Subaru Impreza 2004 User manual

FUJI HEAVY INDUSTRIES LTD. G1870GE5

2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

CHASSIS SECTION

This service manual has been prepared

to provide SUBARU service personnel

with the necessary information and data

for the correct maintenance and repair

of SUBARU vehicles.

This manual includes the procedures

for maintenance, disassembling, reas-

sembling, inspection and adjustment of

components and diagnostics for guid-

ance of experienced mechanics.

Please peruse and utilize this manual

fully to ensure complete repair work for

satisfying our customers by keeping

their vehicle in optimum condition.

When replacement of parts during

repair work is needed, be sure to use

SUBARU genuine parts.

All information, illustration and specifi-

cations contained in this manual are

based on the latest product information

available at the time of publication

approval.

FRONT SUSPENSION FS

REAR SUSPENSION RS

WHEEL AND TIRE SYSTEM WT

DIFFERENTIALS DI

TRANSFER CASE TC

DRIVE SHAFT SYSTEM DS

ABS ABS

ABS (DIAGNOSTICS) ABS(diag)

BRAKE BR

PARKING BRAKE PB

POWER ASSISTED SYSTEM

(POWER STEERING) PS

BRAKE

Page

1. General Description ....................................................................................2

2. Front Brake Pad ........................................................................................25

3. Front Disc Rotor ........................................................................................29

4. Front Disc Brake Assembly.......................................................................31

5. Rear Brake Pad.........................................................................................37

6. Rear Disc Rotor.........................................................................................40

7. Rear Disc Brake Assembly .......................................................................42

8. Rear Drum Brake Shoe.............................................................................47

9. Rear Drum Brake Drum ............................................................................49

10. Rear Drum Brake Assembly......................................................................50

11. Master Cylinder .........................................................................................53

12. Brake Booster ...........................................................................................55

13. Proportioning Valve...................................................................................59

14. Brake Fluid ................................................................................................60

15. Air Bleeding...............................................................................................62

16. Brake Hose ...............................................................................................65

17. Brake Pipe.................................................................................................67

18. Brake Pedal...............................................................................................68

19. Stop Light Switch ......................................................................................73

20. Hill Holder..................................................................................................75

21. General Diagnostics..................................................................................78

BR-2

BRAKE

General Description

1. General Description

A: SPECIFICATIONS

Model BASE, TS GX, RS, OBK WRX STi

Front

disc

brake

Size 14 inch type 15 inch type 16 inch type 17 inch type

Type Disc (Floating type, ventilated) Disc (Fixed type, ventilated)

Effective disc

diameter 210 mm (8.27 in) 228 mm (8.98 in) 255 mm (10.04 in) 268 mm (10.55 in)

Disc thickness ×

Outer diameter

24 ×260 mm

(0.94 ×10.24 in)

24 ×277 mm

(0.94 ×10.91 in)

24 ×294 mm

(0.94 ×11.57 in)

30 ×326 mm

(1.18 ×12.83 in)

Effective cylinder

diameter 57.2 mm (2.252 in) 42.8 mm (1.685 in) ×2 40.4 mm (1.591 in) ×4

40.0 mm ×2,

46.0 mm ×2

(1.575 in ×2,

1.811 in ×2)

Pad dimensions

(length ×width ×

thickness)

115.0 ×44.3 ×11.0

(4.528 ×1.744 ×0.433

in)

117.8 ×50.5 ×11.0

(4.638 ×1.988 ×0.433

in)

116.0 ×47.7 ×10.0

(4.567 ×1.878 ×0.394

in)

129.8 ×60.5 ×9.2 mm

(5.110 ×2.382 ×0.362

in)

Clearance adjust-

ment Automatic adjustment

Rear

disc

brake

Size —14 inch type 15 inch type 17 inch type

Type —Disc (Floating type) Disc (Fixed type, ventilated)

Effective disc

diameter —230 mm (9.06 in) 261 mm (10.28 in) 268 mm (10.55 in)

Disc thickness ×

Outer diameter —10 ×266 mm

(0.39 ×10.47 in)

18 ×290 mm

(0.71 ×11.42 in)

20 ×316 mm

(0.79 ×12.44 in)

Effective cylinder

diameter —38.1 mm (1.500 in) 36.0 mm (1.417 in)

Pad dimensions

(length ×width ×

thickness)

—

89.4 ×33.7 ×9.0 mm

(3.520 ×1.327 ×0.354

in)

71.8 ×35.0 ×11.5 mm

(2.827 ×1.378 ×0.453

in)

74.8 ×45.0 ×9.0 mm

(2.945 ×1.772 ×0.354

in)

Clearance adjust-

ment —Automatic adjustment

Rear

drum

brake

Type Drum

(Leading-Trailing type) ———

Effective drum

diameter 228.6 mm (9 in) ———

Effective cylinder

diameter 17.5 mm (0.689 in) ———

Lining dimensions

(length ×width ×

thickness)

218.8 ×35.0 ×4.1 mm

(8.61 ×1.378 ×0.161

in)

———

Clearance adjust-

ment Automatic adjustment ———

Master

cylinder

Type Tandem

Effective diameter 23.81 mm (0.9374 in)

[25.4 mm (1 in)] 26.99 mm (1-1/16 in)

Reservoir type Sealed type

Brake fluid reser-

voir capacity 205 cm3(12.51 cu in)

Brake

booster

Type Vacuum suspended

Effective diameter

230 mm (9.06 in)

[180 + 205 mm

(7.09 + 8.07 in)]

205 + 230 mm

(8.07 + 9.06 in)

BR-3

BRAKE

General Description

[ ]: Model with ABS.

NOTE:

Refer to “PB section”for parking brake SPECIFICATIONS. <Ref. to PB-2, SPECIFICATIONS, General De-

scription.>

Propor-

tioning

valve

Split point 1,961 kPa

(20 kg/cm2, 285 psi) —

Reduce ratio 0.4 —

Brake line Dual circuit system

Brake fluid

AUTI

•Avoid mixing brake fluid

of different brands to pre-

vent the fluid performance

from degrading.

•When brake fluid is sup-

plemented, be careful not to

allow any dust into the res-

ervoir.

•Use fresh DOT3 brake

fluid when replacing or

refilling the fluid.

FMVSS No. 116, DOT3

ITEM STANDARD SERVICE LIMIT

Front brake

Pad thickness

14″, 15″11 mm (0.43 in) 1.5 mm (0.059 in)

16″10 mm (0.39 in) 1.5 mm (0.059 in)

17″9.2 mm (0.362 in) 1.2 mm (0.047 in)

Disc thickness

Except

for 17″24 mm (0.94 in) 22 mm (0.87 in)

17″30 mm (1.18 in) 28 mm (1.10 in)

Disc runout —0.075 mm (0.0030 in)

Rear brake (Disc type)

Pad thickness

14″9.0 mm (0.354 in) 1.5 mm (0.059 in)

15″11.5 mm (0.452 in) 1.5 mm (0.059 in)

17″9.0 mm (0.354 in) 1.2 mm (0.047 in)

Disc thickness

14″10 mm (0.39 in) 8.5 mm (0.335 in)

15″18 mm (0.71 in) 16 mm (0.63 in)

17″20 mm (0.79 in) 18 mm (0.71 in)

Disc runout —0.07 mm (0.0028 in)

Rear brake (Drum type) Inside diameter 228.6 mm (9 in) 230.6 mm (9.08 in)

Lining thickness 4.1 mm (0.161 in) 1.5 mm (0.059 in)

Rear brake (Disc type

parking)

Inside diameter 170 mm (6.69 in) 171 mm (6.73 in)

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)

Model BASE, TS GX, RS, OBK WRX STi

BR-4

BRAKE

General Description

Brake pedal

force

Fluid pressure

BASE, TS GX, RS, OBK WRX STi

Without ABS With ABS

Brake

booster

Brake fluid pressure

without engine running

147 N

(15 kgf, 33 lb)

686 kPa

(7 kg/cm2,

100 psi)

588 kPa

(6 kg/cm2,

85 psi)

588 kPa

(6 kg/cm2, 85 psi)

294 N

(30 kgf, 66 lb)

1,961 kPa

(20 kg/cm2,

284 psi)

1,667 kPa

(17 kg/cm2,

242 psi)

1,471 kPa

(15 kg/cm2, 213 psi)

Brake fluid pressure

with engine running

and vacuum at 66.7

kPa (500 mmHg, 19.69

inHg)

147 N

(15 kgf, 33 lb)

5,982 kPa

(61 kg/cm2,

868 psi)

5,982 kPa

(61 kg/cm2,

868 psi)

5,296 kPa

(54 kg/cm2,

768 psi)

4,707 kPa

(48 kg/cm2,

683 psi)

4,021 kPa

(41 kg/cm2,

583 psi)

294 N

(30 kgf, 66 lb)

7,649 kPa

(78 kg/cm2,

1,109 psi)

8,434 kPa

(86 kg/cm2,

1,223 psi)

9,120 kPa

(93 kg/cm2, 1,323 psi)

8,336 kPa

(85 kg/cm2,

1,209 psi)

Brake pedal Free play 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-5

BRAKE

General Description

B: COMPONENT

1. FRONT DISC BRAKE

•14 INCH TYPE

(1) Caliper body (9) Support (17) Bushing

(2) Air bleeder screw (10) Pad clip

(3) Guide pin (Green) (11) Outer shim Tightening torque: N·m (kgf-m, ft-lb)

(4) Pin boot (12) Inner shim T1: 8 (0.8, 5.8)

(5) Piston seal (13) Pad (Outside) T2: 18 (1.8, 13.0)

(6) Piston (14) Pad (Inside) T3: 37 (3.8, 27.5)

(7) Piston boot (15) Disc rotor T4: 80 (8.2, 59)

(8) Lock pin (Yellow) (16) Disc cover

BR-00377

(1) (2)

(3)

(9)

(10)

(11)

(15)

(16)

(12)

(13)

(14)

(5)

(6)

(7)

(4)

(17)

(8)

BR-6

BRAKE

General Description

•15 INCH TYPE

(1) Caliper body (9) Support (17) Bushing

(2) Air bleeder screw (10) Pad clip

(3) Guide pin (Green) (11) Outer shim Tightening torque: N·m (kgf-m, ft-lb)

(4) Pin boot (12) Inner shim T1: 8 (0.8, 5.8)

(5) Piston seal (13) Pad (Outside) T2: 27 (2.8, 19.9)

(6) Piston (14) Pad (Inside) T3: 37 (3.8, 27.5)

(7) Piston boot (15) Disc rotor T4: 80 (8.2, 59)

(8) Lock pin (Yellow) (16) Disc cover

BR-00378

(2)

(3)

(4)

(1)

(5)

(6)

(7)

(9)

(10)

(8)

(17)

(4)

(11)

(12)

(15)

(11)

(16)

(13)

(14)

BR-7

BRAKE

General Description

•16 INCH TYPE

(1) Housing (9) Piston boot (17) Spacer

(2) Air bleeder screw (10) Boot ring

(3) Caliper body (11) Outer shim Tightening torque: N·m (kgf-m, ft-lb)

(4) M clip (12) Inner shim T1: 8 (0.8, 5.8)

(5) Cross spring (13) Pad (Outside) T2: 18 (1.8, 13.0)

(6) Pad pin (14) Pad (Inside) T3: 80 (8.2, 59)

(7) Piston seal (15) Disc rotor

(8) Piston (16) Disc cover

BR-00379

(15)

(11)

(12)

(13)

(14)

(12)

(11)

(7)

(8)

(9)

(10)

(9)

(8)

(7)

(6)

(5)

(4)

(3)

(2)

(1)

(17)

(16)

BR-8

BRAKE

General Description

•17 INCH TYPE

(1) Housing (8) Piston boot (15) Disc rotor

(2) Caliper body (9) Piston (16) Disc cover

(3) Air bleeder screw (10) Piston seal

(4) Guide plate (11) Pad shim (Outside) Tightening torque: N·m (kgf-m, ft-lb)

(5) Cross spring (12) Pad shim (Inside) T1: 18 (1.8, 13.0)

(6) Clip (13) Pad (Outside) T2: 20 (2.0, 14.5)

(7) Pad pin (14) Pad (Inside) T3: 155 (15.8, 114.3)

BR-00380

(15)

(5)

(4)

(6)

(14)

(3)

(2)

(1)

(16)

(13)

(11)

(11) (10)

(10)

(9)

(8)

(8) (7)

(12)

BR-9

BRAKE

General Description

2. REAR DISC BRAKE

•14 INCH TYPE

(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 (33) Bushing

(8) Boot ring (21) Parking brake shoe (Secondary)

(9) Lock pin (Yellow) (22) Parking brake shoe (Primary) Tightening torque: N·m (kgf-m, ft-lb)

(10) Support (23) Strut T1: 8 (0.8, 5.8)

(11) Pad clip (24) Strut shoe spring T2: 37 (3.8, 27.5)

(12) Inner pad (25) Shoe guide plate T3: 52 (5.3, 38.3)

(13) Outer pad (26) Secondary shoe return spring

BR-00326

(1)

(2)

(3)

(4)

(33)

(10)

(14)

(11)

(18)

(19) (20) (21)

(22)

(23)

(24)

(25)

(26)

(27)

(28)

(29)

(30)

(31)

(32)

(12)

(13)

(14)

(17)

(16)

(15)

(5)

(6)

(7)

(8)

(9)

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