14FO_US.

book 1 ページ ２０１３年７月２４日 水曜日 午後７時３５分

BRAKE

BR
Page
1. General Description ...................................................................................2
2. Front Brake Pad .......................................................................................15
3. Front Disc Rotor .......................................................................................19
4. Front Disc Brake Assembly ......................................................................22
5. Rear Brake Pad ........................................................................................30
6. Rear Disc Rotor ........................................................................................33
7. Rear Disc Brake Assembly ......................................................................37
8. Master Cylinder ........................................................................................44
9. Brake Booster ..........................................................................................47
10. Brake Fluid ...............................................................................................60
11. Air Bleeding ..............................................................................................61
12. Brake Hose ..............................................................................................65
13. Brake Pipe ................................................................................................68
14. Brake Pedal ..............................................................................................69
15. Stop Light Switch .....................................................................................74
16. Brake Vacuum Pump ...............................................................................79
17. Brake Vacuum Sensor .............................................................................81
18. General Diagnostic Table .........................................................................82
14FO_US.book 2 ページ ２０１３年７月２４日 水曜日 午後７時３５分

General Description
BRAKE

1. General Description
A: SPECIFICATION
Size 16-inch type 17-inch type
Type Disc (floating type, ventilated)
Effective disc diameter mm (in) 244 (9.61) 261 (10.28)
Front disc Disc thickness × Diameter mm (in) 24 × 294 (0.94 × 11.57) 30 × 316 (1.18 × 12.44)
brake Effective cylinder diameter mm (in) 42.8 (1.685) × 2
Pad dimensions 117.8 × 50.5 × 11.0 130.0 × 53.5 × 11.0
mm (in)
(Length × Width × Thickness) (4.638 × 1.988 × 0.433) (5.118 × 2.106 × 0.433)
Clearance adjustment Automatic adjustment
Size 15-inch type 16-inch type
Type Disc (floating type, solid) Disc (floating type, ventilated)
Effective disc diameter mm (in) 238 (9.37) 243 (9.57)
Rear disc Disc thickness × Diameter mm (in) 10 × 274 (0.39 × 10.79) 18 × 278 (0.71 × 10.94)
brake Effective cylinder diameter mm (in) 38.1 (1.500) 40.4 (1.591)
Pad dimensions 92.0 × 33.0 × 9.0 95.5 × 34.8 × 11.0
mm (in)
(Length × Width × Thickness) (3.622 × 1.299 × 0.354) (3.759 × 1.370 × 0.433)
Clearance adjustment Automatic adjustment
Type Tandem
Master Effective diameter mm (in) 23.8 (15/16)
cylinder Reservoir type Sealed type
Brake fluid reservoir capacity cm3 (cu in) 240 (12.51)
Brake Type Vacuum suspended
booster Effective diameter mm (in) 208 + 229 (8.19 + 9.02)
Brake line Dual circuit system
FMVSS No. 116, DOT3 or DOT4
CAUTION:
• Avoid mixing brake fluid of different brands to prevent fluid per-
formance from degrading.
Brake fluid
• When filling with brake fluid, be careful not to allow any dust to
enter the reservoir.
• Use new SUBARU genuine brake fluid when replacing or refilling
the fluid.

BR-2
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General Description
BRAKE

NOTE:
Refer to “PARKING BRAKE” for parking brake specifications. <Ref. to PB-2, SPECIFICATION, General De-
scription.>
Item Standard Limit
Pad thickness mm (in) All models 11 (0.43) 1.5 (0.059)
16-inch 24 (0.94) 22 (0.87)
Front brake Disc thickness mm (in)
17-inch 30 (1.18) 28 (1.10)
Disc runout mm (in) All models — 0.05 (0.0020)
Pad thickness mm (in) Solid disc 9.0 (0.354) 1.5 (0.059)
Pad thickness mm (in) Ventilated disc 11 (0.43) 1.5 (0.059)
Rear brake (disc type) Disc thickness mm (in) Solid disc 10 (0.39) 8.5 (0.335)
Disc thickness mm (in) Ventilated disc 18 (0.71) 16 (0.63)
Disc runout mm (in) — 0.05 (0.0020)
Inside diameter mm (in) 170 (6.69) 171 (6.73)
Parking brake
Lining thickness mm (in) 3.5 (0.14) 1.5 (0.059)

Brake pedal force N (kgf, lbf) Fluid pressure kPa (kgf/cm2, psi)
Brake fluid pressure with engine 147 (15, 33) 553 (5, 77)
stopped 294 (30, 66) 1,551 (16, 225)
Brake
booster Brake fluid pressure with engine 147 (15, 33) 6,177 (63, 896)
running and vacuum pressure at
66.7 kPa (500 mmHg, 19.69 inHg) 294 (30, 66) 11,273 (115, 1,635)

Free 0.5 — 2 (0.020 — 0.079)

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

BR-3
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General Description
BRAKE

B: COMPONENT
1. FRONT DISC BRAKE
(A)

(B)

(B) (11)
T3
(3)
(4)

T2 T1 (A)
(11)
(2)

(3)
(A)
(A ) (1) (4)

(10)
(5)
(6)
(B) (12)
(7)

(A )
(13)

(12)
(1 4 )
(B)
(1 6 ) (9)
(1 5 ) (B ) (8)

(14) (4)

(13)
(13) (9)

(8)
(14)
(4)
(16)

(15)

(14)
(13)

(18) (17)

BR-01084

(A) 16-inch type (B) 17-inch type

(1) Caliper body (9) Lock pin - front brake (silver) (17) Disc rotor
(2) Bleeder - screw (10) Support - front disc brake (18) Back plate - front brake
(3) Guide pin - front brake (black) (11) Pad clip - upper
(4) Pin boot (12) Pad clip - lower Tightening torque: N·m (kgf-m, ft-lb)
(5) Piston seal (13) Shim - disc brake front outer T1: 8 (0.82, 5.9)
(6) Piston - disc brake (14) Shim - disc brake front inner T2: 27 (2.75, 19.9)
(7) Piston boot (15) Pad - disc brake front outer T3: 80 (8.16, 59.0)
(8) Lock pin - sleeve (16) Pad - disc brake front inner

BR-4
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General Description
BRAKE

2. REAR DISC BRAKE

T1
T3 (4)

T2 (5)
(6)

(7)
(3)
(8)
(9)
(13)
(10)
(14) (15)

(2)
(1) (11)

(12)
(6)

(19)

(21)
(22) (16)
(20) (17) (18)
(23)
(24)

(26) (35)
(25)

(27)
(33)
(30)
(34) (28) (37)

(32)

(31)
(29)
(36) (37)

BR-01086

(1) Housing ASSY - rear axle (15) Pad - disc brake rear inner (29) Adjuster ASSY - rear brake
(2) Support - rear disc brake (16) Pad - disc brake rear outer (30) Spring - primary shoe return
(3) Pad clip - rear brake (17) Shim - disc brake rear inner (31) Spring - adjuster
(4) Bleeder - screw (18) Shim - disc brake rear outer (32) Cup - shoe hold-down
(5) Guide pin - rear brake (black) (19) Pin - secondary shoe hold-down (33) Parking brake shoe (primary)
(6) Pin boot (20) Pin - primary shoe hold-down (34) Back plate - rear brake
(7) Caliper body (21) Retainer - rear brake (35) Disc rotor (solid type)
(8) Piston seal (22) Spring washer - rear brake (36) Disc rotor (ventilated type)
(9) Piston - disc brake (23) Parking lever - rear (37) Adjusting hole cover
(10) Piston boot (24) Pin - parking lever
(11) Lock pin - rear brake (silver) (25) Parking brake shoe (secondary) Tightening torque: N·m (kgf-m, ft-lb)
(12) Lock pin - sleeve (26) Spring - secondary shoe return T1: 8 (0.82, 5.9)
(13) Shim - disc brake rear outer (27) Spring - strut T2: 27 (2.75, 19.9)
(14) Shim - disc brake rear inner (28) Strut - brake T3: 66 (6.73, 48.7)

BR-5
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General Description
BRAKE

3. MASTER CYLINDER

(1)

(2)

(3)
(10)

(9)
(8)

(7)

(6)

T
(4)

(5)

BR-01046

(1) Cap - reservoir tank (6) Cylinder body ASSY Tightening torque: N·m (kgf-m, ft-lb)
(2) Filter - master cylinder (7) Seal T: 13 (1.33, 9.6)
(3) Caution label (model with caution (8) Reservoir tank
label)
(4) Seal sub ASSY (9) Pin
(5) Bracket - master cylinder (10) Level - indicator

BR-6
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General Description
BRAKE

4. FRONT BRAKE PIPES AND HOSES

• Models without EyeSight
(1)

T2

T1

T1 (3)

T3
T3

T1

(2) (5)

T1 (6)

T4

T2

(7)
(4)

BR-00916

(1) Connector - two-way (5) Front brake hose RH/LH Tightening torque: N·m (kgf-m, ft-lb)
(2) VDC control module and hydraulic (6) Clamp T1: 15 (1.53, 11.1)
control unit (VDCCM&H/U)
(3) Front brake pipe ASSY (7) Gasket T2: 18 (1.84, 13.3)
(4) Master cylinder ASSY T3: 19 ( 1.94, 14.0)
T4: 33 (3.36, 24.3)

BR-7
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General Description
BRAKE

• Models with EyeSight

T1

(9)

(11) (10)

T2

T4 (12) (8)
(11) T4
T4 (1)

(4)
(2) (7)
T4

T3

T2
T5

T2
(7)
(5)
(6)

T5
(3)

(6)
BR-01096

(1) Front brake pipe ASSY (7) Clamp Tightening torque: N·m (kgf-m, ft-lb)
(2) VDC control module and hydraulic (8) Brake hose ASSY T1: 7.5 (0.76, 5.5)
control unit (VDCCM&H/U)
(3) Master cylinder ASSY (9) Bracket T2: 15 (1.53, 11.1)
(4) Front brake hose RH (10) Bracket T3: 18 (1.84, 13.3)
(5) Front brake hose LH (11) Clip T4: 19 (1.94, 14.0)
(6) Gasket (12) Clamp T5: 33 (3.36, 24.3)

BR-8
14FO_US.book 9 ページ ２０１３年７月２４日 水曜日 午後７時３５分

General Description
BRAKE

5. CENTER AND REAR BRAKE PIPES AND HOSES

(1)

T1

T1

(5)

T1
T3

(2)
(6)
T2 (6)
(7)
T2

(3) (4)

T1

T2
T1 (8)
(6)
(6)

T3

(5)

BR-00914

(1) Center brake pipe ASSY (5) Clamp Tightening torque: N·m (kgf-m, ft-lb)
(2) Bracket (6) Gasket T1: 15 (1.53, 11.1)
(3) Connector (7) Rear brake hose RH T2: 18 (1.84, 13.3)
(4) Rear brake pipe ASSY (8) Rear brake hose LH T3: 33 (3.36, 24.3)

BR-9
14FO_US.book 10 ページ ２０１３年７月２４日 水曜日 午後７時３５分

General Description
BRAKE

6. BRAKE BOOSTER

(1)

BR-00870

(1) Vacuum booster ASSY Tightening torque: N·m (kgf-m, ft-lb)

T: 18 (1.84, 13.3)

BR-10
14FO_US.book 11 ページ ２０１３年７月２４日 水曜日 午後７時３５分

General Description
BRAKE

7. BRAKE PEDAL
• CVT model

T1
(1)
T1

(2)

T2

(6)
(7)

(3)

(7) (8)

(9)
(4)

(5)

BR-00987

(1) Brake pedal ASSY (6) Spacer - pedal Tightening torque: N·m (kgf-m, ft-lb)
(2) Switch - stop light (7) Bushing - pedal T1: 18 (1.84, 13.3)
(3) Snap pin (8) Stopper - pedal T2: 30 (3.06, 22.1)
(4) Pad - brake pedal (sport type) (9) Clevis pin
(5) Pad - brake pedal (normal type)

BR-11
14FO_US.book 12 ページ ２０１３年７月２４日 水曜日 午後７時３５分

General Description
BRAKE

• MT model

T2
(19)

(16) T1
(10) (13) T2
(11) (14)
(15)
(12) (18)
(13)

(10)
(11) (17) T2

T1 (2)
(1)

(22) T2
(7)

(3)
(21)
(10)
(20) (4)
(1) (2)

(1) T2
(7)

(8)
(9) (2)

(4)

(5)
(6)

CL-00875

(1) Stopper (10) Bushing C (19) Pedal bracket

(2) Bushing (11) Clutch clevis pin (20) Clutch master cylinder bracket
(3) Spring pin (12) Assist rod A (21) Lever
(4) Snap pin (13) Clip (22) Clutch start switch
(5) Pad - brake pedal (14) Assist spring
(6) Brake pedal (15) Assist bushing Tightening torque: N·m (kgf-m, ft-lb)
(7) Clevis pin (16) Assist rod B T1: 8 (0.82, 5.9)
(8) Clutch pedal pad (17) Clutch switch T2: 18 (1.84, 13.3)
(9) Clutch pedal (18) Switch - stop light

BR-12
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General Description
BRAKE

8. BRAKE VACUUM PUMP

(3)

T1

(1)
(4)

T2

(2)

T2

BR-01078

(1) Vacuum pump ASSY (3) Vacuum hose COMPL Tightening torque: N·m (kgf-m, ft-lb)
(2) Bracket COMPL - vacuum pump (4) Bracket - generator T1: 7.5 (0.76, 5.5)
T2: 19 (1.9, 14.0)

BR-13
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General Description
BRAKE

C: CAUTION
• Wear appropriate work clothing, including a helmet, protective goggles and protective shoes when per-
forming any work.
• Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, in-
stallation, disassembly and replacement.
• Use SUBARU genuine grease etc. or equivalent. Do not mix grease etc. of different grades or manufac-
turers.
• Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or cloth
between the part and the vise.
• Be sure to tighten fasteners including bolts and nuts to the specified torque.
• Place shop jacks or rigid racks at the specified points.

BR-14
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Front Brake Pad

BRAKE

2. Front Brake Pad

A: REMOVAL
1) Lift up the vehicle, and then remove the front wheels.
2) Remove the front brake pad.
(1) Remove the caliper bolt on the lower side.
(2) Raise the caliper body assembly and support it.

BR-00808

NOTE:
Do not disconnect the brake hose from the caliper body assembly.
(3) Remove the brake pad from support - front disc brake.

BR-00923

BR-15
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Front Brake Pad

BRAKE

B: INSTALLATION
NOTE:
Before installation, remove mud and foreign matter from the caliper body assembly and support - front disc
brake.
1) Check the brake pad. <Ref. to BR-18, INSPECTION, Front Brake Pad.>
2) Apply a thin coat of grease to the pad clip. (A)
Grease:
Molykote M7439 (Part No. 003602001) or an item contained in the pad kit
3) Apply a thin coat of grease to the pad and both sides of the shim - disc brake front inner (a). (B)
Grease:
Molykote AS880N (Part No. K0777YA010) or an item contained in the pad kit

(A) (B)

(a)
BR-00929

BR-16
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Front Brake Pad

BRAKE

4) Install the brake pad to the support - front disc brake.

CAUTION:
• Be sure to install so that the pad return spring faces the input side of the direction of brake rotor
rotation, as shown in the figure.
• Correctly install the pad return spring to the supporting surface of the pad clip as shown in the fig-
ure.
• If the pad return spring is deformed or damaged, replace the brake pad with a new part.

(A) (B)

(a)
(c)

(a)
(b)
(b)

BR-00811

(A) 16-inch (B) 17-inch

(a) Pad return spring (b) Supporting surface of pad clip (c) Direction of brake rotor rotation

NOTE:
Install the brake pad indicator in proper direction.

(A) (B)

(a) (c) (a) (c)

(e) (e)

(f) (f) (f) (f)

(e) (e)

(b) (d) (b) (d)

(e) (e)

(f) (f) (f) (f)

BR-00810

(A) 16-inch (B) 17-inch

(a) LH — IN (c) RH — IN (e) Pad indicator

(b) LH — OUT (d) RH — OUT (f) Pad return spring

BR-17
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Front Brake Pad

BRAKE

5) Install the caliper body assembly to the support - front disc brake.
Tightening torque:
Caliper bolt: 27 N·m (2.75 kgf-m, 19.9 ft-lb)
6) Install the front wheels.
Tightening torque:
120 N·m (12.24 kgf-m, 88.5 ft-lb)
C: INSPECTION
1) Check the pad thickness (A).
NOTE:
• 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 if there is oil or grease on it.

(A) (B)

BR-00919

Standard (A) Wear limit (B)

Pad thickness 11 mm (0.43 in) 1.5 mm (0.059 in)

NOTE:
• Always replace the pads of both wheels and both sides as a set.
• Replace pad clips if they are twisted or worn.
• Wear indicators are installed on the inner and outer disc brake pads.
If the pad is worn to the limit, the end of wear indicator contacts disc rotor, and a squeaking sound is heard
as the wheel rotates. If the sound is heard, replace the pad.
• Replace the pad if there is oil or grease on it.
2) If the wear limit is exceeded in the inspection, replace the brake pad.

BR-18
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Front Disc Rotor

BRAKE

3. Front Disc Rotor

A: REMOVAL
1) Lift up the vehicle, and then remove the front wheels.
2) Remove the caliper body assembly from the housing assembly - front axle.
(1) Remove the bolt from the brake hose bracket.
(2) Remove the mounting bolt, and remove the caliper body assembly.

BR-00909

(3) Prepare wiring harnesses etc. to be discarded, and suspend the caliper body assembly from the strut
assembly.

BR-01058

BR-19
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Front Disc Rotor

BRAKE

3) Remove the front disc rotor.

NOTE:
When the disc rotor is difficult to be removed from the hub unit COMPL - front axle, screw in 8 mm (0.31 in)
bolt to the threaded part of the disc rotor (A), and remove the disc rotor.

(A)

DS-00560

B: INSTALLATION
NOTE:
Before installation, remove mud and foreign matter from the caliper body assembly.
1) Before installation, check the front disc rotor. <Ref. to BR-20, INSPECTION, Front Disc Rotor.>
2) Install each part in the reverse order of removal.
Tightening torque:
Brake hose bracket: 33 N·m (3.36 kgf-m, 24.3 ft-lb)
Mounting bolt: 80 N·m (8.16 kgf-m, 59.0 ft-lb)
Front wheel: 120 N·m (12.24 kgf-m, 88.5 ft-lb)
C: INSPECTION
1. DISC ROTOR RUNOUT CHECK
1) Check the hub unit COMPL - front axle for free play and runout before the inspection of disc rotor runout
limit. <Ref. to DS-33, INSPECTION, Front Hub Unit Bearing.>
2) Tighten the wheel nuts to secure disc rotor.

BR-20
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Front Disc Rotor

BRAKE

3) Set a dial gauge 10 mm (0.39 in) inward from the disc rotor outer circumference, and check the disc rotor
runout while rotating the disc rotor.
Disc rotor runout limit: 0.05 mm (0.0020 in)

BR-00813

4) If the runout limit is exceeded in the inspection, replace the disc rotor.
2. DISC ROTOR THICKNESS CHECK
1) Set a micrometer 10 mm (0.39 in) inward from the disc rotor outer perimeter, and then measure the disc
rotor thickness (A).

(A)

BR-01059

Size Standard Wear limit Disc rotor outer diameter

16-inch 24 mm (0.94 in) 22 mm (0.87 in) 260 mm (10.24 in)
Disc rotor thickness (A)
17-inch 30 mm (1.18 in) 28 mm (1.10 in) 316 mm (12.44 in)

2) If the wear limit is exceeded in the inspection, replace the disc rotor.

BR-21
14FO_US.book 22 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Front Disc Brake Assembly

BRAKE

4. Front Disc Brake Assembly

A: REMOVAL
CAUTION:
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.
1) Lift up the vehicle, and then remove the front wheels.
2) Remove the caliper body assembly.
(1) Remove the union bolt and caliper bolt, and remove the caliper body assembly from the support - front
disc brake.

BR-01075

3) Remove the support - front disc brake.

NOTE:
Remove the support - front disc brake only when replacing the disc rotor or the support - front disc brake. It
is not necessary to remove it when servicing the caliper body assembly.
(1) Remove the brake pad from support - front disc brake.

BR-00923

BR-22
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Front Disc Brake Assembly

BRAKE

(2) Remove the mounting bolts, and then remove the support - front disc brake from the housing assem-
bly - front axle.

BR-00908

B: INSTALLATION
NOTE:
Before installation, remove mud and foreign matter from the caliper body assembly and support - front disc
brake.
1) Check each part. <Ref. to BR-29, INSPECTION, Front Disc Brake Assembly.>
2) Apply a thin coat of grease to the support - front disc brake.
Grease:
Molykote M7439 (Part No. 003602001)

BR-00928

3) Install the support - front disc brake to the housing assembly - front axle.
Tightening torque:
Mounting bolt: 80 N·m (8.16 kgf-m, 59.0 ft-lb)
4) Apply a thin coat of grease to the pad clip. (A)
Grease:
Molykote M7439 (Part No. 003602001) or an item contained in the pad kit

BR-23
14FO_US.book 24 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Front Disc Brake Assembly

BRAKE

5) Apply a thin coat of grease to the pad and both sides of the shim - disc brake front inner (a). (B)
Grease:
Molykote AS880N (Part No. K0777YA010) or an item contained in the pad kit

(A) (B)

(a)
BR-00929

6) Install the brake pad to the support - front disc brake.

CAUTION:
• Be sure to install so that the pad return spring faces the input side of the direction of brake rotor
rotation, as shown in the figure.
• Correctly install the pad return spring to the supporting surface of the pad clip as shown in the fig-
ure.
• If the pad return spring is deformed or damaged, replace the brake pad with a new part.

(A) (B)

(a)
(c)

(a)
(b)
(b)

BR-00811

(A) 16-inch (B) 17-inch

(a) Pad return spring (b) Supporting surface of pad clip (c) Direction of brake rotor rotation

BR-24
14FO_US.book 25 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Front Disc Brake Assembly

BRAKE

NOTE:
Install the brake pad indicator in proper direction.

(A) (B)

(a) (c) (a) (c)

(e) (e)

(f) (f) (f) (f)

(e) (e)

(b) (d) (b) (d)

(e) (e)

(f) (f) (f) (f)

BR-00810

(A) 16-inch (B) 17-inch

(a) LH — IN (c) RH — IN (e) Pad indicator

(b) LH — OUT (d) RH — OUT (f) Pad return spring

7) Install the caliper body assembly to the support - front disc brake.
Tightening torque:
Caliper bolt: 27 N·m (2.75 kgf-m, 19.9 ft-lb)
8) Connect the brake hose using a new brake hose gasket.
Tightening torque:
Union bolt: 18 N·m (1.84 kgf-m, 13.3 ft-lb)
9) Bleed air from the brake system. <Ref. to BR-63, BRAKE LINE, PROCEDURE, Air Bleeding.>
10) Install the front wheels.
Tightening torque:
120 N·m (12.24 kgf-m, 88.5 ft-lb)

BR-25
14FO_US.book 26 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Front Disc Brake Assembly

BRAKE

C: DISASSEMBLY
CAUTION:
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 installation hole to push out the
piston - disc brake.

30 mm (1.18 in) BR-00932

3) Remove the piston boot (b) and piston seal (c) from the caliper body cylinder (a).
CAUTION:
Do not damage the cylinder and piston seal groove.

(a)
(c)
(a)

(b)

BR-00933

BR-26
14FO_US.book 27 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Front Disc Brake Assembly

BRAKE

4) Remove the guide pin - front brake, lock pin - front brake, lock pin - sleeve, and pin boot from the support -
front disc brake.

(A) (B)

(a) (a)
(d) (d)

(b) (b)
(c) (c)
(d) (d)

BR-00817

(A) 16-inch (B) 17-inch

(a) Guide pin (black) (c) Bushing (d) Pin boot

(b) Lock pin (silver)

D: ASSEMBLY
1) Before assembly, check each part. <Ref. to BR-29, INSPECTION, Front Disc Brake Assembly.>
2) Clean the inside of the caliper body cylinder using brake fluid.
3) Apply a coat of brake fluid to piston seal and install the piston seal to the caliper body cylinder groove.
4) Apply a coat of brake fluid to the inner surface of caliper body cylinder and the entire outer surface of the
piston - disc brake.
5) Apply grease contained in the piston seal kit to the piston boot, and install it to the groove at the end of the
cylinder.
6) Insert the piston - disc brake into the caliper body cylinder.

BR-27
14FO_US.book 28 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Front Disc Brake Assembly

BRAKE

7) Position the piston boot in the grooves on the piston - disc brake and the caliper body cylinder.
CAUTION:
Do not force the piston - disc brake into the caliper body cylinder.

(a)
(b)
(c)
(d)
(b)

(a)

BR-00931

(a) Piston - disc brake (c) Caliper body assembly (d) Piston seal
(b) Piston boot

8) Apply grease contained in the piston seal kit to the lock pin - front brake, the outer surface of guide pin -
front brake, the inner surface of support cylinder, and the grooves of pin boot.
9) Install the pin boot to the lock pin - front brake and guide pin - front brake, and insert them into the support
cylinder.
CAUTION:
Insert the lock pin - front brake and guide pin - front brake into specified position, and make sure that
they slide and seat properly.

: (c)
(a)
(b)

BR-00930

(a) Pin boot (b) Lock pin - front brake or guide pin - (c) Grease applied area
front brake

BR-28
14FO_US.book 29 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Front Disc Brake Assembly

BRAKE

E: INSPECTION
1) Check the caliper body cylinder and 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.

BR-29
14FO_US.book 30 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Rear Brake Pad

BRAKE

5. Rear Brake Pad

A: REMOVAL
1) Lift up the vehicle, and then remove the rear wheels.
2) Remove the rear brake pad.
(1) Remove the bolts and remove the brake hose bracket.
(2) Remove the caliper bolt, and raise and hold the caliper body assembly.

BR-01076

NOTE:
Do not disconnect the brake hose from the caliper body assembly.
(3) Remove the brake pad from support - rear disc brake.

BR-00819

BR-30
14FO_US.book 31 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Rear Brake Pad

BRAKE

B: INSTALLATION
NOTE:
Before installation, remove mud and foreign matter from the caliper body assembly and support - rear disc
brake.
1) Before installation, check the brake pad. <Ref. to BR-32, INSPECTION, Rear Brake Pad.>
2) Apply a thin coat of grease to the pad clip.
Grease:
Molykote M7439 (Part No. 003602001) or an item contained in the pad kit

BR-00949

3) Apply a thin coat of grease to the shim - disc brake rear inner (a) and the shim - disc brake rear outer (b).
Grease:
Grease contained in the pad kit or WAKO grease V160

(A) (B)

(a) (a)

(b) (b)

BR-01087

(A) Pad - disc brake rear outer (B) Pad - disc brake rear inner

4) Install the brake pad to the support - rear disc brake.

BR-31
14FO_US.book 32 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Rear Brake Pad

BRAKE

5) Install the caliper body assembly to the support - rear disc brake.
Tightening torque:
Caliper bolt: 27 N·m (2.75 kgf-m, 19.9 ft-lb)
6) Install the brake hose bracket.
Tightening torque:
Brake hose bracket: 33 N·m (3.36 kgf-m, 24.3 ft-lb)
7) Install the rear wheels.
Tightening torque:
120 N·m (12.24 kgf-m, 88.5 ft-lb)
C: INSPECTION
1) Check the pad thickness.
NOTE:
• 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 if there is oil or grease on it.
• A wear indicator is installed on the pad - disc brake rear inner. If the pad is worn to the limit, the end of wear
indicator contacts disc rotor, and a squeaking sound is heard as the wheel rotates. If the sound is heard, re-
place the pad.

(A) (B)

BR-00918

Disc rotor type Standard (A) Wear limit (B)

Solid disc 9 mm (0.35 in)
Pad thickness 1.5 mm (0.059 in)
Ventilated disc 11 mm (0.43 in)

2) If the wear limit is exceeded in the inspection, replace the brake pad.

BR-32
14FO_US.book 33 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Rear Disc Rotor

BRAKE

6. Rear Disc Rotor

A: REMOVAL
1) Lift up the vehicle, and then remove the rear wheels.
2) Release the lever assembly - hand brake.
3) Remove the caliper body assembly from the housing assembly - rear axle.
(1) Remove the bolt from the brake hose bracket.
(2) Remove the mounting bolt, and remove the caliper body assembly.

BR-01060

(3) Prepare wiring harnesses etc. to be discarded, and suspend the caliper body assembly from the strut
assembly.

BR-01069

BR-33
14FO_US.book 34 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Rear Disc Rotor

BRAKE

4) Remove the rear disc rotor.

NOTE:
If it is difficult to remove the disc rotor, perform the following two methods in order.
1. Remove the adjusting hole cover (A), insert the flat tip screwdriver, and rotate the adjuster assembly - rear
brake until the brake shoe moves far enough to remove the disc rotor.

(d)
(e)

(b) (a)

(c)

(A)

PB-00247

(a) Adjuster ASSY - rear brake (c) Disc rotor (e) Shorten the adjuster ASSY - rear
brake
(b) Flat tip screwdriver (d) Extend the adjuster ASSY - rear
brake

2. If the disc rotor is not removed after performing above step, screw in an 8 mm (0.31 in) bolt to the threaded
part (A) of the disc rotor, and remove the disc rotor.

(A)

BR-01062

BR-34
14FO_US.book 35 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Rear Disc Rotor

BRAKE

B: INSTALLATION
NOTE:
Before installation, remove mud and foreign matter from the caliper body assembly.
1) Before installation, check the rear disc rotor. <Ref. to BR-35, INSPECTION, Rear Disc Rotor.>
2) Install each part in the reverse order of removal.
3) Adjust the parking brake. <Ref. to PB-23, ADJUSTMENT, Parking Brake Assembly (Rear Disc Brake).>
Tightening torque:
Brake hose bracket: 33 N·m (3.36 kgf-m, 24.3 ft-lb)
Mounting bolt: 66 N·m (6.73 kgf-m, 48.7 ft-lb)
Rear wheel: 120 N·m (12.24 kgf-m, 88.5 ft-lb)
C: INSPECTION
1. DISC ROTOR RUNOUT CHECK
1) Check the hub unit COMPL - rear axle for free play and runout before the inspection of disc rotor runout
limit. <Ref. to DS-54, INSPECTION, Rear Hub Unit Bearing.>
2) Secure the disc rotor by tightening the five wheel nuts.
3) Set a dial gauge 10 mm (0.39 in) inward from the disc rotor outer circumference, and check the disc rotor
runout while rotating the disc rotor.
Disc rotor runout limit:
0.05 mm (0.0020 in)

BR-01063

4) If the runout limit is exceeded in the inspection, replace the disc rotor.

BR-35
14FO_US.book 36 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Rear Disc Rotor

BRAKE

2. DISC ROTOR THICKNESS CHECK

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

(A)

BR-01064

Disc rotor type Standard Wear limit Disc rotor outer diameter
Solid disc 10 mm (0.39 in) 8.5 mm (0.33 in) 274 mm (10.79 in)
Disc rotor thickness (A)
Ventilated disc 18 mm (0.71 in) 16 mm (0.63 in) 278 mm (10.94 in)

2) If the wear limit is exceeded in the inspection, replace the disc rotor.

BR-36
14FO_US.book 37 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Rear Disc Brake Assembly

BRAKE

7. Rear Disc Brake Assembly

A: REMOVAL
CAUTION:
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.
1) Lift up the vehicle, and then remove the rear wheels.
2) Remove the caliper body assembly from the support - rear disc brake.
(1) Remove the brake hose bracket and union bolt.

BR-01065

(2) Remove the caliper bolt, and remove the caliper body assembly.

BR-00907

3) Remove the support - rear disc brake.

NOTE:
Remove the support - rear disc brake only when replacing the disc rotor or the support - rear disc brake. It
is not necessary to remove it when servicing the caliper body assembly.
(1) Remove the brake pad from support - rear disc brake.
(2) Remove the mounting bolts, and then remove the support - rear disc brake from the housing assembly -
rear axle.

BR-37
14FO_US.book 38 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Rear Disc Brake Assembly

BRAKE

B: INSTALLATION
NOTE:
Before installation, remove mud and foreign matter from the caliper body assembly and support - rear disc
brake.
1) Before installation, check each part. <Ref. to BR-43, INSPECTION, Rear Disc Brake Assembly.>
2) Apply a thin coat of grease contained in the pad kit to the support - rear disc brake.
Grease:
Molykote M7439 (Part No. 003602001) or an item contained in the pad kit

BR-00928

3) Install the support - rear disc brake to the housing assembly - rear axle.
Tightening torque:
Mounting bolt: 66 N·m (6.73 kgf-m, 48.7 ft-lb)
4) Apply a thin coat of grease to the pad clip.
Grease:
Molykote M7439 (Part No. 003602001) or an item contained in the pad kit

BR-00949

BR-38
14FO_US.book 39 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Rear Disc Brake Assembly

BRAKE

5) Apply a thin coat of grease to the shim - disc brake rear inner (a) and the shim - disc brake rear outer (b).
Grease:
Grease contained in the pad kit or WAKO grease V160

(A) (B)

(a) (a)

(b) (b)

BR-01087

(A) Pad - disc brake rear outer (B) Pad - disc brake rear inner

6) Install the brake pad to the support - rear disc brake.

7) Install the caliper body assembly to the support - rear disc brake.
Tightening torque:
Caliper bolt: 27 N·m (2.75 kgf-m, 19.9 ft-lb)
8) Install the brake hose bracket.
Tightening torque:
Brake hose bracket: 33 N·m (3.36 kgf-m, 14.3 ft-lb)
9) Connect the brake hose using a new brake hose gasket.
Tightening torque:
Union bolt: 18 N·m (1.84 kgf-m, 13.3 ft-lb)
10) Bleed air from the brake system. <Ref. to BR-63, BRAKE LINE, PROCEDURE, Air Bleeding.>
11) Install the rear wheels.
Tightening torque:
120 N·m (12.24 kgf-m, 88.5 ft-lb)

BR-39
14FO_US.book 40 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Rear Disc Brake Assembly

BRAKE

C: DISASSEMBLY
CAUTION:
Be careful not to allow foreign matter to enter the brake hose connector.
1) Remove mud and foreign matter from the caliper body assembly.
2) Remove the piston boot from caliper body cylinder.

BR-00934

3) Remove the piston - disc brake.

(1) Place a wooden block in the caliper body assembly 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 installation hole to push out the
piston - disc brake.

30 mm (1.18 in) BR-00935

BR-40
14FO_US.book 41 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Rear Disc Brake Assembly

BRAKE

4) Remove the piston seal from caliper body cylinder.

CAUTION:
Do not damage the cylinder and piston seal groove.

BR-00936

5) Remove the guide pin - rear brake, lock pin - rear brake, lock pin - sleeve, and pin boot from the support -
rear disc brake.

(a)

(d)
(b)

(c)

(d)

BR-00826

(a) Guide pin - rear brake (black) (c) Lock pin - sleeve (d) Pin boot
(b) Lock pin - rear brake (silver)

D: ASSEMBLY
1) Before installation, check each part. <Ref. to BR-43, INSPECTION, Rear Disc Brake Assembly.>
2) Clean the inside of the caliper body cylinder using brake fluid.
3) Apply a coat of brake fluid to piston seal and install the piston seal to the caliper body cylinder groove.
4) Apply a coat of brake fluid to the inner surface of caliper body cylinder and the entire outer surface of the
piston - disc brake.
5) Apply grease contained in the piston seal kit to the piston boot, and install it to the groove at the end of the
cylinder.

BR-41
14FO_US.book 42 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Rear Disc Brake Assembly

BRAKE

6) Insert the piston - disc brake into the caliper body cylinder.
CAUTION:
Do not force the piston - disc brake into the caliper body cylinder.
7) Position the piston boot in the grooves on the piston - disc brake and the caliper body cylinder.

(a)
(b)

(c)
(d)
(b)

(a)

BR-00947

(a) Piston - disc brake (c) Caliper body (d) Piston seal
(b) Piston boot

8) Apply grease contained in the piston seal kit to the lock pin - rear brake, the outer surface of guide pin -
rear brake, the inner surface of support cylinder, and the grooves of pin boot.
9) Install the pin boot to the lock pin - rear brake and guide pin - rear brake, and insert them into the support
cylinder.
CAUTION:
Insert the lock pin - rear brake and guide pin - rear brake into specified position, and make sure that
they slide and seat properly.

: (c)
(a)
(b)

BR-00930

(a) Pin boot (b) Lock pin - rear brake or guide pin - (c) Grease applied area
rear brake

BR-42
14FO_US.book 43 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Rear Disc Brake Assembly

BRAKE

E: INSPECTION
1) Check the caliper body cylinder and 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.

BR-43
14FO_US.book 44 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Master Cylinder
BRAKE

8. Master Cylinder
A: REMOVAL
CAUTION:
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.
1) Disconnect the ground cable from battery.
2) Drain brake fluid from the reservoir tank completely.
3) Remove the master cylinder assembly.
CAUTION:
• Do not remove the vacuum sensor (e). If removed, replace the vacuum booster assembly with a
new part. (Turbo model)
• Do not allows the vacuum sensor (e) to turn. Otherwise the gasket on the mounting location of the
vacuum sensor may be damaged. (Turbo model)
(1) Disconnect the fluid level gauge connector (a).
(2) Disconnect the clutch hose (b). (MT model)
(3) Turn the flare nuts while pressing the brake pipes toward the master cylinder assembly side and dis-
connect the brake pipes (c).
(4) Remove the nut (d), and slowly remove the master cylinder assembly from the vacuum booster as-
sembly.

(f) (a)

(b)

(c)

(d)

(e)
BR-01091

BR-44
14FO_US.book 45 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Master Cylinder
BRAKE

B: INSTALLATION
1) Replace the seal sub assembly for the master cylinder assembly with a new part.
CAUTION:
Be careful not to install the seal sub assembly in the wrong location.

(c)
(b)
(a)

BR-00948

(a) Primary piston (b) Seal sub ASSY (c) Install the seal sub ASSY to this
surface.

2) Install each part in the reverse order of removal.

Tightening torque:
Master cylinder assembly: 13 N·m (1.33 kgf-m, 9.6 ft-lb)
3) Turn and tighten the flare nut (b) by hand while pressing the brake pipe (a) toward the master cylinder as-
sembly side.
CAUTION:
Be careful not to make scratches or other damage to the inside surface of the brake pipe flare.
Tightening torque:
Brake pipe flare nut: 19 N·m (1.94 kgf-m, 14.0 ft-lb)

(a)

(b)

BR-01088

BR-45
14FO_US.book 46 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Master Cylinder
BRAKE

4) Bleed air from the brake system and clutch system (MT model). <Ref. to BR-61, PROCEDURE, Air Bleed-
ing.>
C: REPLACEMENT
CAUTION:
Since the master cylinder assembly cannot be disassembled, disassembly and cleaning are prohib-
ited. When replacing, replace the master cylinder assembly.

BR-46
14FO_US.book 47 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Booster
BRAKE

9. Brake Booster
A: REMOVAL
CAUTION:
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.
1) Disconnect the ground cable from battery and wait for at least 60 seconds before starting work.
2) Drain brake fluid from the reservoir tank completely.
3) Disconnect the air conditioner pipe. <Ref. to AC-70, REMOVAL, Hose and Pipe.>
4) Remove the power steering control module. <Ref. to PS-41, REMOVAL, Power Steering Control Mod-
ule.>
5) Remove the master cylinder assembly.
CAUTION:
• Do not remove the vacuum sensor (e). If removed, replace the vacuum booster assembly with a
new part. (Turbo model)
• Do not rotate the vacuum sensor when disconnecting the connector of vacuum sensor (e). Other-
wise the gasket on the mounting location of the vacuum sensor may be damaged. (Turbo model)
(1) Disconnect the fluid level gauge connector (a).
(2) Disconnect the clutch hose (b). (MT model)
(3) Turn the flare nuts while pressing the brake pipes toward the master cylinder assembly side and dis-
connect the brake pipes (c).
(4) Disconnect the vacuum sensor connector (e). (Turbo model)
(5) Remove the nut (d), and slowly remove the master cylinder assembly from the vacuum booster as-
sembly.

(f) (a)

(b)

(c)

(d)

(e)
BR-01091

BR-47
14FO_US.book 48 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Booster
BRAKE

6) Remove the clamp and remove the vacuum hose.

BR-00956

7) Remove the brake pipe assembly (a).

(1) Disconnect the starter connector (b) and harness clip (c).
(2) Remove the brake pipe assembly (a) from the pipe clip (d).
(a)
(c)

(d) (c)

(b) (d)

(d)

BR-00975

BR-48
14FO_US.book 49 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Booster
BRAKE

8) Remove the cover assembly - instrument panel LWR driver.

CAUTION:
When removing the cover assembly - instrument panel LWR driver, be sure to pull it toward you. If at-
tempting to remove by turning it upward, the claws may be damaged.

EI-03690

(1) Remove the clips, and remove the cover - instrument panel side LH.

EI-04030

NOTE:
Using a plastic remover, open the cover - instrument panel side LH.
(2) Remove the screws and release the clips and claws.

BR-49
14FO_US.book 50 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Booster
BRAKE

(3) Disconnect the harness connectors, and remove the cover assembly - instrument panel LWR driver
INN and OUT.

EI-04067

9) Remove the nuts to remove the knee airbag module and disconnect the harness connector. <Ref. to AB-
21, DRIVER’S AIRBAG MODULE, KNEE AIRBAG MODULE, CURTAIN AIRBAG MODULE AND PRETEN-
SIONER, PROCEDURE, Airbag Connector.>

AB-03090

BR-50
14FO_US.book 51 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Booster
BRAKE

10) Remove the snap pin (a) and clevis pin (b), and remove the operating rod from the brake pedal.
CAUTION:
• 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.

(b)

(a)

BR-00847

11) Remove the vacuum booster assembly.

CAUTION:
• 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.
• If external force (a) is applied from above when the vacuum booster assembly is placed in this po-
sition, the resin portion as indicated by “P” may become damaged.

(a)

BR-00955

BR-51
14FO_US.book 52 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Booster
BRAKE

(1) Remove the nuts, and then remove the vacuum booster assembly.

BR-00850

B: INSTALLATION
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 (5.37 in)

BR-00957

BR-52
14FO_US.book 53 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Booster
BRAKE

2) Install each part in the reverse order of removal.

CAUTION:
• Apply grease to the snap pin to prevent the operating rod from wear.
• Replace the clevis pin with new parts, and apply thin coat of NIGTIGHT LYW No. 2 grease to the cle-
vis pin.
• When installing the master cylinder assembly, replace the seal sub assembly with a new part, and
install it to the vacuum booster assembly.

(c)
(b)
(a)

BR-00948

(a) Primary piston (b) Seal sub ASSY (c) Install the seal sub ASSY to this
surface.

Tightening torque:
Vacuum booster assembly: 18 N·m (1.84 kgf-m, 13.3 ft-lb)
Master cylinder assembly: 13 N·m (1.33 kgf-m, 9.6 ft-lb)
Operating lock nut: 22 N·m (2.24 kgf-m, 16.2 ft-lb)
Knee airbag module: 7.5 N·m (0.76 kgf-m, 5.5 ft-lb)

BR-53
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Brake Booster
BRAKE

3) Turn and tighten the flare nut (b) by hand while pressing the brake pipe (a) toward the master cylinder as-
sembly side.
CAUTION:
Be careful not to make scratches or other damage to the inside surface of the brake pipe flare.
Tightening torque:
Brake pipe flare nut: 19 N·m (1.94 kgf-m, 14.0 ft-lb)

(a)

(b)

BR-01088

4) Install the air conditioner pipe. <Ref. to AC-12, AIR CONDITIONING UNIT, COMPONENT, General De-
scription.>
5) Bleed air from the brake system. <Ref. to BR-61, PROCEDURE, Air Bleeding.>
6) Perform a road test to make sure the brakes do not drag.

BR-54
14FO_US.book 55 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Booster
BRAKE

C: INSPECTION
1. OPERATION CHECK WHEN NOT USING MEASURING DEVICES
CAUTION:
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 pro-
cedures.
• Air tightness check
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.
NOTE:
The pedal stroke should be the longest at the 1st depression, and it should become shorter at each succes-
sive depression.
3) If no change occurs in the pedal height when pressed, the vacuum booster assembly is faulty.

(A) (B)

(c)
(b) (c)
(b)
(a) (a)
BR-00937

(A) Normal (B) Not OK

(a) 1st (b) 2nd (c) 3rd

NOTE:
• 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.

BR-55
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Brake Booster
BRAKE

• 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) (b)

BR-00938

(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.
NOTE:
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 de-
pressed.
Keep the pedal depressed for 30 seconds. If the pedal height does not change, the function of vacuum boost-
er assembly is normal. If the pedal height increases, it is faulty.
NOTE:
If a faulty part is detected after inspection, check precisely with measuring devices.

BR-56
14FO_US.book 57 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Booster
BRAKE

2. OPERATION CHECK WHEN USING MEASURING DEVICES

CAUTION:
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.

(a) (b)

(c) (d) (e)

BR-00939

(a) Pressure gauge (c) Adapter hose (e) Pedal force gauge
(b) Vacuum gauge (d) Vacuum hose

• Air tightness check

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

(a) (b)

BR-00940

(a) Pressure gauge (b) Vacuum gauge

BR-57
14FO_US.book 58 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Booster
BRAKE

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,
0.98 inHg) 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 in-
dicates 66.7 kPa (500 mmHg, 19.69 inHg).

(a) (b)

(c)

(d)

BR-00941

(a) Pressure gauge (c) Pedal force gauge (d) Depressed

(b) Vacuum gauge

BR-58
14FO_US.book 59 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Booster
BRAKE

3) Stop the engine and check the vacuum gauge.

If the value matches the following standard, the vacuum booster 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,
0.98 inHg) or less.
If a faulty part is detected after inspection, refer to “AIR TIGHTNESS CHECK”.
<Ref. to BR-55, INSPECTION, Brake Booster.>
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 spec-
ification listed.
Brake pedal force: N (kgf, lbf) 147 (15, 33) 294 (30, 66)
Fluid pressure: kPa (kgf/cm2, psi) 533 (5, 77) 1,551 (16, 225)

• Boosting action check

1) Set the vacuum gauge reading to 66.7 kPa (500 mmHg, 19.69 inHg) with the engine running.
2) Check the fluid pressure when the brake pedal is depressed. The pressure must be greater than the spec-
ification listed.
Brake pedal force: N (kgf, lbf) 147 (15, 33) 294 (30, 66)
Fluid pressure: kPa (kgf/cm2, psi) 6,177 (63, 896) 11,273 (115, 1,635)

BR-59
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Brake Fluid
BRAKE

10.Brake Fluid
A: INSPECTION
1) Check that the amount of brake fluid is between the lines of “MIN” (a) and “MAX” (b) from a straight view
or within 90° to the right and left forward.
If out of the specified range, refill with brake fluid (c) or drain it.
If the brake fluid level is close to “MIN”, check the brake pad for wear and refill with brake fluid.
CAUTION:
Always check the level using the specified direction because there is a partition in the reservoir tank.

(c)

(b)

(c)
(a)

BR-00966

2) Check the fluid for discoloration. If the fluid is extremely discolored, replace with the new fluid.
B: REPLACEMENT
CAUTION:
• 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.
• Avoid mixing brake fluid of different brands to prevent fluid performance from degrading.
• Be careful not to allow dirt or dust to enter the reservoir tank.
NOTE:
• During the operation, keep the reservoir tank filled with brake fluid to prevent entry of air.
• Operate the brake pedal slowly.
• 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 and set rigid racks at the specified locations, or keep the vehicle lifted.
2) Remove both the front and rear wheels.
3) Drain brake fluid from the reservoir tank.
4) Refill the reservoir tank with recommended brake fluid.
Recommended brake fluid:
FMVSS No. 116, DOT3 or DOT4
Perform the same procedure as for bleeding the brake line, until new brake fluid comes out from vinyl tube.
<Ref. to BR-61, PROCEDURE, Air Bleeding.>

BR-60
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Air Bleeding
BRAKE

11.Air Bleeding
A: PROCEDURE
CAUTION:
• 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.
• Avoid mixing brake fluid of different brands to prevent fluid performance from degrading.
• Be careful not to allow dirt or dust to enter the reservoir tank.
• The engine must not be running when bleeding the brake lines.
• For models with EyeSight, bleeding the brake lines while the engine is running may cause the Eye-
Sight warning light to illuminate. If the EyeSight warning light illuminates, refer to “Basic Diagnostic
Procedure” of “EyeSight (DIAGNOSTICS)” and check DTCs. <Ref. to ES(diag)-2, PROCEDURE, Basic
Diagnostic Procedure.>
1. MASTER CYLINDER
NOTE:
• When the master cylinder assembly is replaced or the reservoir tank is empty, bleed the brake master cyl-
inder and the clutch master cylinder (MT model).
• If bleeding of the master cylinder assembly is not necessary, omit the following procedures, and perform
bleeding of the brake line. <Ref. to BR-63, BRAKE LINE, PROCEDURE, Air Bleeding.>
1) Add the brake fluid to the reservoir tank of the master cylinder assembly.
NOTE:
• MT model: Add the brake fluid until it flows out from the clutch hose nipple.
• Except for MT model: Add the brake fluid up to the “MAX” level.
• While bleeding air, keep the reservoir tank filled with brake fluid at MIN level or higher to prevent entry of
air.
2) Disconnect the brake line at primary and secondary sides.
3) Wrap the master cylinder assembly with a plastic bag.
4) Depress the brake pedal slowly and hold it.

BR-00943

BR-61
14FO_US.book 62 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Air Bleeding
BRAKE

5) Plug the outlet plug with your finger, and then release the brake pedal.

BR-00944

6) Repeat the step 4) and 5) several times.

7) Remove the plastic bag.
8) Turn and tighten the flare nut (b) by hand while pressing the brake pipe (a) toward the master cylinder as-
sembly side.
CAUTION:
Be careful not to make scratches or other damage to the inside surface of the brake pipe flare.
Tightening torque:
Brake pipe flare nut: 19 N·m (1.94 kgf-m, 14.0 ft-lb)

(a)

(b)

BR-01088

9) Bleed air from the brake line. <Ref. to BR-63, BRAKE LINE, PROCEDURE, Air Bleeding.>

BR-62
14FO_US.book 63 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Air Bleeding
BRAKE

2. BRAKE LINE
1) When the master cylinder assembly is replaced or the reservoir tank is empty, bleed the master cylinder
assembly before bleeding the brake line. <Ref. to BR-61, MASTER CYLINDER, PROCEDURE, Air Bleed-
ing.>
2) Fill the reservoir tank of the master cylinder assembly with brake fluid.
NOTE:
While bleeding air, keep the reservoir tank filled with brake fluid to prevent entry of air.
3) Attach one end of the vinyl tube to the bleeder - screw and the other end to the brake fluid container.

BR-00942

4) Depress the brake pedal several times, and hold it.

5) Loosen the bleeder - screw to drain brake fluid. Tighten the bleeder - screw quickly, and release the brake
pedal.
6) Repeat the steps 4) to 5) until there are no more air bubbles in the vinyl tube.
7) Repeat the steps from 2) to 6) above to bleed air from each wheel.
NOTE:
Perform air bleed starting in the order from the farthest wheel cylinder from the master cylinder assembly.
8) Securely tighten the bleeder - screw.
Tightening torque:
Bleeder - screw: 8 N·m (0.82 kgf-m, 5.9 ft-lb)
9) Check that there are no brake fluid leaks in the entire brake system.
10) Check the pedal stroke.
(1) Warm up the engine until the engine speed stabilizes.
(2) Depress and hold the brake pedal with a force of 500 N (51 kgf, 112 lbf).
(3) Adjust the tilt position of the steering wheel to the lowest position.
(4) Measure the distance between brake pedal and steering wheel.

BR-63
14FO_US.book 64 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Air Bleeding
BRAKE

(5) Release the pedal, and measure the distance between pedal and steering wheel again.

(a)

1 2
(b)

BR-00945

(a) Steering wheel (b) Toe board

Specification of pedal stroke:

110 mm (4.33 in) or less when depressing the pedal with a force of 500 N (51 kgf, 112 lbf)
11) If the distance is more than specification, there is a possibility of air being caught in the brake line. Bleed
the brake line of all air until the pedal stroke meets the specification.
12) Operate the hydraulic control unit in the sequence control mode. <Ref. to VDC-24, ABS Sequence Con-
trol.>
13) Check the pedal stroke again.
14) If the distance is more than specification, there is a possibility of air being caught in the hydraulic unit. Re-
peat above steps 2) to 9) until the pedal stroke meets the specification.
15) Fill the reservoir tank with brake fluid up to the “MAX” level.
16) Perform a road test and ensure that the brakes operate normally.

BR-64
14FO_US.book 65 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Hose
BRAKE

12.Brake Hose
A: REMOVAL
1. FRONT BRAKE HOSE
1) Separate the brake pipe (b) from brake hose (a) using a flare nut wrench.
2) Remove the clamp, strut mounting bolt and union bolt, and remove the front brake hose.

(a)

(b)

BR-00950

2. REAR BRAKE HOSE

1) Remove the brake hose bracket bolt and union bolt.

BR-01060

2) Press and separate the brake pipe (a) using a flare nut wrench.

BR-65
14FO_US.book 66 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Hose
BRAKE

3) Remove the brake hose clamp (b), and remove the rear brake hose (c).

(b)

(a) (c)

BR-01094

B: INSTALLATION
1. FRONT BRAKE HOSE
1) Secure the brake hose to strut mount.
Tightening torque:
Brake hose: 33 N·m (3.36 kgf-m, 24.3 ft-lb)
2) Connect the brake hose to the front caliper body assembly using a new gasket.
Tightening torque:
Union bolt: 18 N·m (1.84 kgf-m, 13.3 ft-lb)
3) Position the disc in straight position and route the brake hose through the hole in the bracket on the wheel
apron side.
CAUTION:
Do not twist the brake hose.
4) Temporarily tighten the flare nut which connects brake pipe and hose.
5) Secure the brake hose to wheel apron bracket with clamp.

BR-66
14FO_US.book 67 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Hose
BRAKE

6) Turn and tighten the flare nut (b) by hand while pressing the brake pipe (a) toward the master cylinder as-
sembly side.
CAUTION:
Be careful not to make scratches or other damage to the inside surface of the brake pipe flare.
Tightening torque:
Brake pipe flare nut: 19 N·m (1.94 kgf-m, 14.0 ft-lb)

(a)

(b)

BR-01088

7) Bleed air from the brake system. <Ref. to BR-61, PROCEDURE, Air Bleeding.>
2. REAR BRAKE HOSE
1) Route the brake hose through the hole of bracket, and lightly tighten the flare nut to connect brake pipe.
2) Insert the clamp to secure brake hose.
Tightening torque:
Brake hose bracket: 33 N·m (3.36 kgf-m, 24.3 ft-lb)
3) Install the brake hose to rear caliper body using a new gasket.
Tightening torque:
Union bolt: 18 N·m (1.84 kgf-m, 13.3 ft-lb)
4) Tighten the flare nut to the specified torque.
Tightening torque:
Brake pipe flare nut: 15 N·m (1.53 kgf-m, 11.1 ft-lb)
5) Bleed air from the brake system. <Ref. to BR-61, PROCEDURE, Air Bleeding.>
C: INSPECTION
Check the 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.

BR-67
14FO_US.book 68 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Pipe
BRAKE

13.Brake Pipe
A: REMOVAL
CAUTION:
• Yellow connectors and harnesses with yellow tapes around them are the connectors and harness-
es for the airbag system. Using a tester above such circuits may cause malfunction of airbag system.
Follow the cautions for “AIRBAG SYSTEM” in this case. <Ref. to AB-9, CAUTION, General Descrip-
tion.>
• Be careful not to damage the airbag system wiring harness when servicing the center brake pipe.
• When removing the brake pipe, do not bend.
NOTE:
The airbag system wiring harness is routed near the center brake pipe.
B: INSTALLATION
CAUTION:
• Yellow connectors and harnesses with yellow tapes around them are the connectors and harness-
es for the airbag system. Using a tester above such circuits may cause malfunction of airbag system.
Follow the cautions for “AIRBAG SYSTEM” in this case. <Ref. to AB-9, CAUTION, General Descrip-
tion.>
• Be careful not to damage the airbag system wiring harness when servicing the center brake pipe.
• When installing the brake pipe, do not bend.
• After installing the brake pipe and hose, perform air bleed.
• After installing the brake hoses, make sure that they do not contact the tires or suspension assem-
bly, etc.
NOTE:
The airbag system wiring harness is routed near the center brake pipe.
Tightening torque:
Front brake pipes & hoses: <Ref. to BR-7, FRONT BRAKE PIPES AND HOSES, COMPONENT, Gen-
eral Description.>
Center & rear brake pipes and hoses: <Ref. to BR-9, CENTER AND REAR BRAKE PIPES AND HOS-
ES, COMPONENT, General Description.>
C: INSPECTION
Check the pipe for crack and damage, and also check the connection for fluid leakage. If any faulty is found,
repair or replace the relevant part.
NOTE:
Use a mirror when inspecting back sides and other locations which are hard to see.

BR-68
14FO_US.book 69 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Pedal
BRAKE

14.Brake Pedal
A: REMOVAL
1. CVT MODEL
1) Disconnect the ground cable from battery and wait for at least 60 seconds before starting work.
2) Remove the cover assembly - instrument panel LWR driver.
CAUTION:
When removing the cover assembly - instrument panel LWR driver, be sure to pull it toward you. If at-
tempting to remove by turning it upward, the claws may be damaged.

EI-03690

(1) Remove the clips, and remove the cover - instrument panel side LH.

EI-04030

NOTE:
Using a plastic remover, open the cover - instrument panel side LH.
(2) Remove the screws and release the clips and claws.

BR-69
14FO_US.book 70 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Pedal
BRAKE

(3) Disconnect the harness connectors, and remove the cover assembly - instrument panel LWR driver
INN and OUT.

EI-04067

3) Remove the nuts to remove the knee airbag module and disconnect the harness connector. <Ref. to AB-
21, DRIVER’S AIRBAG MODULE, KNEE AIRBAG MODULE, CURTAIN AIRBAG MODULE AND PRETEN-
SIONER, PROCEDURE, Airbag Connector.>

AB-03090

BR-70
14FO_US.book 71 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Pedal
BRAKE

4) Remove the brake pedal assembly.

(1) Disconnect the switch - stop light connector.
(2) Remove the snap pin (a) and clevis pin (b), and remove the operating rod from the brake pedal.
CAUTION:
• 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.

(b)

(a)

BR-00847

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

BR-01095

2. MT MODEL
NOTE:
Brake pedal is integrated with the clutch pedal.
For removal procedures of the brake pedal, refer to Clutch section. <Ref. to CL-25, REMOVAL, Clutch Ped-
al.>

BR-71
14FO_US.book 72 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Pedal
BRAKE

B: INSTALLATION
1) Install each part in the reverse order of removal.
CAUTION:
• Apply grease to the snap pin to prevent the operating rod from wear.
• Replace the clevis pin with new parts, and apply thin coat of NIGTIGHT LYW No. 2 grease to the cle-
vis pin.
Tightening torque:
Brake pedal: 18 N·m (1.84 kgf-m, 13.3 ft-lb)
Knee airbag module: 7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
2) Check that the brake light operate properly.
3) Check the brake pedal after installation. <Ref. to BR-72, INSPECTION, Brake Pedal.>
C: INSPECTION
1) Move the pad - brake pedal in a horizontal direction with a force of approx. 10 N (1 kgf, 2 lbf), and check
that the pedal deflection is in the range of specifications.
CAUTION:
If excessive deflection is noted, replace with a new bushing.
Deflection of brake pedal:
Wear limit: 5.0 mm (0.197 in) or less

(a) (b)

BR-00959

(a) Brake pedal (except for MT model) (b) Brake pedal (MT model)

BR-72
14FO_US.book 73 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Brake Pedal
BRAKE

2) Check the position of the pedal pad.

Pedal height L:
140 — 150 mm (5.51 — 5.91 in)
Brake pedal free play A:
0.5 — 2 mm (0.020 — 0.079 in) [When pulling the brake pedal upward with a force of less than 10 N
(1 kgf, 2 lbf).]

(a)

(d)

(c) (b)
A

BR-00960

(a) Switch - stop light (c) Toe board (d) Brake booster operating rod
(b) Mat

3) If it is not within the specification, loosen the lock nuts of vacuum booster operating rod, and rotate the rod
to adjust the pedal height L within the specification.
4) Tighten the lock nut.
Tightening torque:
Operating lock nut: 22 N·m (2.24 kgf-m, 16.2 ft-lb)
NOTE:
Check the brake pedal height. When adjusting, also adjust the switch - stop light.

BR-73
14FO_US.book 74 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Stop Light Switch

BRAKE

15.Stop Light Switch

A: REMOVAL
1) Disconnect the ground cable from battery and wait for at least 60 seconds before starting work.
2) Remove the cover assembly - instrument panel LWR driver.
CAUTION:
When removing the cover assembly - instrument panel LWR driver, be sure to pull it toward you. If at-
tempting to remove by turning it upward, the claws may be damaged.

EI-03690

(1) Remove the clips, and remove the cover - instrument panel side LH.

EI-04030

NOTE:
Using a plastic remover, open the cover - instrument panel side LH.
(2) Remove the screws and release the clips and claws.

BR-74
14FO_US.book 75 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Stop Light Switch

BRAKE

(3) Disconnect the harness connectors, and remove the cover assembly - instrument panel LWR driver
INN and OUT.

EI-04067

3) Remove the nuts to remove the knee airbag module and disconnect the harness connector. <Ref. to AB-
21, DRIVER’S AIRBAG MODULE, KNEE AIRBAG MODULE, CURTAIN AIRBAG MODULE AND PRETEN-
SIONER, PROCEDURE, Airbag Connector.>

AB-03090

BR-75
14FO_US.book 76 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Stop Light Switch

BRAKE

4) Remove the switch - stop light.

(1) Disconnect the switch - stop light connector.
(2) Remove the switch - stop light by turning it counterclockwise.

BR-00961

B: INSTALLATION
1) Install the switch - stop light.
CAUTION:
• When pushing the switch - stop light against the spacer, do not apply excessive force.
• Tighten the switch - stop light with a turning torque of 3.0 N·m (0.31 kgf-m, 2.2 ft-lb) or less.
(1) Prepare the spacer (a) with approx. 0.5 mm (0.020 in) in thickness.
(2) Align the groove of the holder - stop light switch with the cutout portion of push rod for the switch - stop
light.
(3) While pulling up the brake pedal toward you, set the spacer (a) between the stopper (b) and the
switch - stop light (c).
(4) Insert the switch - stop light (c) and turn it clockwise by 45° to secure.

(b) (c)

(a)

BR-01221

BR-76
14FO_US.book 77 ページ ２０１３年７月２４日 水曜日 午後７時３５分

Stop Light Switch

BRAKE

2) Remove the spacer (a).

3) Pull up the brake pedal and make sure that the clearance (A) between the switch - stop light end part and
the stopper is 1.5 — 2.5 mm (0.06 — 0.1 in).
Specification:
Clearance (A) of the switch - stop light: 1.5 — 2.5 mm (0.06 — 0.1 in)

(c)
(b)

(A)

(a)

BR-01223

(a) Brake pedal (b) Stopper (c) Switch - stop light

4) Connect the switch - stop light connector.

5) Install the knee airbag module and the cover assembly - instrument panel LWR driver. <Ref. to AB-41, IN-
STALLATION, Knee Airbag Module.>
6) Connect the battery ground terminal.
7) Check that the brake light operate properly.
NOTE:
Operate the brake pedal by 5 mm (0.2 in) or more, and check that the stop light illuminates.
8) Check the operation of switch - stop light.
(1) Turn to IG OFF and connect the Subaru Select Monitor.
(2) Turn to IG ON and display the data of the “Brake Switch” and “Pressure Sensor Output” according to
the Subaru Select Monitor display.
(3) Check that the switch - stop light is OFF with the brake pedal not depressed.
(4) Quickly depress the brake pedal 5 times.
(5) Slowly release the brake pedal depressed at the fifth time and check that the master cylinder pressure
is within the standard value when the switch - stop light changes from OFF to ON.
Specification:
Less than 1 Mpa (10 bar)

BR-77
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Stop Light Switch

BRAKE

C: INSPECTION
1. INSPECT THE RESISTANCE
1) Disconnect the switch - stop light connector.
2) Check the resistance between the terminals of switch - stop light.
Preparation tool:
Circuit tester

2 1
4 3

2 1
4 3

BR-00965

Terminal No. Inspection conditions Standard

When brake pedal is depressed 1 M or more
1—2
When brake pedal is released Less than 1 
When brake pedal is depressed Less than 1 
3—4
When brake pedal is released 1 M or more

3) Replace the switch - stop light if the inspection result is not within the standard value.

BR-78
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Brake Vacuum Pump

BRAKE

16.Brake Vacuum Pump

A: REMOVAL
1. BRAKE VACUUM PUMP
1) Disconnect the ground cable from battery.
2) Remove the vacuum pump assembly.
(1) Disconnect the connectors of the vacuum pump assembly.
(2) Remove the vacuum hose COMPL.

BR-01079

(3) Remove the bolts, then remove the vacuum pump assembly.

BR-01081

BR-79
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Brake Vacuum Pump

BRAKE

3) Remove the bolts, and then remove the bracket - generator.

BR-01082

B: INSTALLATION
1. BRAKE VACUUM PUMP
Install in the reverse order of removal.
Tightening torque:
Bracket - generator: 19 N·m (1.9 kgf-m, 14.0 ft-lb)
Vacuum pump assembly: 7.5 N·m (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
1. BRAKE VACUUM PUMP
Refer to “Read Diagnostic Trouble Code (DTC)” of “BRAKE VACUUM CONTROL”. <Ref. to BVC(diag)-10,
OPERATION, Read Diagnostic Trouble Code (DTC).>
2. VACUUM HOSE
Check to see that air only flows in one direction, when air is blown into or sucked from the hose.

BR-80
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Brake Vacuum Sensor

BRAKE

17.Brake Vacuum Sensor

A: NOTE
CAUTION:
• Do not remove the vacuum sensor (a). If removed, replace the vacuum booster assembly (b) with
a new part.
• Do not rotate the vacuum sensor (a) when disconnecting the connector of vacuum sensor (a). Oth-
erwise the grommet on the mounting location of the vacuum sensor (a) may be damaged.

(b)

(a)
BR-01099

BR-81
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General Diagnostic Table

BRAKE

18.General Diagnostic Table

A: INSPECTION
Trouble and possible cause Corrective action
1. Insufficient braking (1) Fluid leakage from the hydraulic mechanism Repair or replace. (cup, piston seal, piston
boot, master cylinder piston kit, pipe or
hose)
(2) Entry of air into the hydraulic mechanism Bleed air.
(3) Wear, deteriorated surface material, water or fluid on Replace, grind or clean.
lining
(4) Improper operation of master cylinder assembly, disc Repair or replace.
caliper, vacuum booster assembly or check valve
2. Unstable or uneven (1) Fluid on lining or rotor Correct the cause of fluid leakage, and
braking clean or replace.
(2) Rotor defective Repair or replace the rotor.
(3) Improper lining contact, deteriorated surface, deterio- Repair by grinding, or replace.
rated or worn lining material
(4) Deformed back plate Repair or replace.
(5) Overinflation of tires Adjust the air pressure.
(6) Defective wheel alignment Adjust alignment.
(7) Loose back plate or support installation bolt Tighten to the specified torque.
(8) Defective hub unit COMPL Replace.
(9) Defective hydraulic system Replace the cylinder, brake pipe or hose.
(10) Unstable performance of the parking brake Check, adjust or replace the rear brake and
cable system.
3. Excessive pedal (1) Entry of air into the hydraulic mechanism Bleed air.
stroke (2) Excessive play in the master cylinder push rod Adjust.
(3) Fluid leakage from the hydraulic mechanism Repair or replace. (cup, piston seal, piston
boot, master cylinder piston kit, pipe or
hose)
(4) Improper lining contact or worn lining Repair or replace.
4. Brake dragging or (1) Insufficient pedal play Adjust play.
improper brake (2) Improper master cylinder return Clean or replace the cylinder.
return
(3) Clogged hydraulic system Replace.
(4) Improper return or adjustment of parking brake Repair or adjust.
(5) Weakened spring tension or breakage of shoe return Replace the spring.
spring
(6) Improper disc caliper operation Repair or replace.
(7) Faulty wheel bearing Replace.
5. Brake noise (1) (1) Hardened or deteriorated brake pad Replace the pad.
(creaking sound) (2) Worn brake pad Replace the pad.
(3) Loose back plate or support installation bolt Tighten to the specified torque.
(4) Loose hub unit COMPL Tighten to the specified torque.
(5) Dirty rotor Clean the rotor, or clean and replace brake
assembly.
6. Brake noise (2) (1) Worn brake pad Replace the pad.
(hissing sound) (2) Improperly installed pad Correct or replace the pad.
(3) Loose or bent rotor Retighten or replace.
7. Brake noise (3) Excessively worn pad or support Replace the pad or the support.
(click sound)

BR-82