Contents Wiring diagrams Section: Mechanical - Hydraulic All sections

Brake System: Removal & Installation Subaru Forester SJ

Mechanical - Hydraulic 49 illustrations ~4250 words

INSTALLATION

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

Scheme 63

Scheme 63: INSTALLATION

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Scheme 65
  1. Check the brake pad. < Ref. to «INSPECTION»(ref-662128-S30603212782014101300000) , 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
  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 figure. If the pad return spring is deformed or damaged, replace the brake pad with a new part. NOTE: Install the brake pad indicator in proper direction.
  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)

Scheme 66

Scheme 66: 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. 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.

Scheme 67

Scheme 67: REMOVAL

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Scheme 68

Scheme 69

Scheme 69
  1. Lift up the vehicle, and then remove the front wheels.
  2. Remove the caliper body assembly from the housing assembly - front axle. Remove the bolt from the brake hose bracket. Remove the mounting bolt, and remove the caliper body assembly. Prepare wiring harnesses etc. to be discarded, and suspend the caliper body assembly from the strut assembly.
  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.

Note. Before installation, remove mud and foreign matter from the caliper body assembly.

  1. Before installation, check the front disc rotor. < Ref. to «INSPECTION»(ref-662128-S16663549442014101300000) , 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)

Scheme 70

Scheme 70: 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 «INSPECTION»(ref-662131-S05044086882014101300000) , Front Hub Unit Bearing. >
  2. Tighten the wheel nuts to secure disc rotor.
  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)
  4. If the runout limit is exceeded in the inspection, replace the disc rotor.

Scheme 71

Scheme 71: 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). Size Standard Wear limit Disc rotor outer diameter Disc rotor thickness (A) 16-inch 24 mm (0.94 in) 22 mm (0.87 in) 260 mm (10.24 in) 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.

REMOVAL

CAUTIONDo 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.

Scheme 72

Scheme 72

Scheme 73

Scheme 73
  1. Lift up the vehicle, and then remove the front wheels.
  2. Remove the caliper body assembly. Remove the union bolt and caliper bolt, and remove the caliper body assembly from the support - front disc brake.
  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. Remove the brake pad from support - front disc brake. Remove the mounting bolts, and then remove the support - front disc brake from the housing assembly - front axle.

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

Scheme 74

Scheme 74: INSTALLATION

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Scheme 76
  1. Check each part. < Ref. to «INSPECTION»(ref-662128-S10279724592014101300000) , Front Disc Brake Assembly. >
  2. Apply a thin coat of grease to the support - front disc brake. Grease: Molykote M7439 (Part No. 003602001)
  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
  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
  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 figure. If the pad return spring is deformed or damaged, replace the brake pad with a new part. NOTE: Install the brake pad indicator in proper direction.
  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 «BRAKE LINE»(ref-662128-S20030420092014101300000) , PROCEDURE, Air Bleeding. >
  10. Install the front wheels. Tightening torque: 120 N.m (12.24 kgf-m, 88.5 ft-lb)

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

Scheme 77

Scheme 77: INSTALLATION

Scheme 78

Scheme 78
  1. Before installation, check the brake pad. < Ref. to «INSPECTION»(ref-662128-S38998734322014101300000) , 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
  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
  4. Install the brake pad to the support - rear disc 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)

Scheme 79

Scheme 79: 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, replace the pad. Disc rotor type Standard (A) Wear limit (B) Pad thickness Solid disc 9 mm (0.35 in) 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.

Scheme 80

Scheme 80: REMOVAL

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Scheme 83
  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. Remove the bolt from the brake hose bracket. Remove the mounting bolt, and remove the caliper body assembly. Prepare wiring harnesses etc. to be discarded, and suspend the caliper body assembly from the strut assembly.
  4. Remove the rear disc rotor. NOTE: If it is difficult to remove the disc rotor, perform the following two methods in order. 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. 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.

Note. Before installation, remove mud and foreign matter from the caliper body assembly.

  1. Before installation, check the rear disc rotor. < Ref. to «INSPECTION»(ref-662128-S28562583032014101300000) , Rear Disc Rotor. >
  2. Install each part in the reverse order of removal.
  3. Adjust the parking brake. < Ref. to «ADJUSTMENT»(ref-662111-S08174014912014101300000) , 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)

Scheme 84

Scheme 84: 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 «INSPECTION»(ref-662131-S28075601062014101300000) , 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)
  4. If the runout limit is exceeded in the inspection, replace the disc rotor.

Scheme 85

Scheme 85: 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). Disc rotor type Standard Wear limit Disc rotor outer diameter Disc rotor thickness (A) Solid disc 10 mm (0.39 in) 8.5 mm (0.33 in) 274 mm (10.79 in) 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.
CAUTIONDo 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.

Scheme 86

Scheme 86

Scheme 87

Scheme 87
  1. Lift up the vehicle, and then remove the rear wheels.
  2. Remove the caliper body assembly from the support - rear disc brake. Remove the brake hose bracket and union bolt. Remove the caliper bolt, and remove the caliper body assembly.
  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. Remove the brake pad from support - rear disc brake. Remove the mounting bolts, and then remove the support - rear disc brake from the housing assembly - rear axle.

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

Scheme 88

Scheme 88
  1. Before installation, check each part. < Ref. to «INSPECTION»(ref-662128-S12421861812014101300000) , 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
  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
  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
  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 «BRAKE LINE»(ref-662128-S20030420092014101300000) , PROCEDURE, Air Bleeding. >
  11. Install the rear wheels. Tightening torque: 120 N.m (12.24 kgf-m, 88.5 ft-lb)
CAUTIONDo 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.

Scheme 89

Scheme 89
  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) Disconnect the fluid level gauge connector (a). Disconnect the clutch hose (b). (MT model) Turn the flare nuts while pressing the brake pipes toward the master cylinder assembly side and disconnect the brake pipes (c). Remove the nut (d), and slowly remove the master cylinder assembly from the vacuum booster assembly.

Scheme 90

Scheme 90: INSTALLATION

Scheme 91

Scheme 91
  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.
  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 assembly 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)
  4. Bleed air from the brake system and clutch system (MT model). < Ref. to «PROCEDURE»(ref-662128-S34945780212014101300000) , Air Bleeding. >

REPLACEMENT

CAUTIONSince the master cylinder assembly cannot be disassembled, disassembly and cleaning are prohibited. When replacing, replace the master cylinder assembly.
CAUTIONDo 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.

Scheme 92

Scheme 92

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Scheme 100

Scheme 100
  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 «REMOVAL»(ref-662134-S35863784852014101300000) , Hose and Pipe. >
  4. Remove the power steering control module. < Ref. to «REMOVAL»(ref-662133-S21989845472014101300000) , Power Steering Control Module. >
  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). Otherwise the gasket on the mounting location of the vacuum sensor may be damaged. (Turbo model) Disconnect the fluid level gauge connector (a). Disconnect the clutch hose (b). (MT model) Turn the flare nuts while pressing the brake pipes toward the master cylinder assembly side and disconnect the brake pipes (c). Disconnect the vacuum sensor connector (e). (Turbo model) Remove the nut (d), and slowly remove the master cylinder assembly from the vacuum booster assembly.
  6. Remove the clamp and remove the vacuum hose.
  7. Remove the brake pipe assembly (a). Disconnect the starter connector (b) and harness clip (c). Remove the brake pipe assembly (a) from the pipe clip (d).
  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 attempting to remove by turning it upward, the claws may be damaged. Remove the clips, and remove the cover - instrument panel side LH. NOTE: Using a plastic remover, open the cover - instrument panel side LH. Remove the screws and release the clips and claws. Disconnect the harness connectors, and remove the cover assembly - instrument panel LWR driver INN and OUT.
  9. Remove the nuts to remove the knee airbag module and disconnect the harness connector. < Ref. to «DRIVER'S AIRBAG MODULE, KNEE AIRBAG MODULE, CURTAIN AIRBAG MODULE AND PRETENSIONER»(ref-662142-S01932333622014101300000) , PROCEDURE, Airbag Connector. >
  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.
  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 position, the resin portion as indicated by "P" may become damaged. Remove the nuts, and then remove the vacuum booster assembly.

Scheme 101

Scheme 101: INSTALLATION

Scheme 102

Scheme 102
  1. Check and adjust the operating rod of the vacuum booster assembly. Measure the length between the vacuum booster assembly mounting surface and clevis pin hole. 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)
  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 clevis pin. When installing the master cylinder assembly, replace the seal sub assembly with a new part, and install it to the vacuum booster assembly. 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)
  3. Turn and tighten the flare nut (b) by hand while pressing the brake pipe (a) toward the master cylinder assembly 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)
  4. Install the air conditioner pipe. < Ref. to «AIR CONDITIONING UNIT»(ref-662134-S22847778172014101300000) , COMPONENT, General Description. >
  5. Bleed air from the brake system. < Ref. to «PROCEDURE»(ref-662128-S34945780212014101300000) , Air Bleeding. >
  6. Perform a road test to make sure the brakes do not drag.
CAUTIONDo 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 «PROCEDURE»(ref-662128-S34945780212014101300000) , Air Bleeding. >
CAUTIONYellow connectors and harnesses with yellow tapes around them are the connectors and harnesses 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 CAUTION , General Description. > 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.

CAUTIONYellow connectors and harnesses with yellow tapes around them are the connectors and harnesses 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 CAUTION , General Description. > 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 assembly, etc.

Note. The airbag system wiring harness is routed near the center brake pipe.

Tightening torque

Front brake pipes & hoses: < Ref. to FRONT BRAKE PIPES AND HOSES , COMPONENT, General Description. >

Center & rear brake pipes and hoses: < Ref. to CENTER AND REAR BRAKE PIPES AND HOSES , COMPONENT, General Description. >

  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 clevis 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 «INSPECTION»(ref-662128-S27923221152014101300000) , Brake Pedal. >

Scheme 103

Scheme 103: INSPECTION

Scheme 104

Scheme 104
  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
  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).]
  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.

Scheme 105

Scheme 105
  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 attempting to remove by turning it upward, the claws may be damaged. Remove the clips, and remove the cover - instrument panel side LH. NOTE: Using a plastic remover, open the cover - instrument panel side LH. Remove the screws and release the clips and claws. Disconnect the harness connectors, and remove the cover assembly - instrument panel LWR driver INN and OUT.
  3. Remove the nuts to remove the knee airbag module and disconnect the harness connector. < Ref. to «DRIVER'S AIRBAG MODULE, KNEE AIRBAG MODULE, CURTAIN AIRBAG MODULE AND PRETENSIONER»(ref-662142-S01932333622014101300000) , PROCEDURE, Airbag Connector. >
  4. Remove the switch - stop light. Disconnect the switch - stop light connector. Remove the switch - stop light by turning it counterclockwise.

Scheme 106

Scheme 106: INSTALLATION

Scheme 107

Scheme 107
  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. Prepare the spacer (a) with approx. 0.5 mm (0.020 in) in thickness. Align the groove of the holder - stop light switch with the cutout portion of push rod for the switch - stop light. While pulling up the brake pedal toward you, set the spacer (a) between the stopper (b) and the switch - stop light (c). Insert the switch - stop light (c) and turn it clockwise by 45° to secure.
  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)
  4. Connect the switch - stop light connector.
  5. Install the knee airbag module and the cover assembly - instrument panel LWR driver. < Ref. to «INSTALLATION»(ref-662142-S39182608312014101300000) , 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. Turn to IG OFF and connect the Subaru Select Monitor. Turn to IG ON and display the data of the "Brake Switch" and "Pressure Sensor Output" according to the Subaru Select Monitor display. Check that the switch - stop light is OFF with the brake pedal not depressed. Quickly depress the brake pedal 5 times. 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)

Scheme 108

Scheme 108: 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 Terminal No. Inspection conditions Standard 1 - 2 When brake pedal is depressed 1 Mohms or more When brake pedal is released Less than 1 ohms 3 - 4 When brake pedal is depressed Less than 1 ohms When brake pedal is released 1 Mohms or more
  3. Replace the switch - stop light if the inspection result is not within the standard value.

Scheme 109

Scheme 109: BRAKE VACUUM PUMP

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Scheme 111

Scheme 111
  1. Disconnect the ground cable from battery.
  2. Remove the vacuum pump assembly. Disconnect the connectors of the vacuum pump assembly. Remove the vacuum hose COMPL. Remove the bolts, then remove the vacuum pump assembly.
  3. Remove the bolts, and then remove the bracket - generator.