Subaru 2001 Impreza Service Manual
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Subaru 2001 Impreza Service Manual

Subaru 2001 Impreza Service Manual

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2001 IMPREZA SERVICE MANUAL
TRANSMISSION SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
CONTROL SYSTEMS
AUTOMATIC TRANSMISSION
AUTOMATIC TRANSMISSION
(DIAGNOSTICS)
MANUAL TRANSMISSION AND
DIFFERENTIAL
CLUTCH SYSTEM
CS
AT
AT
MT
CL
G1830GE4

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  • Page 1 2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX TRANSMISSION SECTION CONTROL SYSTEMS AUTOMATIC TRANSMISSION AUTOMATIC TRANSMISSION (DIAGNOSTICS) MANUAL TRANSMISSION AND DIFFERENTIAL This service manual has been prepared to provide SUBARU service personnel CLUTCH SYSTEM with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.

  • Page 2: Table Of Contents

    AUTOMATIC TRANSMISSION Page General Description ..................2 Automatic Transmission Fluid ..............9 Differential Gear Oil...................11 Road Test....................12 Stall Test ....................13 Time Lag Test ...................15 Line Pressure Test ..................16 Transfer Clutch Pressure Test ..............18 Automatic Transmission Assembly ............19 Transmission Mounting System ..............25 Extension Case Oil Seal ................27 Inhibitor Switch..................28 Front Vehicle Speed Sensor ..............31 Rear Vehicle Speed Sensor..............34...

  • Page 3: General Description

    GENERAL DESCRIPTION AUTOMATIC TRANSMISSION 1. General Description 4. TRANSMISSION GEAR RATIO A: SPECIFICATIONS Gear ratio 2.785 1. TORQUE CONVERTER CLUTCH 1.545 1.000 Model 1.6 L model 2.0 L model 0.694 Symmetric, 3 element, single stage, 2 Type 2.272 phase torque converter Stall torque 2.2 —...
  • Page 4 GENERAL DESCRIPTION AUTOMATIC TRANSMISSION 6. SELECTOR POSITION 8. COOLING AND HARNESS Transmission in neutral, output member immov- Model 1.6 L and 2.0 L models P (Park) able, and engine start possible Liquid-cooled cooler incorpo- Cooling system rated in radiator Transmission in reverse for backing (Reverse) ATF cooling system (Radi- 4.630 kW (3,981 kcal/h, 15,797...
  • Page 5 GENERAL DESCRIPTION AUTOMATIC TRANSMISSION B: COMPONENT NOTE: For information about other transmission mounting components, refer to “AUTOMATIC TRANSMISSION” <Pub. No. G0853ZE> a separate publication. 1. TRANSMISSION MOUNTING TR0265 Pitching stopper Tightening torque: N·m (kgf-m, ft-lb) Rear bracket (FWD) T1: 35 (3.6, 26) Rear cushion rubber (FWD) T2: 39 (4.0, 29) Rear cushion rubber (AWD)
  • Page 6 GENERAL DESCRIPTION AUTOMATIC TRANSMISSION C: CAUTION • Use SUBARU genuine gear oil, grease etc. or the equivalent. Do not mix gear oil, grease etc. with • Wear working clothing, including a cap, protec- that of another grade or from other manufacturers.
  • Page 7 GENERAL DESCRIPTION AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 498575400 OIL PRESSURE Used for measuring oil pressure. GAUGE ASSY B3M2040 498897200 ADAPTER Used oil pump housing when measuring reverse clutch pressure and line pressure. B3M2041 498545400 FILTER WRENCH Used for removing and installing ATF filter. B3M2042 498277200 STOPPER SET...
  • Page 8 GENERAL DESCRIPTION AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 41099AA020 ENGINE SUPPORT Used for supporting engine. B3M1976 41099AA010 ENGINE SUPPORT Used for supporting engine. BRACKET B3M1975 499977300 CRANK PULLEY Used for stopping rotating of crankshaft pulley WRENCH when loosening and tightening crankshaft pulley bolts.
  • Page 9 GENERAL DESCRIPTION AUTOMATIC TRANSMISSION ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 22771AA030 SELECT MONITOR Troubleshooting for electrical systems. • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) B2M3877 499267300 STOPPER PIN Used for installing inhibitor switch.

  • Page 10: Automatic Transmission Fluid

    AUTOMATIC TRANSMISSION FLUID AUTOMATIC TRANSMISSION 2. Automatic Transmission (4) Fluid temperature rising speed • By idling the engine Fluid Time for temperature rise to 60°C (140°F) with at- mospheric temperature of 0°C (32°F): More than A: INSPECTION 25 minutes 1) Check the level of the ATF. <Reference>...
  • Page 11 AUTOMATIC TRANSMISSION FLUID AUTOMATIC TRANSMISSION Capacity: Fill the same amount of fluid drained from drain plug hole. Capacity when transmission is overhauled: 1.6 L model: 8.0 — 8.3 2 (8.5 — 8.8 US qt, 7.0 — 7.3 Imp 2.0 L model: 8.4 —...

  • Page 12: Differential Gear Oil

    DIFFERENTIAL GEAR OIL AUTOMATIC TRANSMISSION 3. Differential Gear Oil 3) Lower the vehicle. 4) Pour gear oil into the gauge hole. A: INSPECTION Recommended fluid: 1) Park vehicle on a level surface. Use GL-5 or equivalent. 2) Remove oil level gauge and wipe it clean. Gear oil capacity: 3) Reinsert the level gauge all the way.

  • Page 13: Road Test

    ROAD TEST AUTOMATIC TRANSMISSION 4. Road Test A: INSPECTION 1. GENERAL PRECAUTION Road tests should be conducted to properly diag- nose the condition of the automatic transmission. CAUTION: When performing test, do not exceed posted speed limit. 2. D RANGE SHIFT FUNCTION Check shifting between 1st ⇔...

  • Page 14: Stall Test

    STALL TEST AUTOMATIC TRANSMISSION 5. Stall Test 8) Record the stall speed. 9) If stall speed in 2 range is higher than specifica- A: INSPECTION tions, low clutch slipping and 2-4 brake slipping may occur. To identify it, conduct the same test as 1.
  • Page 15 STALL TEST AUTOMATIC TRANSMISSION 3. EVALUATION Stall speed (at sea level) Position Cause • Throttle valve not fully open Less than specifications • Erroneous engine operation • Torque converter clutch's one-way clutch slipping • Line pressure too low • Low clutch slipping •...

  • Page 16: Time Lag Test

    TIME LAG TEST AUTOMATIC TRANSMISSION 6. Time Lag Test A: INSPECTION 1. GENERAL INFORMATION If the select lever is shifted while the engine is idling, there will be a certain time elapse or lag be- fore the shock can be felt. This is used for checking the condition of the low clutch, reverse clutch, low &...

  • Page 17: Line Pressure Test

    LINE PRESSURE TEST AUTOMATIC TRANSMISSION 7. Line Pressure Test 2. TEST METHODS 1) Temporarily attach the ST to a suitable place in A: MEASUREMENT the driver's compartment, remove the blind plug lo- cated in front of the toe board and pass the hose of 1.
  • Page 18 LINE PRESSURE TEST AUTOMATIC TRANSMISSION 4) Check for duty ratio changes by opening and closing throttle valve using Subaru Select Monitor. (1) Insert the cartridge to Subaru Select Moni- tor. <Ref. to AT-5, PREPARATION TOOL, Gen- eral Description.> S2M0286 (2) Connect Subaru Select Monitor to data link connector.

  • Page 19: Transfer Clutch Pressure Test

    TRANSFER CLUTCH PRESSURE TEST AUTOMATIC TRANSMISSION 8. Transfer Clutch Pressure 2. EVALUATION Test NOTE: If oil pressure is not produced or if it does not A: INSPECTION change in the AWD mode, the transfer duty sole- noid or transfer valve assembly may be malfunc- 1.

  • Page 20: Automatic Transmission Assembly

    AUTOMATIC TRANSMISSION ASSEMBLY AUTOMATIC TRANSMISSION 9. Automatic Transmission As- 10) Remove pitching stopper. sembly A: REMOVAL 1) Set the vehicle on the lift. 2) Open front hood fully, and support with stay. 3) Disconnect battery ground terminal. 4) Remove air intake duct. <Ref. to IN(SOHC)-7, REMOVAL, Air Intake Duct.>...
  • Page 21 AUTOMATIC TRANSMISSION ASSEMBLY AUTOMATIC TRANSMISSION 19) Drain ATF to remove ATF drain plug. CAUTION: Plug opening to prevent entry of foreign parti- cles into transmission fluid. B3M1036C (A) Oil pan S2M0908 (B) Drain plug 14) Set ST. NOTE: 20) Disconnect ATF cooler hoses from pipes of Also is available Part No.
  • Page 22 AUTOMATIC TRANSMISSION ASSEMBLY AUTOMATIC TRANSMISSION 25) Remove spring pins and separate front drive 30) Separate transmission assembly and rear shafts from each side of the transmission. cushion rubber. G2M0325 26) Remove nuts which hold lower side of trans- mission to engine. B3M2047 27) Place transmission jack under transmission.
  • Page 23 AUTOMATIC TRANSMISSION ASSEMBLY AUTOMATIC TRANSMISSION B: INSTALLATION 6) Tighten nuts and bolts which hold lower side of transmission to engine. 1) Install rear cushion rubber to transmission as- sembly. Tightening torque: 50 N·m (5.1 kgf-m, 36.9 ft-lb) Tightening torque: 1.6L MODEL: 123 N·m (12.5 kgf-m, 90 ft-lb) 2.0L MODEL: 38 N·m (3.9 kgf-m, 28 ft-lb)
  • Page 24 AUTOMATIC TRANSMISSION ASSEMBLY AUTOMATIC TRANSMISSION 9) Install torque converter clutch to drive plate. CAUTION: (1) Tighten bolts which hold torque converter Always use a new spring pin. clutch to drive plate. (2) Tighten other bolts while rotating the engine by using ST. CAUTION: Be careful not to drop bolts into torque convert- er clutch housing.
  • Page 25 AUTOMATIC TRANSMISSION ASSEMBLY AUTOMATIC TRANSMISSION 18) Install heat shield cover. 31) Check select lever operation. 19) Install front, center, rear exhaust pipes and <Ref. to AT-28, INSPECTION, Inhibitor Switch.> muffler. 32) Check the ATF level. <Ref. to AT-9, Automatic With OBD Transmission Fluid.>...

  • Page 26: Transmission Mounting System

    TRANSMISSION MOUNTING SYSTEM AUTOMATIC TRANSMISSION 10.Transmission Mounting Sys- CAUTION: • Make sure that the support plates of trans- mission jack don't touch the oil pan. A: REMOVAL 6) Remove the crossmember. 1. PITCHING STOPPER 1) Disconnect battery ground terminal. 2) Remove the air intake duct. <Ref. to IN(SOHC)- 7, REMOVAL, Air Intake Duct.>...
  • Page 27 TRANSMISSION MOUNTING SYSTEM AUTOMATIC TRANSMISSION 2. CROSSMEMBER AND CUSHION RUB- 1) Install the rear cushion rubber. Tightening torque: 1.6 L model: 123 N·m (12.5 kgf-m, 90 ft-lb) 2.0 L model: 38 N·m (3.9 kgf-m, 28 ft-lb) 2) Install the crossmember. Tightening torque: T1: 35 N·m (3.6 kgf-m, 26 ft-lb) T2: 70 N·m (7.1 kgf-m, 51.4 ft-lb)

  • Page 28: Extension Case Oil Seal

    EXTENSION CASE OIL SEAL AUTOMATIC TRANSMISSION 11.Extension Case Oil Seal 13) Install the rear exhaust pipe and muffler. With OBD A: INSPECTION <Ref. to EX(SOHC)-11, INSTALLATION, Rear Ex- haust Pipe.> and <Ref. to EX(SOHC)-12, INSTAL- Make sure ATF does not leak from the joint of the LATION, Muffler.>...

  • Page 29: Inhibitor Switch

    INHIBITOR SWITCH AUTOMATIC TRANSMISSION 12.Inhibitor Switch 3) Check if there is continuity at equal points when the select lever is turned 1.5° in both directions A: INSPECTION from the N range. If there is continuity in one direction and the conti- When driving condition or starter motor operation is nuity in the other or if there is continuity at unequal erroneous, first check the shift linkage for improper...
  • Page 30 INHIBITOR SWITCH AUTOMATIC TRANSMISSION C: REMOVAL 9) Remove plate assembly from transmission case. 1) Set up the vehicle on the lift. 2) Move select lever to neutral position. 3) Remove air intake duct and cleaner case. 4) Disconnect inhibitor switch connector. B3M1030H (A) Select cable (B) Plate ASSY...
  • Page 31 INHIBITOR SWITCH AUTOMATIC TRANSMISSION 12) Remove inhibitor switch from transmission. 6) Install plate assembly to transmission. Tightening torque: T: 24.5 N·m (2.50 kgf-m, 18.1 ft-lb) B3M1033B (A) Inhibitor switch B3M1030I 13) Dsiconnect inhibitor switch harness from inhib- itor switch. (A) Select cable (B) Plate ASSY D: INSTALLATION 7) Install snap pin to range select lever.

  • Page 32: Front Vehicle Speed Sensor

    FRONT VEHICLE SPEED SENSOR AUTOMATIC TRANSMISSION 13.Front Vehicle Speed Sensor 8) Remove front, center, exhaust pipes and muffler. With OBD A: REMOVAL <Ref. to EX(SOHC)-7, REMOVAL, Front Exhaust Pipe.>, <Ref. to EX(SOHC)-11, REMOVAL, Rear 1) Set up the vehicle on the lift. Exhaust Pipe.>...
  • Page 33 FRONT VEHICLE SPEED SENSOR AUTOMATIC TRANSMISSION 15) Remove front and rear vehicle speed sensor 17) Disconnect duty solenoids and ATF tempera- and torque converter turbine speed sensor. ture sensor connectors. Remove connectors from clip and disconnect connectors at 9 places. •...
  • Page 34 FRONT VEHICLE SPEED SENSOR AUTOMATIC TRANSMISSION 2) Connect harness connectors at 9 places. 4) Install the oil pan. Connect connectors of same color, and secure Tightening torque: connectors to valve body sing clips. 25 N·m (2.5 kgf-m, 18.1 ft-lb) 5) Install the front and rear vehicle speed sensor, and also the torque converter turbine speed sen- sor, and then fasten the harness.

  • Page 35: Rear Vehicle Speed Sensor

    REAR VEHICLE SPEED SENSOR AUTOMATIC TRANSMISSION 14.Rear Vehicle Speed Sensor A: REMOVAL When removing the rear vehicle speed sensor, re- fer to “Front Vehicle Speed Sensor.” <Ref. to AT- 31, REMOVAL, Front Vehicle Speed Sensor.> B: INSTALLATION When installing the rear vehicle speed sensor, refer to “Front Vehicle Speed Sensor.”...

  • Page 36: Torque Converter Turbine Speed Sensor

    TORQUE CONVERTER TURBINE SPEED SENSOR AUTOMATIC TRANSMISSION 15.Torque Converter Turbine Speed Sensor A: REMOVAL When removing the torque converter turbine speed sensor, refer to “Front Vehicle Speed Sensor.” <Ref. to AT-31, REMOVAL, Front Vehicle Speed Sensor.> B: INSTALLATION When installing the torque converter turbine speed sensor, refer to “Front Vehicle Speed Sensor.”...

  • Page 37: Control Valve Body

    CONTROL VALVE BODY AUTOMATIC TRANSMISSION 16.Control Valve Body 5) Disconnect duty solenoids and ATF temperature sensor connectors. Remove connectors from clip A: REMOVAL and disconnect connectors. 1) Lift-up the vehicle. 2) Clean transmission exterior. 3) Drain ATF completely. NOTE: Tighten ATF drain plug after draining ATF. Tightening torque: 25 N·m (2.5 kgf-m, 18.1 ft-lb) B2M2263J...
  • Page 38 CONTROL VALVE BODY AUTOMATIC TRANSMISSION B: INSTALLATION 5) Apply proper amount of liquid gasket to the en- tire oil pan mating surface. 1) Set the range select lever in “N” position. Fluid packing: 2) Install the control valve and ground earth con- Tree Bond 1217B nectors.

  • Page 39: Shift Solenoids, Duty Solenoids And Atf Temperature Sensor

    SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR AUTOMATIC TRANSMISSION 17.Shift Solenoids, Duty Sole- 6) Remove solenoids, duty solenoids and ATF tem- perature sensor. noids and ATF Temperature Sensor A: REMOVAL 1) Lift-up the vehicle. 2) Clean transmission exterior. 3) Drain ATF completely. NOTE: Tighten ATF drain plug after draining ATF.
  • Page 40 SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR AUTOMATIC TRANSMISSION 7) Raise vehicle and drain ATF. 12) Remove select cable nut. G3M0308 B3M1036B 13) Move gear select cable so that extension bolts can be removed. (A) Oil pan 14) Remove bolts. (B) Drain plug 15) Remove extension case.
  • Page 41 SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR AUTOMATIC TRANSMISSION B: INSTALLATION 3) Apply proper amount of liquid gasket to the en- tire oil pan mating surface. 1) Install solenoids and ATF temperature sensor. Fluid packing: Tightening torque: Tree Bond 1217B T: 8 N·m (0.8 kgf-m, 5.8 ft-lb) B3M1040 4) Install oil pan.
  • Page 42 SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR AUTOMATIC TRANSMISSION 1. TRANSFER DUTY SOLENOID AND 4) Install rear crossmember. (1) Tighten bolts. TRANSFER VALVE BODY Tightening torque: 1) Install transfer duty solenoid and transfer valve body. T1: 35 N·m (3.6 kg-m, 26 ft-lb) (1) Install transfer duty solenoid and transfer T2: 70 N·m (7.1 kg-m, 51.4 ft-lb) valve body.
  • Page 43 SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR AUTOMATIC TRANSMISSION 11) Fill ATF up to the middle of the "COLD" side on level gauge by using the gauge hole. Recommended fluid: Dexron III type automatic transmission fluid Fluid capacity: 1.6 L model; 8.0 - 8.3 L (8.5 - 8.8 US qt, 7.0 - 7.3 lmp qt) 2.0 L model;...

  • Page 44: Atf Filter

    ATF FILTER AUTOMATIC TRANSMISSION 18.ATF Filter C: INSPECTION Replace the part if any defect is found from the in- A: REMOVAL spection. Check for rust, hole, ATF leaks, and other damage. NOTE: The ATF filter is maintenance free. 1) Lift-up the vehicle. 2) Using ST, remove ATF filter.

  • Page 45: Transmission Control Module (Tcm)

    TRANSMISSION CONTROL MODULE (TCM) AUTOMATIC TRANSMISSION 19.Transmission Control Mod- RHD model ule (TCM) A: REMOVAL 1) Disconnect battery ground terminal. TR0327 (A) Transmission control module (B) Column shaft 4) Remove transmission control module. G6M0095 2) Remove lower cover and then disconnect con- B: INSTALLATION nector.

  • Page 46: Atf Cooler Pipe And Hose

    ATF COOLER PIPE AND HOSE AUTOMATIC TRANSMISSION 20.ATF Cooler Pipe and Hose 7) Remove ATF cooler pipe from frame. A: REMOVAL 1) Set the vehicle on the lift. 2) Remove battery and washer tank. 3) Lift-up the vehicle. 4) Remove the under cover. 5) Disconnect ATF cooler hose from radiator.
  • Page 47 ATF COOLER PIPE AND HOSE AUTOMATIC TRANSMISSION B: INSTALLATION 3) Connect ATF cooler hose to pipe transmission side. 1) Install the oil cooler outlet and inlet pipes. NOTE: CAUTION: • Install so that the hose is not folded over, exces- Be sure to use a new aluminum washer.
  • Page 48 ATF COOLER PIPE AND HOSE AUTOMATIC TRANSMISSION C: INSPECTION Repair or replace any defective hoses, pipes, clamps, and washers found from the inspection be- low. 1) Check for ATF leaks in joints between the trans- mission, radiator, pipes, and hoses. 2) Check for deformed clamps.
  • Page 49 ATF COOLER PIPE AND HOSE AUTOMATIC TRANSMISSION AT-48...

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