Subaru 2001 IMPREZA User manual

FUJI HEAVY INDUSTRIES LTD. G1830GE5
2001 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
BRAKE BR
PARKING BRAKE PB
POWER ASSISTED SYSTEM
(POWER STEERING) PS

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

BR-2
BRAKE GENERAL DESCRIPTION
1. General Description
A: SPECIFICATIONS
[ ] : ABS equipped vehicle.
NOTE:
Refer to “PB section”for parking brake SPECIFICATIONS. <Ref. to PB-2, SPECIFICATIONS, General De-
scription.>
Front
disc
brake
Size 14 inch type 15 inch type 16 inch type
Type Disc (Floating type, ventilated)
Effective disc diameter 210 mm (8.27 in) 228 mm (8.98 in) 255 mm (10.04 in)
Disc thickness ×Outer diame-
ter 24 ×260 mm (0.94 ×10.24 in) 24 ×277 mm (0.94 ×10.91 in) 24 ×294 mm (0.94 ×11.57 in)
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
(length ×width ×thickness) 112.4 ×44.3 ×11.0 mm (4.425 ×1.744 ×0.433 in) 112.3 ×50.0 ×11.0 mm (4.421 ×1.969 ×0.433 in) 116.0 ×48.3 ×10.0 mm (4.567 ×1.902 ×0.344 in)
Clearance adjustment Automatic adjustment
Rear
disc
brake
Type —Disc (Floating type)
Effective disc diameter —230 mm (9.06 in) 261 mm (10.28 in)
Disc thickness ×Outer diame-
ter —10 ×266 mm (0.39 ×10.47 in) 18 ×290 mm (0.71 ×11.42 in)
Effective cylinder diameter —38.1 mm (1.500 in)
Pad dimensions
(length ×width ×thickness) —82.4 ×33.7 ×9.0 mm (3.244 ×1.327 ×0.354 in) 71.8 ×35.0 ×11.5 mm (2.827 ×1.378 ×0.453 in)
Clearance adjustment —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 adjustment 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 reservoir 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)
Propor-
tioning
valve
Split point 1,961 kPa
(20 kg/cm2, 285 psi)
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.
•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.
FMVSS No. 116, DOT3 or DOT4

BR-3
BRAKE
GENERAL DESCRIPTION
ITEM STANDARD SERVICE LIMIT
Front brake
Pad thickness
(including back metal) 14”,15”17 mm (0.571 in) 7.5 mm (0.295 in)
16”14.5 mm (0.67 in) 6.0 mm (0.236 in)
Disc thickness 24 mm (0.94 in) 22 mm (0.87 in)
Disc runout —0.075 mm (0.0030 in)
Rear brake (Disc type)
Pad thickness
(including back metal) 14”14 mm (0.55 in) 6.5 mm (0.256 in)
15”16 mm (0.63 in) 6.0 mm (0.236 in)
Disc thickness 14”10 mm (0.39 in) 8.5 mm (0.335 in)
15”18 mm (0.71 in) 10.0 mm (0.63 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)
Brake pedal
force
Fluid pressure
14 inch type 15 inch type 16 inch type
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)
686 kPa
(7 kg/cm2,
100 psi)
588 kPa
(6 kg/cm2, 85 psi)
294 N
(30 kgf, 66 lb)
1,961 kPa
(20 kg/cm2,
284 psi)
1,961 kPa
(20 kg/cm2,
284 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)
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)
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-4
BRAKE GENERAL DESCRIPTION
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-5
BRAKE
GENERAL DESCRIPTION
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-6
BRAKE GENERAL DESCRIPTION
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-7
BRAKE
GENERAL DESCRIPTION
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-8
BRAKE GENERAL DESCRIPTION
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-9
BRAKE
GENERAL DESCRIPTION
6. REAR DRUM BRAKE
T1
T2
T3
(1) (2)
(8)
(8)
(9)
(3)
(13)
(12)
(11)
(16)
(10)
(24)
(21)
(23)
(22)
(20)
(19)
(15)
(14)
(17)
(18)
(3)
(4)
(5)
(5)
(6)
(7)
(4)
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-10
BRAKE GENERAL DESCRIPTION
7. MASTER CYLINDER
•LHD models
S4M0186A
T1
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(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-11
BRAKE
GENERAL DESCRIPTION
•RHD models
B4M1155C
T1
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(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-12
BRAKE GENERAL DESCRIPTION
8. BRAKE PIPES AND HOSE
•LHD model
BR0073
AT MODEL
MT MODEL WITHOUT HILL HOLDER
WITHOUT ABS
MT MODEL WITH HILL HOLDER

BR-13
BRAKE
GENERAL DESCRIPTION
(1) Front brake pipe assembly (12) Two-way connector (19) Rear brake hose LH (FWD drum
brake model)
(2) Proportioning valve (13) Rear brake pipe assembly
(3) Front brake hose RH (14) Rear brake hose RH (Disc brake
model) (20) Rear brake pipe LH (FWD drum brake model)
(4) Front brake hose LH
(5) Clamp (15) Rear brake pipe RH (FWD drum
brake model) (21) Rear brake hose LH (AWD drum brake model)
(6) Gasket
(7) ABS control module and hydraulic
control unit (16) Rear brake hose RH (FWD drum brake model) (22) Adapter pipe
(8) Bracket (17) Rear brake hose (AWD drum
brake model) Tightening torque: N·m (kgf-m, ft-lb) (9) Master Cylinder T1: 15 (1.5, 10.8)
(10) Hill holder (18) Rear brake hose LH (Disc brake
model) T2: 18 (1.8, 13.0)
(11) Center brake pipe assembly T3: 32 (3.3, 23.6)

BR-14
BRAKE GENERAL DESCRIPTION
•RHD model
BR0074
AT MODEL
MT MODEL WITHOUT HILL HOLDER
WITHOUT ABS
MT MODEL WITH HILL HOLDER

BR-15
BRAKE
GENERAL DESCRIPTION
(1) Front brake pipe assembly (12) Two-way connector (19) Rear brake hose LH (FWD drum
brake model)
(2) Proportioning valve (13) Rear brake pipe assembly
(3) Front brake hose RH (14) Rear brake hose RH (Disc brake
model) (20) Rear brake pipe LH (FWD drum brake model)
(4) Front brake hose LH
(5) Clamp (15) Rear brake pipe RH (FWD drum
brake model) (21) Rear brake hose LH (AWD drum brake model)
(6) Gasket
(7) ABS control module and hydraulic
control unit (16) Rear brake hose RH (FWD drum brake model) (22) Adapter pipe
(8) Bracket (17) Rear brake hose (AWD drum
brake model) Tightening torque: N·m (kgf-m, ft-lb) (9) Master Cylinder T1: 15 (1.5, 10.8)
(10) Hill holder (18) Rear brake hose LH (Disc brake
model) T2: 18 (1.8, 13.0)
(11) Center brake pipe assembly T3: 32 (3.3, 23.6)

BR-16
BRAKE GENERAL DESCRIPTION
9. BRAKE BOOSTER
•Models with ABS
•Models without 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
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-17
BRAKE
GENERAL DESCRIPTION
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-18
BRAKE GENERAL DESCRIPTION
11.BRAKE PEDAL
•1.6 L Model
BR0060
RHD
LHD
(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-19
BRAKE
GENERAL DESCRIPTION
•2.0 L Model
BR0061
RHD
LHD
(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)