Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Service manual — part 562
BR-33
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 com-
pletely.
1) Drain brake fluid from the reservoir tank com-
pletely.
2) Disconnect the harness connector of the fluid
level gauge.
3) Remove the brake pipe from the master cylinder.
4) Remove the master cylinder mounting nuts, and
carefully remove the master cylinder from the brake
booster.
B: INSTALLATION
1) Replace the O-ring for the master cylinder with a
new part.
CAUTION:
Be careful not to install the O-ring in the wrong
location.
2) Install each part in the reverse order of removal.
Tightening torque:
Master cylinder mounting nut
13 N·m (1.33 kgf-m, 9.6 ft-lb)
Piping flare nut
15 N·m (1.53 kgf-m, 11.1 ft-lb)
CAUTION:
Be sure to use recommended brake fluid. <Ref.
to BR-2, SPECIFICATION, General Descrip-
3) Bleed air from the brake system. <Ref. to BR-41,
C: REPLACEMENT
1) Remove mud and dirt from the surface of brake
master cylinder.
2) Secure the master cylinder in a vise.
CAUTION:
To avoid damaging the master cylinder, place
between aluminum plates or other material
when holding with a vise.
3) Remove the pin which secures the master cylin-
der and reservoir tank, then remove the reservoir
tank and seal.
4) While pushing in the primary piston, remove the
C-ring using pliers.
5) While pushing in the primary piston, remove the
cylinder pin (1) from the port on the reservoir tank
attachment location using a magnet pick-up tool.
6) Extract the primary piston assembly and sec-
ondary piston assembly straight out while taking
care not to scratch the inner surface of the cylinder.
7) Clean the inside of master cylinder with brake
fluid. Check the inside of the cylinder for damage,
deformation and wear. Replace the master cylinder
as an assembly if faulty.
(1) Primary piston
(2) O-ring
(3) Do not install the O-ring on this groove.
BR-00363
(1)
(2)
(3)
BR-00364
BR-00169
BR-00069
(1)
BR-34
Master Cylinder
BRAKE
8) Apply brake fluid to the inner surface of master
cylinder and piston assembly.
9) Make sure that the inner surface of master cylin-
der and the piston assembly are free of foreign
matter. Install the primary piston assembly and the
secondary piston assembly to master cylinder,
while taking care not to scratch the master cylinder
inner surface.
10) While pushing-in the primary piston, install the
cylinder pin.
11) While pushing-in the primary piston, install the
C-ring to the groove using pliers.
CAUTION:
Make sure the C-ring is installed to the groove
securely.
12) Install the seal (1) to reservoir tank.
13) Install the reservoir tank to the master cylinder,
and secure with pin.
14) Replace the O-ring for the master cylinder with
a new part.
D: INSPECTION
Inspect for brake fluid leakage from the master cyl-
inder.
NOTE:
After replacing the piston kit, if an brake fluid leak-
age is found even though there is no damage or
scratches on the inside of the cylinder, the master
cylinder inner wall may be worn. In this case, re-
place the master cylinder as an assembly.
(1) Primary piston
(2) O-ring
(3) Do not install the O-ring on this groove.
BR-00169
BR-00072
(1)
BR-00363
(1)
(2)
(3)
BR-35
Brake Booster
BRAKE
9. Brake Booster
A: REMOVAL
1) Remove or disconnect the following parts in the
engine compartment.
(1) Disconnect the connector of brake fluid level
gauge.
(2) Remove the brake pipe from the master cyl-
inder.
(3) Remove the master cylinder installation nut.
(4) Disconnect the vacuum hose from brake
booster.
2) Remove the following parts from the pedal
bracket.
(1) Snap pin and clevis pin
(2) Four brake booster installation nuts
3) Remove the brake booster while avoiding the
brake pipe.
CAUTION:
• Do not disassemble the brake booster.
• If external force (1) is applied from above
when brake booster is placed in this position,
the resin portion as indicated by “P” may be-
come damaged.
NOTE:
• Make sure that the booster shell and vacuum
pipe are not subject to strong impacts.
• Be careful not to drop the brake booster. If the
booster is dropped, replace it.
• Use special care when handling the operating
rod. If excessive force is applied to the operating
rod, the angle may change by ±3°, and it may result
in damage to power piston cylinder.
• Be careful when placing the brake booster on
floor.
• Do not change the push rod length.
B: INSTALLATION
1) Check and adjust the operating rod of the brake
booster.
Specification L:
136.3 mm (5.37 in)
If it is out of specification, adjust it with the brake
booster operating rod.
(1) Nut
(2) Clevis pin
(3) Snap pin
(4) Operating rod
(5) Brake pedal
(2)
(4)
(5)
(3)
BR-00685
(1)
(1)
P
BR-00075
BR-00076
L
BR-36
Brake Booster
BRAKE
2) Mount the brake booster in position.
3) Install clevis pin and snap pin which secure the
operating rod to the brake pedal.
NOTE:
• Replace with a new clevis pin.
• Apply NIGTIGHT LYW No. 2 grease to the clevis
pin.
4) Connect the vacuum hose to the brake booster.
5) After replacing the O-ring, install the master cyl-
inder to brake booster.
6) Connect the brake pipes to the master cylinder.
7) Connect the connector of the brake fluid level
gauge.
8) Apply grease to the operating rod connecting pin
to prevent it from wear.
9) Bleed air from the brake system. <Ref. to BR-41,
10) Perform a road test to make sure the brakes do
not drag.
C: INSPECTION
NOTE:
On the model with brake assist mechanism, the fol-
lowing phenomena occur when the brake pedal is
depressed. However, those are not malfunction but
the phenomena that occur when the brake assist
mechanism functions properly.
• Brake feel is soft when brake pedal is depressed
hard or quicker than usual.
• ABS operating sound is heard when brake pedal
is depressed hard or quicker than usual.
(1) Nut
(2) Clevis pin
(3) Snap pin
(4) Operating rod
(5) Brake pedal
(2)
(4)
(5)
(3)
BR-00685
(1)
(1) Primary piston
(2) O-ring
(3) Do not install the O-ring on this groove.
BR-00363
(1)
(2)
(3)
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