Subaru 2002 Impreza User manual

I
2002 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
~
TRANSMISSION SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary informationand data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experiencedmechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
c- -
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIESLTD.
G1830BE4

1
CONTROL SYSTEMS
CSr
Page
General Description .................................................................................... 2
ElectricalComponent
.................................................................................. 6
AT Shift Lock System .................................................................................. 8
Select Lever
.............................................................................................. 23
Select Cable
.............................................................................................. 26
AT Shift Lock Solenoid and “P” Position Switch ........................................ 29
Integrated Module ..................................................................................... 31
MT Gear Shift Lever .................................................................................. 32
1 .
2 .
3 .
4 .
5 .
6 .
7 .
8 .
9 . General Diagostic
...................................................................................... 38
c- .

GENERAL DESCRIPTION
CONTROL SYSTEMS
I
1. General Description
A: SPECIFICATIONS
I Item I Specification -1
I Vibration torque of rodagainst lever N.m (kgf-m,ft-lb) I 0.7 (0.07, 0.5) or less
cs-2

I
GENERAL DESCRIPTION
CONTROL SYSTEMS
B: COMPONENT
1. AT SELECT LEVER
‘.
.
‘-‘ I
‘. I
‘. ‘
‘-A
TR054t
Indicatorlight bulb
Detentarm
Detentspring
Select lever
Springpin
Arm
Pin
Plate
Grommet
Packing
Grip
Indicatorcover
Cushion
Guideplate
Snap pin
Outercable
Innercable
Nut
B
NutA
Clip
Lock plate
Shift lock solenoid
Clamp
Cover
(25) Slider
(26) Clip
(27) “P” positionswitch
(28) Spring
(29) Button
Tighteningtorque:N.m (kgf-m, fi-lb)
T1: 7.5 (0.76, 5.5)
T2: 13 (1.3,9.4)
T3:
lS(1.8, 13.0)
T4: 33 (3.4,25)
cs-3

I GENERAL DESCRIPTION
CONTROL SYSTEMS
2. MT GEAR SHIFT LEVER
TI30594
(1) Gear shift knob
(2) Console boot
(3) Plate complete
(4) Lever
(5) Bush
(6) Bush
(7) Lockingwire
(8) Boot
(9) Snap ring
(IO) O-ringA
(11) O-ringB
(12) BushA
(13) Cushionrubber
(14) Bush6
(1 5) Joint
(16) Rod
(17) Bracket
(18) Washer
(19) Stay
(20) Spacer
Tighteningtorque: N-m(kgf-m,ft-lb)
T1: 7.5
(0.76, 5.5)
T2: 12 (1.2, 8.7)
T3: lS(1.8, 13.0)
cs-4

I
CONTROL SYSTEMS
GENERAL DESCRIPTION
C: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
Keep the disassembled parts in order and pro-
tect them from dust or dirt.
Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
Use SUBARU genuine grease etc. or the equiv-
alent.
Do not mix grease etc. with that of another
grade or from other manufacturers.
Be sure to tighten fasteners including bolts and
nuts to the specified torque.
Placeshopjacks or safety stands at the specified
points.
Apply grease onto sliding or revolution surfaces
before installation.
c. BeforeinstallingO-rings or snap rings,apply suf-
ficient amount of grease to avoid damage and de-
formation.
Before securing a part on a vice, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vice.
Before disconnecting electrical connectors, be
sure to disconnect the negative terminal from bat-
tery.
cs-5

I
ELECTRICALCOMPONENT
CONTROL SYSTEMS
2. Electrical Component
A: LOCATION
(1) Inhibitorswitch
(2) Integratedmodule
(3) Stop lightswitch
(4) Key warning switch
(5) Shift locksolenoid
(6) “P” positionswitch
(7) Key lock solenoid
CS-6

ELECTRICALCOMPONENT
CONTROL SYSTEMS
\ \o\ ' B2M2246E
(2)
TR0548
TR0549
I
cs-7

AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS
I BO031 1
I
16 15 14 13 12 11 10 9
3. AT Shift Lock System
A: ELECTRICAL SPECIFICATION
Contents InpuVOutputsignal
Measuredvalue and measuringconditions
Connector
No. Terminal No.
10 9 8 7 6 5 4 3 2 1
20 19 18
17 16 15 14 13 12 11
Batterypower supply
Ignitionpowersupply
Ignitionpower supply
InhibitorSwitch
(“P” position)
8281 2 9-16V
B280 19
8280 10
8280
5
10 - 15 V when ignitionswitch is at ON or START.
10
- 15 V when ignitionswitch is at ACC.
0 V when select lever is in“Pposition.
9
- 16 V when select lever is inother positionsthan “P
oosition.
Shift lock solenoidsignal
position.
8.5
- 16 V when shift lock is released.
0 V when shift lock is oPeratina.
8281 9
Stop lightswitch
Key warningswitchsignal
I B280 I 9
I
9 - 16 V when key is inserted.
0 V when key is removed.
7.5
- 16 V when turning ignitionswitchto ON, select
6280 20
I “P” positionswitch I B280
Key lock solenoidsignal
Ground
Ground
9
- 16 V when stop lightswitch is ON.
0 V when stop lightswitch is OFF.
0 V when select lever is in“Pposition.
9 - 16 V when select lever is inother positionsthan “P”
8281 3
B281
4
B281 13 -
lever is in “P” positionand brakeswitch is ON.
0 V at other conditionsthan above. .
-
CS-8

I
CONTROL SYSTEMS
AT SHIFT LOCK SYSTEM
B: SCHEMATIC
OQ
(2)
0
0 c----
(4)
L
(4) integratedmodule (7) Shift locksolenoid
(1) Ignitionswitch
(2) Stop lightswitch (5) Inhibitorswitch (8) “P” positionswitch
(6) Key locksolenoid (9) Battery
(3) Keywarningswitch
cs-9

AT SHIFT LOCK SYSTEM
Check
While brakepedalis
depressed,can select lever
movefrom “Prangeto other
positions?
While brakepedal is not
CONTROL SYSTEMS
Yes NO
Go to step 2.
Inspect“SELECT
LEVER CANNOT
BE SHIFT
LOCKED.<Ref.
LEVER CANNOT
BE SHIFT
LOCKED,
INSPECTION,AT
Shift Lock
Sys-
tem.>
Inspect“SELECT
Go to step 3.
toCS-I 4, SELECT
C: INSPECTION
depressed,can select lever
movefrom “P” range to other
positions?
When select leveris in other
than “P” position,does ignition
switchturnto“LOCKposition?
Or when selectleveris in “P
position,does ignitionswitch
turn to “LOCK position?
Step
CHECK SHIFT LOCK.
1)Turnthe ignitionswitch ON.
2)Movethe select lever
to “P” position.
LEVER SHIFT
LOCKCANNOT
BE RELEASED.
<Ref.to CS-16,
SELECT LEVER
SHIFT LOCK
CANNOT BE
RELEASED,
INSPECTION,AT
Shift Lock
Sys-
tem.>
Inspect“KEY
INTERLOCK
DOES NOT BE
LOCKEDOR
RELEASED.<Ref.
INTERLOCK
DOESNOTLOCK
OR RELEASE,
INSPECTION,AT
Shift Lock
Sys-
tem.>
to CS-20, KEY
! CHECK SHIFT LOCK.
I CHECK KEY INTERLOCK.
4T shift lock sys-
em is normal.
cs-10

AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS
cs-11

AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS
1. INTEGRATED MODULE POWER SUPPLY AND GROUND LINE
WIRING DIAGRAM:
rr
P
0
z
0
I
II
A: @
- -
TR0551
cs-12

AT SHIFT LOCK SYSTEM 1
CONTROL SYSTEMS
~
Step
CHECK FUSE (No. 3,4 and 11).
1)Aemovethe fuse (No. 3,4and 11).
! CHECK HARNESSCONNECTOR BETWEEN
INTEGRATEDMODULEAND BODY
GROUND.
1)Turnthe ignitionswitch to OFF.
2)Measurethe resistanceof harnessbetween
integratedmoduleand chassisground.
(8281) No. 4 - Chassisground:
(8281)
No. 13 - Chassisground:
I CHECK BATTERY POWER SUPPLY.
Connector & terminal
1)Turnthe ignitionswitchto ON (engine OFF).
2)Measurethe voltages betweenintegrated
moduleand chassis ground.
Connector & terminal
(8281)
No. 1 (+) - Chassisground (-):
I
CHECK IGNITIONPOWER SUPPLY CIR-
CUIT.
1)Tufnthe ignitionswitch to ACC.
2)Measurethe voltage betweenintegrated
module and chassisground.
Connector & terminal
(8280)
No. 10 (+) - Chassisground (-):
>
CHECK IGNITIONPOWER SUPPLY CIR-
CUIT.
1)Turnthe ignitionswitch to ON (engine OFF).
2)Measurethe voltagebetweenintegrated
moduleand chassisground.
Connector & terminal
(8281)
No. 19 (+) - Chassisground (-):
i CHECK POOR CONTACT.
Check
s the fuse (No. 3,4 or 11)
)lawn out?
s the resistanceless than 1
2?
s the voltage morethan 9 V?
s the voltage morethan 9 V?
s the voltagemore than 9 V?
s there poorcontactin power
;upply andgroundlinecircuit?
Yes
3eplacethe fuse
:No. 3, 4or 11). If
he replacedfuse
:No.3,4 or 11)
iasblownout eas
ly, repairshort cir-
:uit inharness
letweenfuse and
ntegratedmodule.
30 to step 3.
30 to step 4.
So to step5.
Go to step 6.
Repairpoorcon-
tact.
No
So to step2.
Repairopencircuit
in harness
betweeninte-
gratedmoduleand
body ground.
Repairopencircuit
harnessbetween
batteryand inte-
gratedmodule,
and poorcontact
in couplingcon-
nector.
Repairopencircuit
harness between
batteryand inte-
gratedmodule,
and poorcontact
incouplingcon-
nector.
Repairopencircuit
harnessbetween
batteryand inte-
gratedmodule,
and poorcontact
incouplingcon-
nector.
Replacethe inte-
grated module.
CS-13

AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS
2. SELECT LEVER CANNOT BE SHIFT LOCKED
WIRING DIAGRAM:
SBF-1
STOP LIGHT
A: @
B: @ INTEGRATEDMODULE
I la1
I
I1
SHIFT LOCK
I
SOLENOID
I
OC :WITHOUTCRUISE CONTROL MODEL
Is WC :WITHCRUISE CONTROL MODEL
TR0552
cs-14

AT SHIFT LOCK SYSTEM
Check
Doesthe stop light turn ON?
Is the resistancemorethan 1
MR?
CONTROL SYSTEMS
Yes
Go to step 2.
Repairopencircuit
in harness
between inte-
gratedmoduleand
stop lightswitch.
Step
I CHECK STOP LIGHTSWITCH.
2
Depressthe brake pedal.
CHECK HARNESSBETWEENSTOP LIGHT
SWITCH AND INTEGRATEDMODULE.
1)Turnthe ignitionswitch to OFF.
2)Disconnectthe integratedand stoplight
switchconnector.
3)Measurethe resistance
of harnessbetween
stop lightswitch and integratedmodule.
Connector & terminal
Withoutcruise control model
Withoutcruise control model
(864) NO. 1 - (B280) NO. 9:
(B65) NO. 3 - (8280) NO. 9:
3
CHECK HARNESSBETWEENSTOP LIGHT
SWITCH AND INTEGRATEDMODULE.
Measurethe resistanceof harnessbetween
stop lightswitch andchassisground.
Connector & terminal
Withoutcruise control model
Withoutcruise control model
4 CHECKHARNESSBETWEENINTEGRATED
MODULE AND SHIFT LOCK SOLENOID.
1)Disconnectthe shift locksolenoidconnector
2)Measurethe resistanceof harnessbetween
integratedmoduleand shift lock solenoid..
(B64) No. 1 - Chassisground:
(B65) No. 3 - Chassisground:
Connector
& terminal
(B116) NO. 4 - (8281) NO. 9:
5 CHECKHARNESSBETWEENINTEGRATED
MODULEAND SHIFT LOCK SOLENOID.
Measurethe resistanceof harnessbetween
shift locksolenoidandchassisground.
Connector & terminal
(Bll6) No. 4 - Chassisground:
SOLENOIDAND CHASSISGROUND.
Measurethe resistanceof harnessbetween
shift lock solenoidand chassisground.
6
CHECK HARNESS BETWEEN SHIFT LOCK
Connector & terminal
7 CHECK SHIFT LOCK SOLENOID.
(61 16) No. 5 - Chassisground:
Measurethe resistanceof shift lock solenoid
connectorterminals.
Terminal
NO. 4 -NO. 5:
8 CHECK SHIFT LOCK SOLENOID.
Connectthe batterywith shift locksolenoid
connectorterminal and operatesolenoid.
Terminal
NO. 4 (+) - NO. 5 (--)I
9 CHECK POOR CONTACT.
Is the resistancelessthan 1
n?
Repairshortcircuit
in harness
between inte-
gratedmoduleand
stop lightswitch.
Is the resistancemorethan 1
MR?
Is the resistancelessthan 1
Q?
Is the resistance morethan 1
MR?
Repairopencircuit
in harness
betweeninte-
gratedmoduleand
shift locksolenoid.
Repairshortcircuit
in harness
betweeninte-
gratedmoduleand
shift locksolenoid.
Repairopencircuit
in harness
betweenshift lock
solenoidand body
ground.
Is the resistancebetween 10
and
20 R?
Go to step 8.
Doesthe shift lock solenoid
operate properly?
No
Go to step 9.
Inspectthe stop
light system.
So to step 3.
Is there poor contact in key
lock circuit?
Go to step 4.
Repair poor con-
tact.
Go to step 5.
Go to step 6.
Go to step 7.
Replacethe shift
locksolenoid.
Replacethe shift
locksolenoid.
Replacethe inte-
grated module.
CS-15

AT SHIFT LOCK SYSTEM
CONTROL SYSTEMS
3. SELECT LEVER SHIFT LOCK CANNOT BE RELEASED
WIRING DIAGRAM:
STOP LIGHT
SWITCH
INHIBITOR
SWITCH
I
A: @
B: @ INTEGRATEDMODULE
I SHIFT LOCK
~
I
SOLENOID
I
B
n
11213]4]516171819110
11~12~13~14]15]16~17~18~19~20
9 10 11 12
m
TR0553
CS-16

I
AT SHIFT LOCK SYSTEM CONTROL
SYSTEMS
~ ~
Step
CHECK INHIBITOR SWITCH.
1)Turnthe ignitionswitch to ON (engineOFF).
2)Movethe select lever from
“P” to “1” range.
CHECK HARNESSBETWEENINHIBITOR
SWITCH AND INTEGRATEDMODULE.
1)Turnthe ignitionswitchto OFF.
2)Disconnectthe connectortransmissionhar-
nessand intgratedmodule.
3)Measure the resistanceof harnessbetween
integratedmoduleand chassisground.
(6280) No. 5 - Chassisground:
CHECK HARNESSBETWEENINHIBITOR
SWITCHAND INTEGRATEDMODULE.
Measurethe resistance of harnessbetween
integratedmoduleand inhibitorswitch.
Connector & terminal
Connector
& terminal
(612)
NO. 3 - (6280) NO. 5:
CHECK HARNESSBETWEENINHIBITOR
SWITCH AND CHASSISGROUND.
Measurethe resistanceof harnessbetween
integratedmoduleand chassisground.
(612) No. 4 - Chassisground:
CHECK INHIBITOR SWITCH.
1)Movethe select lever to “Pposition.
2)Measurethe resistanceof transmissionhar-
nessconnectorterminals.
Connector & terminal
Connector
& terminal
(T3) NO. 3 - NO. 4:
CHECK OUTPUT SIGNAL FOR INTEGRAT-
ED MODULE.
1)Connectall connectors.
2)Turn the ignitionswitch
to ON.
3)Measurethe voltage betweenintegrated
moduleand chassisground.
Connector & terminal
(6280)
No. 5 (+) - Chassisground (-):
CHECK STOP LIGHTSWITCH.
Depressthe brake pedal.
CHECK HARNESSBETWEENSTOP LIGHT
SWITCH AND AT SHIFT LOCK CONTROL
MODULE.
1)Depressthe brake pedal.
2)Measurethe voltage betweenintegrated
moduleandchassisground.
Connector & terminal
(6280)
No. 9 (+) - Chassisground (-):
CHECKHARNESSBETWEENINTEGRATED
MODULEAND SHIFT LOCK SOLENOID.
1)Turnthe ignitionswitch to OFF.
2)Disconnectthe connectorfrom shift lock
solenoidand integratedmodule.
3)Measurethe resistanceof harnessbetween
integratedmodule and shift lock solenoid.
Connector & terminal
(6281)
NO. 9 - (61161 NO. 4:
Check
;ombination meter indicator
amp and select lever“P,
“R”,
IN”, “3, “2 and “1” are cor-
.ectlymatched?
s the resistancelessthan 1
n?
s the resistancemorethan 1
WR?
s the resistancelessthan 1
n?
s the resistancemorethan 1
wn?
Is the voltage between 9 and
16 V?
Does the stop light turn on?
Is the voltage morethan 9 V?
Is the resistancemorethan 1
MR?
Yes
Go to step 2.
Repairshortcircuit
in harness
betweeninte-
gratedmoduleand
transmissioncon-
nector.
Repairopencircuit
in harness
betweeninte-
gratedmoduleand
transmissioncon-
nector
Go to step 5.
Repairor replace
inhibitorswitch.
Go to step 7.
Go to step 8.
Go to step 9.
Repairopencircuit
in harness
between inte-
gratedmoduleand
shift locksolenoid.
No
4djust inhibitor
;witch and select
:able.
30 to step 3.
30 to step 4.
Sepairopencircuii
n harness
2etween inte-
Jratedmoduleand
:hassis ground.
30 to step 6.
30 to step 15.
Inspectstop light
iystem.
Repair open or
shortcircuitin har,
ness betweeninte
gratedmoduleana
itoplightswitch.
Go to step 10.
CS-17

AT SHIFT LOCK SYSTEM
I
CONTROL SYSTEMS
Step
IO CHECK HARNESSBETWEENINTEGRATEC
MODULE AND SHIFT LOCK SOLENOID.
Measurethe resistanceof harnessbetween
shift lock solenoidandchassis ground.
Connector & terminal
(6281)
No. 9 - Chassisground:
CHECK HARNESSBETWEENSHIFT LOCK
SOLENOIDAND CHASSISGROUND.
Measurethe resistanceof harnessbetween
shift locksolenoidand chassis ground.
I1
Connector & terminal
12 CHECK SHIFT LOCK SOLENOID.
(61 16) No. 5 - Chassisground:
Measurethe resistanceof shift lock solenoid
connectorterminals.
Terminal
NO. 4 - NO. 5:
13 CHECK SHIFT LOCK SOLENOID.
Connectthe batterywith shift locksolenoid
connectorterminal andoperate solenoid.
Terminal
-.. . . NO. 4 (+) - NO. 5 (-)I
14 CHECK OUTPUTSIGNAL FOR AT SHIFT
LOCK CONTROL MODULE.
1)Turnthe ignitionswitchto ON (engine OFF).
2)Measurethe voltage betweenintegrated
moduleand chassis ground.
Connector & terminal
(6281)
No. 9 (+) - Chassisground (-)I
5 CHECK POOR CONTACT.
Check
Is the resistance less than 10
R?
Is the resistancelessthan 1
n?
Is the resistancebetween 10
and 20 R?
Is shift locksolenoidoperating
properly?
Is the voltage morethan 8.5 V?
Is there poorcontact in key
lock circuit?
Yes
Go to step 11.
Go to step 12.
Go to step 13.
So to step 14.
30 to step 15.
3epair poorcon-
act.
No
Repairshortcircui
in harness
between inte-
gratedmodulean(
shift locksolenoid
Repairopencircui
in harness
betweenshift lock
solenoidand chas
sis ground.
Replacethe shift
locksolenoid.
Replacethe shift
locksolenoid.
Replacethe inte-
gratedmodule.
Replacethe inte-
grated module.
CS-18