the front wheels.

Tightening torque:

120 N·m (12.2kgf-m, 88.5ft-lb)

BRAKE > Front Brake Pad　
INSPECTION
1.

Check the thickness of the pad disc brake front.

 

  • When replacing the pad disc brake front, always replace the pads of both wheels and both sides as a set.

  • Replace pad clips if they are twisted or worn.

  • Replace the pad disc brake front if there is oil or grease on it.

  • Pad wear indicators are installed on the pad disc brake front inner and the pad disc brake front outer, and a squeaking sound is heard if the pad is worn to the limit.

Brake pad type

Standard (a)

Wear limit (b)

Brake pad thickness

16-inch type

11 mm (0.43in)

1.5 mm (0.059in)

17-inch type
2.

If the wear limit is exceeded in the inspection, replace the pad disc brake front.

BRAKE > Front Disc Rotor　
REMOVAL
1.

Lift up the vehicle, and then remove the front wheels.

2.

Remove the disc brake assembly front.

(1)

Remove the brake hose bracket and mounting bolt, and remove the disc brake assembly front.

(2)

Prepare wiring harnesses etc. to be discarded, and suspend the disc brake assembly front from the strut assembly.

3.

Remove the brake disc front.

 

When the brake disc front is difficult to be removed, screw in 8 mm (0.31in) bolt to the threaded part (a), and remove the brake disc front.

BRAKE > Front Disc Rotor　
INSTALLATION
 

Before installation, remove mud and foreign matter from the disc brake assembly front.

1.

Check the brake disc front. BRAKE>Front Disc Rotor>INSPECTION

2.

Press back the piston disc brake with a tool as needed.

 

When pressing back the piston disc brake, the clearance between pad disc brake and brake disc becomes large, which makes the brake pedal effort softer.

After the installation of front wheel, be sure to perform the adjustment of the clearance and the pedal effort by depressing the brake pedal repeatedly.

Preparation tool:

Disc brake piston tool

3.

Install the brake disc front.

4.

Install the disc brake assembly front.

Tightening torque:

135 N·m (13.8kgf-m, 99.6ft-lb)

5.

Install the front wheels.

Tightening torque:

120 N·m (12.2kgf-m, 88.5ft-lb)

BRAKE > Front Disc Rotor　
INSPECTION
1. DISC ROTOR RUNOUT CHECK
1.

Check the front hub unit bearing for free play and runout before the inspection of brake disc front runout limit. PROPELLER SHAFT / DRIVE SHAFT / AXLE>Front Hub Unit Bearing>INSPECTION

2.

Check the brake disc front runout.

(1)

Remove the caliper body. BRAKE>Front Disc Brake Assembly>REMOVAL

(2)

Secure the brake disc front by tightening the five wheel nuts.

(3)

Set a dial gauge 10 mm (0.39in) inward from the brake disc front outer circumference, and check the runout of front side while rotating the brake disc front.

Preparation tool:

Dial gauge

Magnet stand

Brake disc front runout limit

0.05 mm (0.002in)

 

<Example of magnet stand and dial gauge installation>

The location where the magnet stand is installed varies to stabilize the magnet stand.

(4)

Set a dial gauge 10 mm (0.39in) inward from the brake disc front outer circumference, and check the runout of backside while rotating the brake disc front.

Preparation tool:

Dial gauge

Magnet stand

Brake disc front runout limit

0.05 mm (0.002in)

 

<Example of magnet stand and dial gauge installation>

The location where the magnet stand is installed varies to stabilize the magnet stand.

3.

If the brake disc front runout exceeds service limit, grind the brake disc front.

4.

Check the brake disc front thickness after grinding. BRAKE>Front Disc Rotor>INSPECTION > DISC ROTOR THICKNESS CHECK

2. DISC ROTOR THICKNESS CHECK
1.

Remove the caliper body. BRAKE>Front Disc Brake Assembly>REMOVAL

2.

Set a micrometer 10 mm (0.39in) inward from the brake disc front outer perimeter, and then measure the disc rotor thickness (a).

Preparation tool:

Micrometer

Size

Standard

Wear limit

Disc rotor outer diameter

Disc rotor thickness (a)

16-inch

24 mm (0.94in)

22 mm (0.87in)

294 mm (11.57in)

17-inch

28 mm (1.1in)

26 mm (1.02in)

316 mm (12.44in)
3.

If the wear limit is exceeded in the inspection, replace the brake disc front.

BRAKE > Front Disc Brake Assembly　
REMOVAL
 

  • Do not allow brake fluid to come in contact with the painted surface of the vehicle body. If it does, wash off with water and wipe away completely.

  • Prepare a container to catch grease or oil, etc. If any grease or oil spills, wipe it off and clean immediately to prevent from penetrating into floor or flowing outside.

1.

Lift up the vehicle, and then remove the front wheels.

2.

Remove the union bolt and brake hose front.

3.

Remove the caliper bolt, and remove the caliper body.

4.

Remove the pad disc brake front.

5.

Remove the mounting bolts, and then remove the support front disc brake.

BRAKE > Front Disc Brake Assembly　
INSTALLATION
 

Before installation, remove mud and foreign matter from the caliper body and support front disc brake.

1.

Check each part. BRAKE>Front Disc Brake Assembly>INSPECTION

2.

Apply a thin coat of grease to the support front disc brake.

Preparation items:

Grease: An item contained in the pad kit or equivalent

3.

Install the support front disc brake.

Tightening torque:

135 N·m (13.8kgf-m, 99.6ft-lb)

4.

Apply a thin coat of grease to the pad disc brake front.

Preparation items:

Grease: An item contained in the pad kit or equivalent

5.

Press back the piston disc brake with a tool as needed.

 

When pressing back the piston disc brake, the clearance between pad disc brake and brake disc becomes large, which makes the brake pedal effort softer.

After the installation of front wheel, be sure to perform the adjustment of the clearance and the pedal effort by depressing the brake pedal repeatedly.

Preparation tool:

Disc brake piston tool

6.

Install the pad disc brake front.

 

When installing, make sure that the pad wear indicator (a) comes on the lower side.

7.

Install the caliper body.

Tightening torque:

27 N·m (2.8kgf-m, 19.9ft-lb)

8.

Connect the brake hose front using a new gasket.

Tightening torque:

26 N·m (2.7kgf-m, 19.2ft-lb)

9.

Bleed air from the brake system. BRAKE>Air Bleeding>PROCEDURE > BRAKE LINE

10.

Install the front wheels.

Tightening torque:

120 N·m (12.2kgf-m, 88.5ft-lb)

BRAKE > Front Disc Brake Assembly　
DISASSEMBLY
 

Be careful not to allow foreign matter to enter the brake hose connector.

1.

Remove mud and foreign matter from the caliper body.

2.

Remove the piston disc brake.

(1)

Place a wooden block in the caliper body as shown in the figure to prevent the piston disc brake from jumping out and being damaged.

(2)

Using an air gun, gradually apply compressed air via the brake hose front installation hole to push out the piston disc brake.

 

Instead of removing the pistons one by one, remove all pistons at once after adjusting the amount of protrusion evenly using a wooden block.

(a)

30 mm (1.18in)
3.

Remove the boot piston (b) and piston seal (c) from the caliper body cylinder (a).

 

Do not damage the cylinder and piston seal groove.

4.

Remove the pin boot from the support front disc brake.

(a)

Slide pin

(b)

Slide pin lock

(c)

Slide pin bushing

(d)

Pin boot
BRAKE > Front Disc Brake Assembly　
ASSEMBLY
1.

Check each part. BRAKE>Front Disc Brake Assembly>INSPECTION

2.

Clean the inside of the caliper body using brake fluid.

Preparation items:

Brake fluid: RECOMMENDED MATERIALS>GREASE>BRAKE FLUID

3.

Install the piston seal and the piston disc brake.

(1)

Apply a coat of brake fluid to piston seal and install the piston seal to the groove inside caliper body.

(2)

Apply a coat of brake fluid to the piston sliding part of caliper body and the entire outer surface of the piston disc brake.

Preparation items:

Brake fluid: RECOMMENDED MATERIALS>GREASE>BRAKE FLUID

(3)

Apply a coat of grease to the boot piston and fit to the groove on the ends of piston disc brake.

Preparation items:

Brake grease: An item contained in the piston seal kit or Nippon Grease NIGLUBE RX-2

(4)

Install the piston disc brake to the caliper body.

 

Do not force the piston disc brake into the sliding part of caliper body.

(a)

Piston disc brake

(b)

Boot piston

(c)

Caliper body

(d)

Piston seal
4.

Apply grease to the following locations.

  • Slide pin lock

  • Slide pin circumference

  • Support front disc brake pin sliding section, and grooves of pin boot

Preparation items:

Brake grease: An item contained in the piston seal kit or Nippon Grease NIGLUBE RX-2

5.

Install the pin boot to the slide pin lock and the slide pin, and insert them into the support front disc brake.

 

After inserting the slide pin lock and slide pin into specified position, make sure that they slide and seat properly by moving each pin by hand.

(a)

Grease applied area
BRAKE > Front Disc Brake Assembly　
INSPECTION
1.

Check the piston sliding part of caliper body and the piston for uneven wear, damage or rust.

2.

Check the rubber parts for damage or deterioration.

3.

If faulty is found in the inspection, replace the relevant part.

BRAKE > Rear Brake Pad　
REMOVAL
1.

Release the parking brake.

2.

Using the Subaru Select Monitor, perform the brake maintenance mode. PARKING BRAKE>Parking Brake System>OPERATION > BRAKE MAINTENANCE MODE

3.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

4.

Lift up the vehicle, and then remove the rear wheels.

5.

Remove the pad COMPL.

(1)

Disconnect the connector.

(2)

Remove the pad clip and the brake hose bracket.

(3)

Remove the cap (a) and guide pin rear brake (b), and remove the pad COMPL.

Preparation tool:

Hexagon wrench: 7 mm (0.28in)

BRAKE > Rear Brake Pad　
INSTALLATION
 

  • Before installation, remove mud and foreign matter from the disc brake assembly rear.

  • Check that the ground terminal of the battery sensor is disconnected.

1.

Install the pad COMPL.

2.

Install the caliper body.

 

Make sure that the adapter cord EPB connector is securely installed.

Tightening torque:

Guide pin rear brake: 25 N·m (2.5kgf-m, 18.4ft-lb)

Brake hose bracket: 33 N·m (3.4kgf-m, 24.3ft-lb)

3.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

4.

Using the Subaru Select Monitor, exit the brake maintenance mode. PARKING BRAKE>Parking Brake System>OPERATION > BRAKE MAINTENANCE MODE

5.

After the operation is completed, apply and release the parking brake five times and ensure that the brake operates normally.

6.

Install the rear wheels.

Tightening torque:

120 N·m (12.2kgf-m, 88.5ft-lb)

BRAKE > Rear Brake Pad　
INSPECTION
1.

Check the pad COMPL thickness.

 

  • Always replace the pad COMPL of both wheels and both sides as a set.

  • Replace pad clips if they are twisted or worn.

  • Replace the pad COMPL if there is oil or grease on it.

  • Pad wear indicators are installed on the pad COMPL inner, and a squeaking sound is heard if the brake pad is worn to the limit.

Standard (a)

Wear limit (b)

Brake pad thickness

9.0 mm (0.354in)

1.5 mm (0.059in)
2.

If the wear limit is exceeded in the inspection, replace the pad COMPL.

BRAKE > Rear Brake Pad　
REPLACEMENT
1.

Release the parking brake.

2.

Using the Subaru Select Monitor, perform the brake maintenance mode. PARKING BRAKE>Parking Brake System>OPERATION > BRAKE MAINTENANCE MODE

3.

Remove the pad COMPL. BRAKE>Rear Brake Pad>REMOVAL

4.

Push back the piston disc brake.

5.

Install the pad COMPL. BRAKE>Rear Brake Pad>INSTALLATION

6.

Using the Subaru Select Monitor, exit the brake maintenance mode. PARKING BRAKE>Parking Brake System>OPERATION > BRAKE MAINTENANCE MODE

7.

After the operation is completed, apply and release the parking brake five times and ensure that the brake operates normally.

 

Perform the following replacement procedure if the Subaru Select Monitor cannot be used.

  1. Remove the caliper body and pad COMPL.

  2. Remove the mounting bolt on the lower side of the support rear disc brake, loosen the upper side bolt, and then slide the support rear disc brake upward and hold it.

  3. Secure the caliper body to the support rear disc brake, and push back the piston disc brake using a tool.

    Preparation tool:

    Disc brake piston tool: KTC disc parking tool rotor (E•F) ABX104

    Disc brake piston tool: OTC brake caliper tool adapter No. 7317A

    or equivalent

  4. Install the support rear disc brake and the caliper body to the specified tightening torque.

    Tightening torque:

    Refer to “COMPONENT” of “General Description” for the tightening torque. BRAKE>General Description>COMPONENT > REAR DISC BRAKE

BRAKE > Rear Disc Rotor　
REMOVAL
1.

Release the parking brake.

2.

Using the Subaru Select Monitor, perform the brake maintenance mode. PARKING BRAKE>Parking Brake System>OPERATION > BRAKE MAINTENANCE MODE

3.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

4.

Lift up the vehicle, and then remove the rear wheels.

5.

Remove the disc brake assembly rear.

(1)

Remove the pad clip and the brake hose bracket.

(2)

Remove the connector and mounting bolt, and remove the disc brake assembly rear.

(3)

Prepare wiring harnesses etc. to be discarded, and suspend the disc brake assembly rear from the shock absorber assembly rear.

6.

Remove the brake disc rear.

 

When the brake disc rear is difficult to be removed, screw in 8 mm (0.31in) bolt to the threaded part of the brake disc rear (a), and remove the brake disc rear.

BRAKE > Rear Disc Rotor　
INSTALLATION
 

  • Before installation, remove mud and foreign matter from the disc brake assembly rear.

  • Check that the ground terminal of the battery sensor is disconnected.

1.

Check the brake disc rear. BRAKE>Rear Disc Rotor>INSPECTION

2.

Install the brake disc rear.

 

When installing the brake disc rear, match the alignment mark (a) of the brake disc rear and the alignment mark (b) of the hub bolt.

3.

Install the disc brake assembly rear.

 

  • Make sure that the adapter cord EPB connector is securely installed.

  • Do not reuse the mounting bolt. Always replace with a new bolt.

Tightening torque:

Mounting bolt: 73 N·m (7.4kgf-m, 53.8ft-lb)

Brake hose bracket: 33 N·m (3.4kgf-m, 24.3ft-lb)

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

5.

Using the Subaru Select Monitor, exit the brake maintenance mode. PARKING BRAKE>Parking Brake System>OPERATION > BRAKE MAINTENANCE MODE

6.

After the operation is completed, apply and release the parking brake five times and ensure that the brake operates normally.

7.

Install the rear wheels.

Tightening torque:

120 N·m (12.2kgf-m, 88.5ft-lb)

BRAKE > Rear Disc Rotor　
INSPECTION
1. DISC ROTOR RUNOUT CHECK
1.

Check the rear hub unit bearing for free play and runout before the inspection of brake disc rear runout limit. PROPELLER SHAFT / DRIVE SHAFT / AXLE>Rear Hub Unit Bearing>INSPECTION

2.

Check the brake disc rear runout.

(1)

Remove the caliper body. BRAKE>Rear Disc Brake Assembly>REMOVAL

(2)

Secure the brake disc rear by tightening the five wheel nuts.

(3)

Set a dial gauge 10 mm (0.39in) inward from the brake disc rear outer circumference, and check the runout of front side while rotating the brake disc rear.

Preparation tool:

Dial gauge

Magnet stand

Brake disc rear runout limit:

0.05 mm (0.002in)

 

<Example of magnet stand and dial gauge installation>

The location where the magnet stand is installed varies to stabilize the magnet stand.

(4)

Set a dial gauge 10 mm (0.39in) inward from the brake disc rear outer circumference, and check the runout of backside while rotating the brake disc rear.

Preparation tool:

Dial gauge

Magnet stand

Brake disc rear runout limit:

0.05 mm (0.002in)

 

<Example of magnet stand and dial gauge installation>

The location where the magnet stand is installed varies to stabilize the magnet stand.

3.

If the brake disc rear runout exceeds service limit, grind the brake disc rear.

4.

Check the brake disc rear thickness after grinding. BRAKE>Front Disc Rotor>INSPECTION > DISC ROTOR THICKNESS CHECK

2. DISC ROTOR THICKNESS CHECK
1.

Remove the caliper body. BRAKE>Rear Disc Brake Assembly>REMOVAL

2.

Set a micrometer 10 mm (0.39in) inward from the brake disc rear outer perimeter, and then measure the disc rotor thickness (a).

Preparation tool:

Micrometer

Standard

Wear limit

Disc rotor outer diameter

Disc rotor thickness (a)

17 mm (0.67in)

15 mm (0.59in)

285 mm (11.22in)
3.

If the wear limit is exceeded in the inspection, replace the brake disc rear.

BRAKE > Rear Disc Brake Assembly　
REMOVAL
 

  • Do not allow brake fluid to come in contact with the painted surface of the vehicle body. If it does, wash off with water and wipe away completely.

  • Prepare a container to catch grease or oil, etc. If any grease or oil spills, wipe it off and clean immediately to prevent from penetrating into floor or flowing outside.

  • Do not remove the parking brake actuator except when there are system malfunctions (such as emergency release of parking brake or abnormal actuator) or when the caliper is replaced. When the parking brake actuator is reused, always replace the O-ring with a new part contained in the caliper body.

1.

Release the parking brake.

2.

Using the Subaru Select Monitor, perform the brake maintenance mode. PARKING BRAKE>Parking Brake System>OPERATION > BRAKE MAINTENANCE MODE

3.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

4.

Lift up the vehicle, and then remove the rear wheels.

5.

Remove the caliper body.

 

  • Do not detach the brake hose rear except when replacing the caliper body.

  • Install the fluid leakage protection plug to the caliper body when the brake hose rear is disconnected.

    If air enters or fluid leaks by tilting, replace the caliper body.

(1)

Disconnect the brake hose rear.

(2)

Install the fluid leakage protection plug to the caliper body.

Preparation items:

Part No.: PLUG BOLT (26642AL000)

Part No.: PLUG GASKET (26642AL010)

Tightening torque:

20 N·m (2.0kgf-m, 14.8ft-lb)

(3)

Remove the pad clip, the connector and the brake hose bracket.

(4)

Remove the cap (a) and guide pin rear brake (b), and remove the caliper body.

Preparation tool:

Hexagon wrench: 7 mm (0.28in)

6.

Remove the pad COMPL.

7.

Remove the mounting bolts, and then remove the support rear disc brake.

BRAKE > Rear Disc Brake Assembly　
INSTALLATION
 

  • Before installation, remove mud and foreign matter from the caliper body and support rear disc brake.

  • Check that the ground terminal of the battery sensor is disconnected.

1.

Check each part. BRAKE>Rear Disc Brake Assembly>INSPECTION

2.

Install the support rear disc brake.

 

Do not reuse the mounting bolt. Always replace with a new bolt.

Tightening torque:

73 N·m (7.4kgf-m, 53.8ft-lb)

3.

Install the pad COMPL.

4.

Install the caliper body.

 

Make sure that the adapter cord EPB connector is securely installed.

Tightening torque:

25 N·m (2.5kgf-m, 18.4ft-lb)

5.

Connect the brake hose rear using a new gasket.

Tightening torque:

26 N·m (2.7kgf-m, 19.2ft-lb)

6.

Install the brake hose bracket.

Tightening torque:

33 N·m (3.4kgf-m, 24.3ft-lb)

7.

Bleed air from the brake system. BRAKE>Air Bleeding>PROCEDURE > BRAKE LINE

8.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

9.

Using the Subaru Select Monitor, exit the brake maintenance mode. PARKING BRAKE>Parking Brake System>OPERATION > BRAKE MAINTENANCE MODE

10.

After the operation is completed, apply and release the parking brake five times and ensure that the brake operates normally.

11.

Install the rear wheels.

Tightening torque:

120 N·m (12.2kgf-m, 88.5ft-lb)

BRAKE > Rear Disc Brake Assembly　
DISASSEMBLY
 

  • The piston disc brake cannot be removed from the caliper body.

  • Do not remove the parking brake actuator except for the system error.

1.

Remove mud and foreign matter from the caliper body.

2.

Remove the boot piston.

3.

Remove the pin boot from caliper body.

BRAKE > Rear Disc Brake Assembly　
ASSEMBLY
 

If the brake hose rear is disconnected, air enters inside. Therefore, this operation should be performed on the vehicle without disconnecting the brake hose rear.

1.

Check each part. BRAKE>Rear Disc Brake Assembly>INSPECTION

2.

Install the pin boot.

3.

Apply a coat of grease to the inside of the new boot piston.

Preparation items:

Grease: Nippon Grease NIGLUBE RX-2

4.

Using the ST, install the boot piston.

Preparation tool:

ST: PISTON BOOT INSTALLER (99099AL000)

BRAKE > Rear Disc Brake Assembly　
INSPECTION
1.

Check the piston sliding part of caliper body and the piston disc brake for uneven wear, damage or rust.

2.

Check the rubber parts for damage or deterioration.

3.

If faulty is found in the inspection, replace the relevant part.

BRAKE > Master Cylinder　
REMOVAL
 

  • Do not allow brake fluid to come in contact with the painted surface of the vehicle body. If it does, wash off with water and wipe away completely.

  • Prepare a container to catch grease or oil, etc. If any grease or oil spills, wipe it off and clean immediately to prevent from penetrating into floor or flowing outside.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Drain brake fluid completely from the oil reservoir COMPL.

3.

Remove the master cylinder assembly.

(1)

Disconnect the level indicator connector (a).

(2)

Disconnect the brake pipe (b).

Preparation tool:

Flare nut wrench

(3)

Remove the nut (c), and slowly remove the master cylinder assembly from the vacuum booster assembly.

BRAKE > Master Cylinder　
INSTALLATION
1.

Replace the cylinder seal assembly of the master cylinder assembly with a new part.

 

Be careful not to install the cylinder seal assembly in the wrong location.

(a)

Primary piston

(b)

Cylinder seal ASSY

(c)

Install the cylinder seal assembly to this surface.
2.

Install the master cylinder assembly.

Tightening torque:

13 N·m (1.3kgf-m, 9.6ft-lb)

3.

Turn and tighten the flare nut (b) by hand while pressing the brake pipe (a) toward the master cylinder assembly side.

 

Be careful not to make scratches or other damage to the inside surface of the brake pipe flare.

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

4.

Bleed air from the brake system. BRAKE>Air Bleeding>PROCEDURE

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

BRAKE > Master Cylinder　
DISASSEMBLY
1.

Remove the oil reservoir COMPL.

 

Be careful not to tighten a vise excessively.

(1)

Place the master cylinder assembly between aluminum plates and fix it on a vise.

(2)

Drive out the pin using a punch and a hammer to remove the oil reservoir COMPL.

2.

Remove the seal reservoir from the master cylinder assembly.

BRAKE > Master Cylinder　
ASSEMBLY
 

When replacing the oil reservoir COMPL, adhere the label to the position shown in the figure.

Preparation items:

Part No.: Fluid mark label (25080GA010)

(a)

Fluid caution label

(b)

Vacuum booster ASSY
1.

Install the seal reservoir to the master cylinder assembly.

2.

Install the oil reservoir COMPL.

 

Be careful not to tighten a vise excessively.

(1)

Place the master cylinder assembly between aluminum plates and fix it on a vise.

(2)

Drive the pin using a punch and a hammer to install the oil reservoir COMPL.

BRAKE > Brake Booster　
REMOVAL
1. BRAKE BOOSTER
 

  • Do not allow brake fluid to come in contact with the painted surface of the vehicle body. If it does, wash off with water and wipe away completely.

  • Before performing service on the airbag module, always refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM” section. AIRBAG SYSTEM>General Description>CAUTION

1.

Disconnect the ground terminal from the battery sensor, and wait for at least 60 seconds before starting work. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the vacuum hose & pipe. BRAKE>Brake Booster>REMOVAL > BRAKE VACUUM HOSE

3.

Remove the engine control module (ECM). FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)>REMOVAL

4.

Remove the master cylinder assembly. BRAKE>Master Cylinder>REMOVAL

5.

Remove the brake pipe from the pipe clamp.

6.

Remove the cover LWR driver. EXTERIOR/INTERIOR TRIM>Instrument Panel Lower Cover>REMOVAL

7.

Remove the knee airbag module. AIRBAG SYSTEM>Knee Airbag Module>REMOVAL

8.

Remove the universal joint. POWER ASSISTED SYSTEM (POWER STEERING)>Universal Joint>REMOVAL

 

To prevent damage to the universal joint and error of handling force, make sure to remove the universal joint.

9.

Remove the column assembly steering. POWER ASSISTED SYSTEM (POWER STEERING)>Steering Column>REMOVAL

10.

Remove the snap pin (a) and clevis pin (b), and remove the operating rod from the pedal COMPL brake.

 

  • Be careful not to apply excessive force to the operating rod when handling the operating rod. The angle may change by ±3°, and it may result in damage to power piston cylinder.

  • Do not change the push rod length.

11.

Disconnect the vacuum sensor assembly connector.

 

  • Do not remove the vacuum sensor assembly. If removed, replace the vacuum booster assembly with a new part.

  • Do not rotate the vacuum sensor assembly when disconnecting the connector of vacuum sensor assembly. Otherwise the grommet on the mounting location of the vacuum sensor assembly may be damaged.

12.

Remove the vacuum booster assembly.

 

  • Do not disassemble the vacuum booster assembly.

  • Make sure that the booster shell and vacuum pipe are not subject to strong impacts.

  • Be careful not to drop the vacuum booster assembly. If the vacuum booster assembly is dropped accidentally, replace it.

  • Be careful when placing the vacuum booster assembly on floor.

  • Place the vacuum booster assembly at this position. If external force (a) is applied from above, the resin (b) may become damaged.

(1)

Remove the nuts, and then remove the vacuum booster assembly.

2. BRAKE VACUUM HOSE
1.

Remove the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>REMOVAL

2.

Remove the vacuum hose & pipe.

 

Perform marking of the vacuum hose on the vacuum pump side as shown in the figure below.

(a)

Vacuum hose

(b)

Marking

(c)

Vacuum pipe

(d)

Vacuum pump
(1)

Disconnect the vacuum hose from the vacuum pump.

(2)

Disconnect the pipe clamp from the bulkhead.

(3)

Disconnect the vacuum hose & pipe from the intake manifold assembly and the vacuum booster assembly.

(4)

Disconnect the vacuum hose from vacuum pipe.

BRAKE > Brake Booster　
INSTALLATION
1. BRAKE BOOSTER
1.

Check and adjust the operating rod of the vacuum booster assembly.

(1)

Measure the length between the vacuum booster assembly mounting surface and clevis pin hole.

(2)

If it is not within the specification, loosen the lock nut, rotate the vacuum booster assembly operating rod to adjust the rod length.

Specification L:

136.3 mm (5.37in)

2.

Install the vacuum booster assembly.

 

  • Apply grease to the snap pin to prevent the operating rod from wear.

  • Replace the clevis pin with a new part, and apply a thin coat of grease to the clevis pin.

    Preparation items:

    Grease (clevis pin): NIGTIGHT LTS No. 2 grease or equivalent

  • When installing the master cylinder assembly, replace the cylinder seal assembly with a new part, and install it to the vacuum booster assembly.

    (a)

    Primary piston

    (b)

    Cylinder seal ASSY

    (c)

    Install the cylinder seal assembly to this surface.

Tightening torque:

18 N·m (1.8kgf-m, 13.3ft-lb)

3.

Install the column assembly steering. POWER ASSISTED SYSTEM (POWER STEERING)>Steering Column>INSTALLATION

4.

Install the universal joint. POWER ASSISTED SYSTEM (POWER STEERING)>Universal Joint>INSTALLATION

5.

Install the knee airbag module. AIRBAG SYSTEM>Knee Airbag Module>INSTALLATION

6.

Install the cover LWR driver.

7.

Install the master cylinder assembly. BRAKE>Master Cylinder>INSTALLATION

8.

Install the engine control module (ECM). FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)>INSTALLATION

9.

Install the vacuum hose & pipe. BRAKE>Brake Booster>INSTALLATION > BRAKE VACUUM HOSE

10.

Bleed air from the brake system. BRAKE>Air Bleeding>PROCEDURE

11.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

12.

Perform a road test to make sure the brakes do not drag.

2. BRAKE VACUUM HOSE
1.

Install the vacuum hose & pipe.

 

Install the vacuum hose on the vacuum pump side so that the marks are aligned.

(a)

Vacuum hose

(b)

Marking

(c)

Vacuum pipe

(d)

Vacuum pump
(1)

Install the vacuum hose onto the vacuum pipe.

(2)

Connect the vacuum hose & pipe to the intake manifold assembly and the vacuum booster assembly.

(3)

Install the vacuum hose to the vacuum pump.

Clearance:

Clearance between vacuum hose and surrounding parts: 15 mm (0.59in) or more

(4)

Install the pipe clamp to the bulkhead.

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

2.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

BRAKE > Brake Booster　
INSPECTION
1. OPERATION CHECK WHEN NOT USING MEASURING DEVICES
 

When checking operation, be sure to apply the parking brake securely.

When an operation check is performed with no measuring devices, a faulty part cannot be identified correctly. But it is possible to identify the outline of the defect by performing the check according to the following procedures.

AIR TIGHTNESS CHECK
 

  • In case of defective operation, inspect the condition of the check valve and vacuum hose as well.

  • Replace them if faulty, and perform the test again.

  • If no improvement is observed, check precisely with gauges.

1.

Start the engine, and idle it for 1 to 2 minutes, then turn it OFF.

2.

Depress the brake pedal several times applying the normal pedal force.

 

The pedal stroke should be the longest at the 1st depression, and it should become shorter at each successive depression.

3.

If no change occurs in the pedal height when pressed, the vacuum booster assembly is faulty.

(A)

Normal

(B)

Not OK

 

(a)

1st

(b)

2nd

(c)

3rd
CHECK OPERATION
1.

While the engine is OFF, depress the brake pedal several times applying the same pedal force, to check for a change in pedal height.

(A)

When engine is stopped

(B)

When engine is started
2.

With the brake pedal depressed, start the engine.

3.

As the engine starts, the brake pedal should move slowly toward the floor. If the pedal height does not change, the vacuum booster assembly is faulty.

 

If a faulty part is detected after inspection, check precisely with measuring devices.

LOADED AIR TIGHTNESS CHECK

Depress the brake pedal while the engine is running, and turn the engine to OFF while the pedal is depressed.

Keep the pedal depressed for 30 seconds. If the pedal height does not change, the function of vacuum booster assembly is normal. If the pedal height increases, it is faulty.

 

If a faulty part is detected after inspection, check precisely with measuring devices.

2. OPERATION CHECK WHEN USING MEASURING DEVICES
 

When checking operation, be sure to apply the parking brake securely.

CHECK WITH MEASURING DEVICES

Connect a measuring device as shown in the figure. After bleeding air from the pressure gauge, perform each check.

Preparation tool:

Pressure gauge

Vacuum gauge

(a)

Pressure gauge

(d)

Vacuum hose

(b)

Vacuum gauge

(e)

Pedal force gauge

(c)

Adapter hose
AIR TIGHTNESS CHECK
1.

Start the engine and keep it running at idle until vacuum pressure indicates 66.7 kPa (500 mmHg, 19.69inHg) while the brake pedal is not depressed.

Preparation tool:

Pressure gauge

Vacuum gauge

(a)

Pressure gauge

(b)

Vacuum gauge
2.

Stop the engine and check the vacuum pressure.

If the value matches the following standard, the vacuum booster assembly function is normal.

Vacuum pressure: standard

The range of vacuum pressure drop within 15 seconds after stopping the engine is 3.3 kPa (25 mmHg, 0.98inHg) or less

If a faulty part is detected after inspection, it may results from one of the following causes.

  • Check valve malfunction

  • Leak from vacuum hose

  • Leak from shell joint section or stud bolt welded section

  • Damaged diaphragm

  • Leak from valve body seal and bearing section

  • Leak from plate and seal assembly section

  • Leak from poppet valve assembly section

LOADED AIR TIGHTNESS CHECK
1.

Start the engine and depress the brake pedal with a pedal force of 196 N (20 kgf, 44 lbf).

2.

Keep the engine running at idle and the pedal depressed until vacuum pressure of the vacuum gauge indicates 66.7 kPa (500 mmHg, 19.69inHg).

Preparation tool:

Pressure gauge

Vacuum gauge

(a)

Pressure gauge

(c)

Pedal force gauge

(b)

Vacuum gauge

(d)

Depressed
3.

Stop the engine and check the vacuum gauge.

If the value matches the following standard, the vacuum booster assembly function is normal.

Vacuum pressure: standard

The range of vacuum pressure drop within 15 seconds after stopping the engine is 3.3 kPa (25 mmHg, 0.98inHg) or less

If a faulty part is detected after inspection, refer to “AIR TIGHTNESS CHECK”.

BRAKE>Brake Booster>INSPECTION

4.

If the vacuum booster assembly is faulty, replace it with a new part.

LACK OF BOOST ACTION CHECK
1.

Turn the engine OFF, and set the value of the vacuum gauge to “0”.

2.

Check the fluid pressure when the brake pedal is depressed. The pressure must be greater than the specification listed.

Brake pedal force: N (kgf, lbf)

147 (15, 33)

294 (30, 66)

Fluid pressure: kPa (kgf/cm2, psi)

512 (5.2, 74)

1,530 (15.6, 222)
BOOSTING ACTION CHECK
1.

Set the vacuum gauge reading to 93 kPa (697 mmHg, 27.47inHg) with the engine running.

2.

Check the fluid pressure when the brake pedal is depressed. The pressure must be greater than the specification listed.

Brake pedal force: N (kgf, lbf)

147 (15, 33)

294 (30, 66)

Fluid pressure: kPa (kgf/cm2, psi)

7,468 (76.1, 1,083)

14,808 (151, 2,148)
3. BRAKE VACUUM HOSE

Check to see that air only flows in one direction, when air is blown into or sucked from the hose.

BRAKE > Brake Fluid　
INSPECTION
 

  • Do not let brake fluid come into contact with the painted surface of the vehicle body. Wash away with water immediately and wipe off if it is spilled by accident.

  • Do not mix different kinds of brake fluid. Mixing different brands of fluid, or mixing different grades of fluid (even if they have the same brand name), may lead to severe accidents due to reduced brake fluid performance.

  • When refilling brake fluid, do not allow dirt or dust to get into the oil reservoir COMPL.

  • Always use new SUBARU genuine brake fluid when replacing or refilling the fluid. Do not reuse drained brake fluid.

1.

Check the fluid for discoloration.

2.

Check that the amount of brake fluid is between the lines of “MIN” and “MAX” from the front view or from the forward right and left within 90°.

 

Always check the level using the specified direction because there is a partition in the oil reservoir COMPL.

(A)

View from upper face

 

(a)

Brake fluid

(b)

Brake fluid level check range

(c)

MAX. level

(d)

MIN. level
3.

If the brake fluid level is close to “MIN”, check the brake pipe or brake hose for any leak first. Then, check that the brake fluid level is reduced due to brake pad wear.

4.

If the fluid is extremely discolored or the fluid level is less than the specified value after inspection, replenish or replace with the new fluid.

BRAKE > Brake Fluid　
REPLACEMENT
 

  • Do not let brake fluid come into contact with the painted surface of the vehicle body. Wash away with water immediately and wipe off if it is spilled by accident.

  • Do not mix different kinds of brake fluid. Mixing different brands of fluid, or mixing different grades of fluid (even if they have the same brand name), may lead to severe accidents due to reduced brake fluid performance.

  • When refilling brake fluid, do not allow dirt or dust to get into the oil reservoir COMPL.

  • Always use new SUBARU genuine brake fluid when replacing or refilling the fluid. Do not reuse drained brake fluid.

 

  • During work, keep the oil reservoir COMPL filled with brake fluid to prevent entry of air.

  • Operate the brake pedal slowly and depress it fully.

  • For convenience and safety, perform the work with 2 people.

  • The required amount of brake fluid is approximately 500 mL (16.9 US fl oz, 17.6 Imp fl oz) for the entire brake system.

1.

Lift up the vehicle.

2.

Remove both the front and rear wheels.

3.

Drain brake fluid from the oil reservoir COMPL.

4.

Replenish the oil reservoir COMPL with the recommended brake fluid, and perform the same procedure as for bleeding the brake line on each brake caliper. BRAKE>Air Bleeding>PROCEDURE

 

Repeat the full stroke depressing operation of the brake pedal slowly, until new brake fluid comes out from a transparent vinyl tube. (On each brake caliper, 20 times or more of pedal operations is necessary in order for new brake fluid from the master cylinder assembly to come out from the bleeder screw.)

Preparation items:

Brake fluid: RECOMMENDED MATERIALS>GREASE>BRAKE FLUID

BRAKE > Air Bleeding　
PROCEDURE
 

  • Do not let brake fluid come into contact with the painted surface of the vehicle body. Wash away with water immediately and wipe off if it is spilled by accident.

  • Do not mix different kinds of brake fluid. Mixing different brands of fluid, or mixing different grades of fluid (even if they have the same brand name), may lead to severe accidents due to reduced brake fluid performance.

  • When refilling brake fluid, do not allow dirt or dust to get into the oil reservoir COMPL.

  • Always use new SUBARU genuine brake fluid when replacing or refilling the fluid. Do not reuse drained brake fluid.

  • For convenience and safety, perform the work with 2 people.

  • During the operation, keep the oil reservoir COMPL filled with brake fluid at MIN level or higher to prevent entry of air.

  • After air bleeding operation, wipe off fluid around each bleeder screw and the oil reservoir COMPL.

For air bleed procedure of each part, refer to the following.

1. MASTER CYLINDER
 

  • When the master cylinder assembly is replaced or the oil reservoir COMPL is empty, bleed the brake master cylinder.

  • If bleeding of the master cylinder assembly is not necessary, omit the following procedures, and perform bleeding of the brake line. BRAKE>Air Bleeding>PROCEDURE > BRAKE LINE

1.

Install the brake pipe to the master cylinder assembly.

(1)

Screw and tighten the flare nut (b) so that the end of the nut contacts the back side of the brake pipe flare, while pressing the brake pipe (a) toward the master cylinder assembly side.

 

Be careful not to make scratches or other damage to the inside surface of the brake pipe flare.

Preparation tool:

Flare nut wrench

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

2.

Fill the oil reservoir COMPL of the master cylinder assembly with brake fluid.

 

  • Replenish brake fluid to the MAX level.

  • During the operation, keep the oil reservoir COMPL filled with brake fluid at MIN level or higher to prevent entry of air.

3.

Attach a transparent vinyl tube to the bleeder screw of the right front caliper body that is the closest from the hydraulic unit assembly VDC, and the other end of the vinyl tube to a collection container.

4.

Loosen the bleeder screw, depress the brake pedal slowly and hold it.

5.

Tighten the bleeder screw, and release the brake pedal quickly.

6.

Repeat steps 4) and 5) until there are no more air bubbles in the brake fluid in the vinyl tube.

 

Air bubbles are removed after repeating the procedures six to seven times.

7.

Attach a transparent vinyl tube to the bleeder screw of the left front caliper body, and the other end of the vinyl tube to a brake fluid collection container.

8.

Repeat steps 4) and 5) until there are no more air bubbles in the brake fluid in the vinyl tube.

 

  • Air bubbles are removed after repeating the procedures seven to eight times.

  • With the procedures so far, bleed is completed for the air that entered in the master cylinder, front brake piping hose passages and front caliper.

    Next, perform the following procedures to bleed air that entered in the rear brake piping hose passages and rear caliper from the hydraulic control unit.

9.

Attach a transparent vinyl tube to the bleeder screw of the left rear caliper body, and the other end of the vinyl tube to a brake fluid collection container.

10.

Loosen the bleeder screw, and repeat the full stroke depressing operation of the brake pedal slowly, until the brake fluid in the transparent vinyl tube has no more air bubbles, then tighten the bleeder screw.

 

By repeating the procedures 15 times or more, air that entered in the rear brake pipe passages from the hydraulic unit assembly VDC reaches the bleeder screw of the left rear caliper body assembly and is discharged.

11.

Attach a transparent vinyl tube to the bleeder screw of the right rear caliper body, and the other end of the vinyl tube to a brake fluid collection container.

12.

Perform step 10).

 

  • By repeating the procedures 10 times or more, air that entered in the rear brake pipe passages from the hydraulic unit assembly VDC reaches the bleeder screw of the right rear caliper body and is discharged.

  • With the procedures so far, bleed is completed for the air that entered in the rear brake piping hose passages and rear caliper from the hydraulic control unit.

    Lastly, perform the following procedures to bleed air that may remain in areas where the brake fluid flow stands.

13.

Attach a transparent vinyl tube to the bleeder screw of the right front caliper body, and the other end of the vinyl tube to a brake fluid collection container.

14.

After repeating firmly depressing of the brake pedal quickly five or six times, depress and hold the pedal.

15.

Loosen the bleeder screw to drain brake fluid. When the brake pedal reaches the full stroke position, tighten the bleeder screw quickly, and release the brake pedal.

16.

Repeat steps 14) and 15) until there are no more air bubbles in the transparent vinyl tube.

 

Repeat the procedures approximately four to five times.

17.

Repeat steps 14) to 16) above for each brake caliper.

 

Bleed air in the order starting from the front RH → front LH → rear LH → rear RH.

18.

Tighten the bleeder screw to the specified torque.

Tightening torque:

Front: 8 N·m (0.8kgf-m, 5.9ft-lb)

Rear: 17 N·m (1.7kgf-m, 12.5ft-lb)

19.

Install the bleeder cap to each bleeder screw.

2. BRAKE LINE
1.

When the master cylinder assembly is replaced or the oil reservoir COMPL is empty, bleed the master cylinder assembly before bleeding the brake line. BRAKE>Air Bleeding>PROCEDURE > MASTER CYLINDER

2.

Fill the oil reservoir COMPL of the master cylinder assembly with brake fluid.

 

While bleeding air, keep the oil reservoir COMPL filled with brake fluid to prevent entry of air.

3.

Attach one end of a transparent vinyl tube to the bleeder screw, and the other end to a brake fluid collection container.

4.

Loosen the bleeder screw, and then repeat the full stroke depressing operation of the brake pedal, until brake fluid in the transparent vinyl tube has no more air bubbles.

 

Air bubbles are removed after repeating the depressing operation 15 times or more for the front caliper, and 20 times or more for the rear caliper.

5.

Perform the steps 2) to 4) above on each brake caliper.

 

Perform in the order starting from the front RH → front LH → rear LH → rear RH.

6.

Tighten the loosened bleeder screw, repeat firmly depressing of the brake pedal 5 to 6 times, and then depress and hold the brake pedal.

7.

Loosen the bleeder screw to drain the brake fluid. When the brake pedal reaches the full stroke position, immediately tighten the bleeder screw and return the brake pedal.

8.

Repeat steps 6) and 7) until there are no more air bubbles in the transparent vinyl tube.

9.

Perform the steps 6) to 8) above on each brake caliper.

 

Perform in the order starting from the front RH → front LH → rear LH → rear RH.

10.

Perform the sequence control mode for the hydraulic control unit in both ABS and VDC systems.

 

  • If there is a possibility that air enters the pressure control section in the hydraulic control unit, perform steps 11) to 16).

  • For normal air bleeding operation, do not operate the sequence control for the hydraulic control unit. (Operating the sequence control may let air in the normal air bleeding passages move to the pressure control section.)

 

  • Normal air bleeding operation does not help bleed air that enters the pressure control section in the hydraulic control unit.

  • If there is a possibility that air enters the pressure control section in the hydraulic control unit (if VDC or ABS operates with air contained in the normal air bleeding passage), perform the sequence control mode for both of the ABS and VDC systems.

11.

Perform the ABS sequence control mode. VEHICLE DYNAMICS CONTROL (VDC)>ABS Sequence Control

 

Be sure to perform the ABS sequence control mode first.

12.

Perform the air bleeding operation of steps 3) and 4) for the bleeder screw on each caliper.

 

  • Perform in the order starting from the front RH → front LH → rear LH → rear RH.

  • As a reference, the number of the full stroke depressing operation is six times.

13.

Perform the VDC sequence control mode. VEHICLE DYNAMICS CONTROL (VDC)>VDC Sequence Control

14.

Perform the air bleeding operation of steps 3) and 4) for the bleeder screw on each caliper.

15.

Repeat from steps 11) to 14) for three cycles.

16.

In case air still remains at step 15), repeat steps 11) to 14) again until all air is removed.

17.

Fill the oil reservoir COMPL with brake fluid up to the “MAX” level.

18.

Tighten the bleeder screw to the specified torque.

Tightening torque:

Front: 8 N·m (0.8kgf-m, 5.9ft-lb)

Rear: 17 N·m (1.7kgf-m, 12.5ft-lb)

19.

Install the bleeder cap to each bleeder screw.

20.

Check that there are no brake fluid leaks at the flare nut portion or in the entire brake system.

21.

After inspection, wipe off fluid around each bleeder screw and the oil reservoir COMPL.

22.

Perform a road test and ensure that the brakes operate normally.

3. HYDRAULIC CONTROL UNIT
1.

Bleed air from the brake line, and perform No. 1) — 22) in section 2. BRAKE>Air Bleeding>PROCEDURE > BRAKE LINE

 

  • If there is a possibility that air enters the pressure control section in the hydraulic control unit, perform No. 11) — 16) in section 2.

  • For normal air bleeding operation, do not operate the sequence control for the hydraulic control unit. (Operating the sequence control may let air in the normal air bleeding passages move to the pressure control section.)

  • Be sure to perform the ABS sequence control mode first before the VDC sequence control mode.

 

If there is a possibility that air enters the pressure control section in the hydraulic control unit, perform the sequence control mode for both of the ABS and VDC systems. (Refer to steps 10) to 16) for brake lining.)

4. CALIPER
1.

Bleed air from the brake line, and perform No. 1) — 22) in section 2. BRAKE>Air Bleeding>PROCEDURE > BRAKE LINE

 

  • For the caliper with electronic parking actuator, never drain the brake fluid in the caliper.

  • When removing the caliper with electronic parking actuator from the vehicle, make sure to apply the brake fluid seal before disconnection.

  • For the caliper as replacement part with electronic parking actuator, do not remove the brake fluid seal except when the caliper is installed on the vehicle.

BRAKE > Brake Hose　
REMOVAL
1. FRONT BRAKE HOSE
1.

Remove the brake hose front.

(1)

Disconnect the brake hose front (a) and the pipe assembly front ABS (b).

Preparation tool:

Flare nut wrench

(2)

Remove the clamp, brake hose bracket bolt and union bolt, and remove the brake hose front.

2. REAR BRAKE HOSE
1.

Remove the brake hose rear.

(1)

Disconnect the brake hose rear (a) and the pipe center brake rear (b).

Preparation tool:

Flare nut wrench

(2)

Remove the clamp, brake hose bracket bolt and union bolt, and remove the brake hose rear.

BRAKE > Brake Hose　
INSTALLATION
1. FRONT BRAKE HOSE
1.

Secure the brake hose front to the brake hose mount part of strut COMPL front.

Tightening torque:

33 N·m (3.4kgf-m, 24.3ft-lb)

2.

Connect the brake hose front to the caliper body using a new gasket.

Tightening torque:

26 N·m (2.7kgf-m, 19.2ft-lb)

3.

Position the brake disc front in straight position and route the brake hose front through the hole in the bracket on the wheel apron side.

 

Do not twist the brake hose front.

4.

Connect the pipe assembly front ABS and brake hose front, and temporarily tighten the flare nut.

5.

Secure the brake hose front to wheel apron bracket with clamp.

6.

Turn and tighten the flare nut (b) by hand while pushing the pipe assembly front ABS (a) away from yourself.

 

Be careful not to make scratches or other damage to the inside surface of the brake pipe flare.

Tightening torque:

15 N·m (1.5kgf-m, 11.1ft-lb)

7.

Bleed air from the brake system. BRAKE>Air Bleeding>PROCEDURE

2. REAR BRAKE HOSE
1.

Route the brake hose rear through the hole of bracket, and lightly tighten the flare nut to connect pipe center brake rear.

2.

Insert the clamp to secure brake hose rear.

Tightening torque:

33 N·m (3.4kgf-m, 24.3ft-lb)

3.

Install the brake hose rear to caliper body using a new gasket.

Tightening torque:

26 N·m (2.7kgf-m, 19.2ft-lb)

4.

Turn and tighten the flare nut (b) by hand while pushing the pipe center brake rear (a) away from yourself.

 

Be careful not to make scratches or other damage to the inside surface of the brake pipe flare.

Tightening torque:

15 N·m (1.5kgf-m, 11.1ft-lb)

5.

Bleed air from the brake system. BRAKE>Air Bleeding>PROCEDURE

BRAKE > Brake Hose　
INSPECTION

Check the brake hose for crack, interference with other parts, damage, and fluid leakage on connecting sections. If any faulty is found, repair or replace the relevant part.

BRAKE > Brake Pipe　
REMOVAL
 

  • Before handling the airbag system components, always refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

  • When removing the brake pipe, do not bend.

1. FRONT BRAKE PIPE
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Lift up the vehicle, and then remove the front wheels.

3.

Remove the support crossmember rear RH. FRONT SUSPENSION>Crossmember Support>REMOVAL

4.

Remove the vacuum booster assembly. BRAKE>Brake Booster>REMOVAL > BRAKE BOOSTER

5.

Remove the brake pipe.

(1)

Separate each brake pipe using a flare nut wrench.

Preparation tool:

Flare nut wrench

(2)

Remove the brake pipe from the clamp and clip.

2. CENTER BRAKE PIPE
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Lift up the vehicle, and then remove the rear wheels.

3.

Remove the support crossmember rear RH. FRONT SUSPENSION>Crossmember Support>REMOVAL

4.

Remove the protector tank. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Tank Protector>REMOVAL

5.

Remove the under cover rear RH. EXTERIOR/INTERIOR TRIM>Floor Under Protector>REMOVAL

6.

Remove the rear exhaust pipe. EXHAUST(H4DO)>Rear Exhaust Pipe>REMOVAL

7.

Remove the propeller shaft. PROPELLER SHAFT / DRIVE SHAFT / AXLE>Propeller Shaft>REMOVAL

8.

Remove the rear differential. DIFFERENTIALS>Rear Differential (VA-type)>REMOVAL

9.

Remove the fuel tank. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Tank>REMOVAL

10.

Remove the support sub frame front.

11.

Remove the pipe assembly center.

(1)

Disconnect the pipe center brake rear using a flare nut wrench.

Preparation tool:

Flare nut wrench

(2)

Remove the pipe assembly center. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>REMOVAL

BRAKE > Brake Pipe　
INSTALLATION
 

  • Before handling the airbag system components, always refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

  • When installing the brake pipe, do not bend.

  • After installing the brake pipe and brake hose, perform air bleed.

  • After installing the brake hoses, make sure that they do not contact the tires or suspension assembly, etc.

1. FRONT BRAKE PIPE
1.

Install the brake pipe.

(1)

Install the brake pipe to the pipe clamp and clip.

(2)

Install each brake pipe using a flare nut wrench.

Preparation tool:

Flare nut wrench

Tightening torque:

Refer to “COMPONENT” of “General Description” for the tightening torque. BRAKE>General Description>COMPONENT > FRONT BRAKE PIPES AND HOSES

2.

Install the vacuum booster assembly. BRAKE>Brake Booster>INSTALLATION > BRAKE BOOSTER

3.

Install the support crossmember rear RH. FRONT SUSPENSION>Crossmember Support>INSTALLATION

4.

Install the front wheels.

Tightening torque:

120 N·m (12.2kgf-m, 88.5ft-lb)

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2. CENTER BRAKE PIPE
1.

Install the pipe assembly center.

(1)

Install the pipe assembly center. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Delivery and Evaporation Lines>INSTALLATION

(2)

Install the pipe center brake rear using a flare nut wrench.

Preparation tool:

Flare nut wrench

Tightening torque:

15 N·m (1.5kgf-m, 11.1ft-lb)

2.

Install the support sub frame front.

Tightening torque:

For tightening torque, refer to “COMPONENT” of “General Description” in “REAR SUSPENSION” section. REAR SUSPENSION>General Description>COMPONENT > REAR SUSPENSION

3.

Install the fuel tank. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Tank>INSTALLATION

4.

Install the rear differential. DIFFERENTIALS>Rear Differential (VA-type)>REMOVAL

5.

Install the propeller shaft. PROPELLER SHAFT / DRIVE SHAFT / AXLE>Propeller Shaft>INSTALLATION

6.

Install the rear exhaust pipe. EXHAUST(H4DO)>Rear Exhaust Pipe>INSTALLATION

7.

Install the under cover rear RH. EXTERIOR/INTERIOR TRIM>Floor Under Protector>INSTALLATION

8.

Install the protector tank. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel Tank Protector>INSTALLATION

9.

Install the support crossmember rear RH. FRONT SUSPENSION>Crossmember Support>INSTALLATION

10.

Install the rear wheels.

Tightening torque:

120 N·m (12.2kgf-m, 88.5ft-lb)

11.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

BRAKE > Brake Pipe　
INSPECTION

Check the brake pipe for crack and damage, and also check the connection for fluid leakage. If any faulty is found, repair or replace the relevant part.

 

Use a mirror when inspecting back sides and other locations which are hard to see.

BRAKE > Brake Pedal　
REMOVAL
 

Before handling the airbag system components, always refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

1.

Disconnect the ground terminal from the battery sensor, and wait for at least 60 seconds before starting work. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the cover LWR driver. EXTERIOR/INTERIOR TRIM>Instrument Panel Lower Cover>REMOVAL

3.

Remove the knee airbag module. AIRBAG SYSTEM>Knee Airbag Module>REMOVAL

4.

Remove the universal joint. POWER ASSISTED SYSTEM (POWER STEERING)>Universal Joint>REMOVAL

 

To prevent damage to the universal joint and error of handling force, make sure to remove the universal joint.

5.

Remove the column assembly steering. POWER ASSISTED SYSTEM (POWER STEERING)>Steering Column>REMOVAL

6.

Remove the duct sub assembly foot driver. AIR CONDITIONER>Air Vent Duct>REMOVAL > FOOT DUCT

7.

Remove the pedal assembly brake.

(1)

Disconnect the stop light switch assembly connector.

(2)

Remove the snap pin (a) and clevis pin (b), and remove the operating rod from the pedal COMPL brake.

 

  • Be careful not to apply excessive force to the operating rod when handling the operating rod. The angle may change by ±3°, and it may result in damage to power piston cylinder.

  • Do not change the push rod length.

(3)

Remove the bolt and nut, and then detach the pedal assembly brake.

BRAKE > Brake Pedal　
INSTALLATION
 

Before handling the airbag system components, always refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

1.

Install the pedal assembly brake.

 

  • Apply grease to the snap pin to prevent the operating rod from wear.

  • Replace the clevis pin with a new part, and apply a thin coat of grease to the clevis pin.

    Preparation items:

    Grease (clevis pin): NIGTIGHT LTS No. 2 grease or equivalent

Tightening torque:

18 N·m (1.8kgf-m, 13.3ft-lb)

2.

Install the duct sub assembly foot driver. AIR CONDITIONER>Air Vent Duct>INSTALLATION > CONSOLE DUCT

3.

Install the column assembly steering. POWER ASSISTED SYSTEM (POWER STEERING)>Steering Column>INSTALLATION

4.

Install the universal joint. POWER ASSISTED SYSTEM (POWER STEERING)>Universal Joint>INSTALLATION

5.

Install the knee airbag module. AIRBAG SYSTEM>Knee Airbag Module>INSTALLATION

6.

Install the cover LWR driver.

7.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

8.

Check that the brake light operate properly.

9.

Check the brake pedal after installation. BRAKE>Brake Pedal>INSPECTION

BRAKE > Brake Pedal　
INSPECTION
1.

Move the pad (AT) pedal in a horizontal direction with a force of approx. 10 N (1 kgf, 2 lbf), and check that the brake pedal deflection is in the range of specifications.

 

If excessive deflection is noted, replace the bushing with a new part.

Deflection of brake pedal:

Limit: 5 mm (0.197in) or less

2.

Check the pad (AT) pedal position.

Brake pedal height L:

139 — 149 mm (5.47 — 5.87in)

Brake pedal free play A:

0.5 — 2.7 mm (0.02 — 0.11in) [When pulling the brake pedal upward with a force of less than 10 N (1 kgf, 2 lbf)]

(a)

Stop light switch ASSY

(b)

Operating rod

(c)

Toe board

(d)

Mat
3.

If it is not within the specification, loosen the lock nuts of operating rod, and rotate the rod to adjust the pedal height L within the specification.

4.

Tighten the lock nut.

 

Check the brake pedal height. When adjusting, also adjust the stop light switch assembly.

Tightening torque:

22 N·m (2.2kgf-m, 16.2ft-lb)

BRAKE > Stop Light Switch　
REMOVAL
 

Before handling the airbag system components, always refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

1.

Disconnect the ground terminal from the battery sensor, and wait for at least 60 seconds before starting work. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the cover LWR driver. EXTERIOR/INTERIOR TRIM>Instrument Panel Lower Cover>REMOVAL

3.

Remove the knee airbag module. AIRBAG SYSTEM>Knee Airbag Module>REMOVAL

4.

Remove the stop light switch assembly.

(1)

Disconnect the stop light switch assembly connector.

(2)

Remove the nut, and remove the stop light switch assembly.

BRAKE > Stop Light Switch　
INSTALLATION
 

Before handling the airbag system components, always refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

1.

Install the stop light switch assembly onto the bracket pedal COMPL with screws and position it with the nut.

2.

Adjust the stop light switch assembly position, and then tighten the nut. BRAKE>Stop Light Switch>ADJUSTMENT

Tightening torque:

8 N·m (0.8kgf-m, 5.9ft-lb)

3.

Install the knee airbag module. AIRBAG SYSTEM>Knee Airbag Module>INSTALLATION

4.

Install the cover LWR driver.

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

BRAKE > Stop Light Switch　
INSPECTION
1. INSPECT THE SPECIFIED POSITION
1.

Measure the clearance between the end of the stop light switch assembly and the stopper.

 

Be careful not to rotate the stop light switch assembly.

Stop light switch assembly clearance A:

1.5 mm (0.06in)

(a)

Stop light switch ASSY

(b)

Stopper

(c)

Brake pedal
2.

Adjust the position of the stop light switch assembly if the inspection result is not within the standard value. BRAKE>Stop Light Switch>ADJUSTMENT

3.

If the stop light switch assembly does not operate properly or it is not secured at the specified position after adjustment, replace the stop light switch assembly.

2. CHECK OUTPUT.
1.

Check the voltage between connector terminals.

Preparation tool:

Circuit tester

Terminals No.

Inspection conditions

Standard

2 — 3

Apply battery voltage between terminals 1 (+) — 3 (−).

When the end of stop light switch is pressed in to make the length (a) 3.6 mm (0.06in) (actually a little shorter than 3.6 mm (0.06 in)), output voltage will be OFF.

0.5 V or less

Apply battery voltage between terminals 1 (+) — 3 (−).

When the end of stop light switch is pulled back to make the length (a) 3.6 mm (0.06in) (actually a little longer than 3.6 mm (0.06 in)), output voltage will be ON.

12 V

4 — 3

Apply battery voltage to 5 (+) — 3 (−).

When the end of stop light switch is pressed in to make the length (a) 4.5 mm (0.18in) (actually a little shorter than 4.5 mm (0.18 in)), output voltage will be ON.

12 V

Apply battery voltage to 5 (+) — 3 (−).

When the end of stop light switch is pulled back to make the length (a) 4.5 mm (0.18in) (actually a little longer than 4.5 mm (0.18 in)), output voltage will be ON.

0.5 V or less
2.

Replace the stop light switch assembly if the inspection result is not within the standard value.

BRAKE > Stop Light Switch　
ADJUSTMENT
1. CLEARANCE ADJUSTMENT
1.

Loosen the lock nut, and adjust the stop light switch assembly position until the clearance (A) between the threaded end of the stop light switch assembly and stopper becomes 1.5 mm (0.06in mm). Then, tighten the lock nut so that the stop light switch assembly position is not displaced.

Tightening torque:

8 N·m (0.8kgf-m, 5.9ft-lb)

2.

Tighten the lock nut.

(a)

Stop light switch ASSY

(b)

Lock nut A

(c)

Lock nut B

(d)

Stopper

(e)

Brake pedal
2. ADJUSTMENT WHEN VDC WARNING LIGHT AND EYESIGHT WARNING LIGHT IS ILLUMINATING
1.

Measure the brake pedal stroke which turns on the stop light switch assembly.

(1)

Release the steering wheel lock, tilt the steering column to the lowest end and fully retract the column by the telescopic system.

(2)

Affix the masking tape (a) to protect the steering wheel from damage, pass the measure (b) through the steering wheel and fix it to the vertical center position of the brake pedal.

 

If the measure (b) interferes with the knee airbag module, remove the knee airbag module. AIRBAG SYSTEM>Knee Airbag Module>REMOVAL

(3)

Set the measure (b) so that it becomes straight from the brake pedal, and add a marking (c) on the masking tape (a).

(4)

Operate the brake pedal, and read the position where the stop light illuminates (the amount of the pedal stroke) using the marking added in the previous step.

 

If the pedal stroke is less than 3 mm (0.12in), it may lead to an incorrect light illumination by vibrations, etc.

2.

If the stop light illuminating position is not within the adjustment value, readjust the stop light switch assembly position.

 

Turning the lock nut A by 90° changes the amount of pedal stroke by approx. 1 mm.

Adjustment value (amount of pedal stroke):

3 mm (0.12in) or more, 5 mm (0.2in) or less

(1)

Loosen the lock nut A.

(2)

Turn the lock nut B to adjust the stop light switch assembly position so that the stop light illuminating position is within the adjustment value.

(3)

After adjustment, tighten the lock nut A.

Tightening torque:

8 N·m (0.8kgf-m, 5.9ft-lb)

(a)

Stop light switch ASSY

(b)

Lock nut A

(c)

Lock nut B

(d)

Stopper

(e)

Brake pedal
(4)

After the lock nut is tightened, check again that the stop light illuminating position is within the adjustment value. If it’s not within the adjustment value, perform the adjustment procedure again.

 

If the stop light illuminating position is less than 3 mm (0.12in), it may lead to an incorrect stop light illumination by vibrations etc. even when the brake pedal is not operated while driving.

BRAKE > Brake Vacuum Pump　
NOTE

For the operation procedure of vacuum pump, refer to “MECHANICAL” section.

BRAKE > Brake Vacuum Pump　
INSPECTION
 

Refer to “MECHANICAL” section for vacuum pump inspection. MECHANICAL(H4DO)>Vacuum Pump>INSPECTION

BRAKE > General Diagnostic Table　
INSPECTION

Trouble and possible cause

Corrective action

1. Insufficient braking

(1) Fluid leakage from the hydraulic mechanism

Repair or replace. (Cup, piston seal, boot piston, master cylinder piston kit, brake pipe or brake hose)

(2) Entry of air into the hydraulic mechanism

Bleed air.

(3) Wear, deteriorated surface material, water or fluid on pad

Replace, grind or clean.

(4) Improper operation of master cylinder assembly, brake caliper, vacuum booster assembly or check valve

Repair or replace.

2. Unstable or uneven braking

(1) Fluid on pad surface or brake disc

Correct the cause of fluid leakage, and clean or replace.

(2) Defective brake disc

Repair or replace the brake disc.

(3) Improper pad contact, deteriorated surface, deteriorated or worn pad material

Repair by grinding, or replace.

(4) Deformed brake back plate

Repair or replace.

(5) Overinflation of tires

Adjust the air pressure.

(6) Defective wheel alignment

Adjust alignment.

(7) Loose brake back plate or support installation bolt

Tighten to the specified torque.

(8) Defective hub unit bearing

Replace.

(9) Defective hydraulic system

Replace the cylinder, brake pipe or brake hose.

(10) Unstable performance of the parking brake

Check, adjust or replace the rear brake.

3. Excessive pedal stroke

(1) Entry of air into the hydraulic mechanism

Bleed air.

(2) Excessive play in the master cylinder push rod

Adjust.

(3) Fluid leakage from the hydraulic mechanism

Repair or replace. (Cup, piston seal, boot piston, master cylinder piston kit, brake pipe or brake hose)

(4) Improper pad contact or worn pad

Repair or replace.

4. Brake dragging or improper brake return

(1) Insufficient pedal play

Adjust play.

(2) Improper master cylinder return

Clean or replace the cylinder.

(3) Clogged hydraulic system

Replace.

(4) Improper return of parking brake

Repair or adjust.

(5) Improper brake caliper operation

Repair or replace.

(6) Defective hub unit bearing

Replace.

5. Brake noise (1) (creaking sound)

(1) Hardened or deteriorated brake pad

Replace the brake pad.

(2) Worn brake pad

Replace the brake pad.

(3) Loose brake back plate or support installation bolt

Tighten to the specified torque.

(4) Loose hub unit bearing

Tighten to the specified torque.

(5) Dirt on brake disc

Clean the brake disc. Clean and replace brake assembly.

6. Brake noise (2) (hissing sound)

(1) Worn brake pad

Replace the brake pad.

(2) Improperly installed brake pad

Correct or replace the brake pad.

(3) Loose or bent brake disc

Retighten or replace.

7. Brake noise (3) (click sound)

Excessively worn brake pad or support

Replace the brake pad or the support.