ON-CAR SERVICES SUBARU. 1992 SERVICE MANUAL Seepxomauna . Idle Compensetor .. Foreword . Ignition Timing Engine Idle Spee Engine Compression Intake Manifold Vacuum . Hydraulic Lash Adjuster. Fuel Injector ... 2-2 A 98 2 2 3 3 4 5 6 7 8 9ON-CAR [0100] 1, Foreword ‘This chapter describes major inspection and service procedures for the engine mounted on the body. For procedures not found in this chapter, refer to the ser- vice procedure section in the appli le chapter. 2. Ignition Timing ‘A: INSPECTION 1, 2200 cc MPFI, 2000 ce MPFI NON-TURBO AND 1800 cc SPFI 1) Warm up the engine. 2) Confirm that the idle switch is ON. nition timing, connect a timing light to lug cord, and illuminate the timing mark with the timing light. SERVICES 3. 1800 ce CARBURETOR AND 1600 ce CARBU- RETOR 1) Warm up the engine. 2) Ensure that vacuum hose is properly connected to distributor vacuum advancer. 3) To check the ignition timing, connect a timing light to #1 cylinder spark plug cord, adjust the engine idle speed to the specification and illuminate the timing mark with the timing light. Ignition timing [BTOC/rpm]: 1800 cc Cerburetor 20° 5*/800 1600 ce Carburetor 20° 5*/900 Ignition timing [BTDC/rpm|;: 2200 co MPFI 23° 10°/800 2000 ce MPF1 NON-TURBO 23° 10°/800 1800 cc SPFI 20° 10°/860(MT) 20° 10°/800{AT) Ignition timing can be observed using select monitor. (Function mode “FO7") 2. 2000 ce MPFI TURBO 1) Warm up the engine. 2) Confirm that the idle switch is ON. 3) Connect “Select Monitor” and observe ignition tim- ing. (Funetion mode “FO7") Ignition timing [BTDC/rpm]: 2000 ce MPFI TURBO. 18° 10°/900 B: ADJUSTMENT 1, 2200 cc MPFI, 2000 cc MPFI (TURBO AND NON-TURBO) AND 1800 ce SPFI If the timing is not correct, check the ignition control ‘system. (Refer to "2-7 Fuel Injection System”.) 2, 1800 cc CARBURETOR AND 1600 cc CARBU- RETOR 1). Loosen the 8 mm bolts) securing distributor. 2) Turn the distributor housing. The timing is advanced when the distributor housing is turned clockwise and is, tetarded when turned counterclockwise. 3) Tighten the bolt(s) and make sure that the timing is correct. Fig. 2 4) Adiust the engine idle speed.ON-CAR SERVICES 3. Engine Idle Speed A: INSPECTION 1. EXCEPT 2000 cc MPF! TURBO 1) Before checking idle speed, check the following: (1) Ensure that air cleaner element, is free from clogging, ignition timing is correct, spark plugs are in good condition, end that hoses are connected prop- erly. (2) Ensure that CHECK ENGINE light is off (Except 1800 ee Carburetor and 1600 cc Carburetor models). 2) Warm up the engine. 3} Attach the pickup sensor on tachometer (Secondary pickup type} to #1 plug cord, ‘The ignition system of the 2200 ce MPF! model pro- vides simultaneous ignition for #1 and #2 plugs. It must be noted that some tachometers may register twice thet of actual engine spood. isocondary pickup type} 82.209 Fig. 3 4) Check idle speed when unloaded (with headlights, heater fan, rear defroster, radiator fan, air conditioner, etc, OFF). Idle speed (No load and gears in neutral position): 2200 cc MPFI 800 + 100 rpm 2000 cc MPF! NON-TURBO 800: 100 rpm 11800 cc SPFI 850 + 100 rpm (MT) 800 + 100 rpm {AT} 1800 cc Carburetor 800+ 50 rpm 1600 cc Carburetor 900 50 rpm 8. Ifidle speed is outside specifications, refer to Gen- eral Troubleshooting chart under “2-7 Fuel Injection System” (MPF! and SPFI model), or “1-5 Periodic Maintenance Services” (Cerburetor model). b. On MPFI and SPFI models, engine speed can be observed using select monitor (Function mode “F04). [04a0)_2-2 2. 2000 cc MPFI TURBO 1) Before checking idle speed, chock the following: (1) Ensure that air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and that hoses are properly con- nected. (2) Ensure that CHECK ENGINE light is off. 2} Warm up the engi 3) Connect “Select Monitor” and observe engine rpm. (Function mode “F04”) 4} Check idle speed when unloaded (with headlights, heater fan, rear defroster, radiator fan, air conditioner, ote. OFF). Idle speed (No load and gears in neutral position): 2000 cc MPFI TURBO 900 + 100 rpm If ic speed is outside specifications, refer to General Troubleshooting chert under “2-7 Fuel Injection System”. 4. Engine Compres: A: MEASUREMENT 1) After warming up the engine, turn off the ignition- starter switch, 2) Make sure that the battery is fully charged. 3) Remove all ignition coils. (TURBO model only) (Refer to “6-1 Ignition coil [W5A2]") 4) Remove all the spark plugs. 8) Disconnect connectors from fuel injector. 6) Fully open the throttle valve. 7) Check the starter motor for satisfactory performance and operation, 8) Crank the engine by means of the starter motor, and read the maximum value on the gouge when the pointer is steady. Hold the compression gauge tight egainst the spark plug hole, 9) Perform at least two measurements per ¢ and make sure that the values are correct. der,[05A0} ON-CAR SERVICES ‘Compression {200 — 300 rpm end fully open throttle): ‘Standard 2200 ce 1,079 — 1,275 kPa (11.0 — 13.0 kg/om*, 166 — 185 psi) 2000 cc NON-TUREO 4,079 — 1,275 kPa (11.0 — 13.0 kg/em*, 156 — 185 psi) 2000 cc TURBO 981 — 1,177 kPa (10.0 — 12.0 kg/em?, 142— 171 psi 1800 ce 981 — 1,177 kPa {10.0—12.0 kg/em?, 142 — 171 psi) 1600 ce 883 — 1,079 kPa (9.0 —11.0 kg/em*, 128 — 156 psi) Limit 2200 co 883 kPa (9.0 kg/em*, 128 psi) 2000 oc NON-TURBO 883 kPa (9.0 kg/cm’, 128 psi) 2000 ce TURBO 834 kPa (8.5 kg/om?, 121 psi) 1800 co ‘785 kPa (8.0 kg/cm?, 114 psi) 1600 cc {686 kPa (7.0 kg/em*, 100 psi) Difference between oylinders /em?, 28 psi) Fig. 4 Fig. 5 5. Intake Manifold Vacuum A: MEASUREMENT 1) Warm up the engine. 2) Disconnect the vacuum hose and install the vacuum gauge to the hose fitting on the manifold. 3) Keep the engine at the idle speed and read the vac- uum gauge indication. By observing the gauge needle movement, the internal condition of the engine can be diagnosed as desoribed in Table below. Vacuum pressure (at idling) 2200 ce MPFI ‘More then ~ 66.7 kPa (500 mmHg, ~ 19.69 inHg) 2000 cc MPFI NON-TURBO ‘More than - 69.3 kPa {520 mmHg, ~ 20.47 inHg) 2000 ce MPFI TURBO More than - 66.7 kPa {- 800 mmHg, ~ 19.69 inHg) 1800 ce SPFI More thon - 60.0 kPa (- 450 mmHg, - 17.72 inHg) 1800 cc Corburetor More thon - 58.7 kPa {440 mmHg, ~ 17.32 inHg) 11600 cc Carburetor More than ~ 58.7 kPa {- 440 mmHg, ~ 17.32 inkig)ON-CAR SERVICES Diagnosis of engine condition by {06A0] 2-2 Teasuroment of manifold vacuum ‘Vacuum gauge indication Possible engine condition 1. Neodio ie steady but lower than normal pos ‘Ths tendency becomes more evident a8 engina temper . Leakage around intake marifold gasket or throttle chamber gasket. 2, When engine speed is reduced slowly from higher speed, need! stops temporarily when iti lowering or becomes steady abr ‘normal postion. Back pressure too high, or exhaust muffler clogged. 3, Needle intermittently drops 19 position lower than normal positior Leakage around oylinder. 4. Needle drops suddenly and intermittently from normal position, Sticky valves, ‘5. When engine speed is gradually increased, noodlo bogint vibrate rapidly at certain speed, and then vibration incroa {engine speed increases. Weak or broken valve springs. 6. Needle vibrates above and below normal postion in narrow Defective ignition system or throttle chamber idle adustment (MPFI}| 6. Hydraulic Lash Adjuster {SOHC model) A: INSPECTION 1) Disconnect blow-by hose. 2) Remove plug cap. 3) Disconnect connectors from fuel injectors. Fig. 7 4) Remove left and right rocker covers. Before removing left rocker cover, disconnect engine harness connector, battery cables and alternator cable. 5) Manually push valve rocker (at lash adjuster loca- tion) to check that there is no air in it. When sir is in lash adjuster, valve rocker moves when pushed with fingers. Fig. 8 6) {f air is in lash adjuster, remove valve rocker ASSY from engine and bleed air completely.REPEC ET? (Ov ON-CAR SERVICES i BLEEDING AIR FROM VALVE LASH ‘ADJUSTER 41) Remove valve rocker ASSY. Fig. 9 2) Manually remove lash adjusters where air is trapped. If lash adjuster is difficult to remove manually, use pli- ers. Be careful not to scratch lash adjuster. 3) Insert lash adjuster into OIL SEAL GUIDE as shown, and fill OIL SEAL GUIDE with engine oil. Using a 2 mm (0.08 in) dia. rod, push check bal Engine oi B Push check bail Olt seat. GUIDE 1499697000) Hydraulic lh edjuter Beets Fig. 10 4) With check ball pushed in, push plunger at an inter- val of one second. 5) Move plunger up and down until air bubbles are no longer emitted from lash adjuster, 6) Remove the rod. Push plunger to ensure that ir is completely bled out. If plunger does not properly lock (when pushed), replace lash adjuster with a new one. 7) Fill rocker arms oil reservoir with en install lash adjuster, Do not rotat installation. 8) Temporarily and equally tighten bolts @through @. Do not allow dowel pin to catch valve rocker ASSY. cil and lash adjuster duri e024] Fig. 17 9) Tighten bolts @through to specified torque. 10) Tighten bolts Mthrough @to specified torque. 11) Install rocker covers. 12) Connect harness connectors, hoses, etc. to their positions. 7. Fuel Injector (MPFI model) 1) Fuel pressure elimination (1) Disconnect fuel pump connector. (2) Start engin (3) Run engine until it stalls. (4) After it stalls, crank starter for approximately 5 seconds and tum ignition switch to “OFF”. 2) Remove spark plug caps. 3) Disconnect connector from fuel injector. 4) Remove fuel injector cover. Fig. 12 5) Extract while turning fuel injectors.ON-CAR SERVICES Fig. 13 2, Do not attempt to pry injectors with » screwdriver or similar tool. Do not pinch injector pin with pliers. b, Be careful not to damage O-ring. ©. If injector Is difficult to remove with your hand, remove injector and fuel pipe as a unit, and push injec- tor out from the back side, q 6) To install, reverse order of removal procedures. 8. Oxygen (O,) Sensor A: REPLACEMENT Oxygen (0,} sensor is one of the importent emission control parts. Therefore, replace it as follows only when itis damaged by external force, or if it seems to be out of order according to troubleshooting etc. 1. 2200 cc MPFI CATALYST, 2000 cc MPFI NON- TURBO AND 1800 ce SPF MODEL REMOVAL 1) Disconnect O, sensor cord. 2) Apply SUBARU CRC (004301003) or its equivalent to threaded portion of oxygen (0;) sensor, and leave it for ‘one minute or more. 3) Loosen oxygen (0;) sensor by turning it 10 to 40 it | tool (SOCKET: 498990110} and socKer (499990110) e218 fosaz}_ 2-2 4) Apply SUBARU CRC (004301003) to threaded por- tion of oxygen (0,) sensor again, and leave it for one minute or more 5) Remove oxygen (0,) sensor by using socket and wrench. ‘When removing, do not force oxygen (O,) sensor aspe- cially when exhaust pipe is cold; otherwise it will dam- ‘age the exhaust pipe. INSTALLATION 1) Apply anti-seize compound (“SS-30” made by JET- LUBE Inc. in U.S.A. or its equivalent) only to threaded portion of oxygen (O,) sensor to make the next removal easier. Never apply anti-seize compound to protector of oxy- gen {O,) sensor. 2) By using socket and torque wrench, install oxygen {O,) sensor onto front exhaust pipe by tightening it to ‘the specified torque. Torque [oxygen (0,} sensor]: 25 — 34 Nem (2.5 — 3.5 kg-m, 18 — 25 ft-lb) 3) Securely connect oxygen (0,) sensor cord. 2, 2000 cc MPFI TURBO MODEL REMOVAL 1) Disconnect 0, sensor cord, 2) Apply SUBARU CRC (004301003) or its equivalent to, threaded portion of oxygen (O,) sensor, and leave it for ‘one minute or more. if 3) Loosen oxygen {O;) sensor by turning it 10 to 40 degrees, SZ \ Oxygen (0, stor s2sia| Fig. 15 4) Apply SUBARU CRC (004301003) to threaded por- tion of oxygen (O,} sensor again, and leave it for one minute or more, 5) Remove oxygen (0,} sensor, When removing, do not force oxygen (0,) sensor espe- lly when exhaust pipe is cold; otherwise it will dam- age the exhaust pipe.[0941] INSTALLATION 1) Apply anti-seize compound (“SS-30" made by JET- LUBE Inc. in U.S.A. or its equivalent) only to threaded portion of oxygen (0;) sensor to make the next removal easier. Never apply anti-seize compound to protector of oxy- gen (03) sensor. 2) By using torque wrench, install oxygen (O,) sensor ‘onto center exhaust pipe by tightening it to the speci- fied torque. ‘Torque [oxygen {O,) sensor]: 25 — 34 Nem (2.5 —3.5 kg-m, 18 — 25 ft-lb) 3) Securely connect oxygen (O;) sensor cord. 9. Hot Air Control System [Car- buretor model (Except G.C.C. model)] INSPECTION 1. HOT AIR CONTROL SYSTEM. Inspect the hot air control system periodically as fol- lows: In warm weather, itis difficult to find out malfunction of the hot air contro! system. in cold weather, however, malfunction of the air control valve due to disconnec- tion or deterioration of the vacuum hose between the intake manifold and vacuum motor and insufficient durability of the air control valve will cause insufficient automatic control operation for intake air, and result in engine disorders: 1) Stall or hesitation of engine operation, 2) Increase in fuel consumption, and 3) Lack of power. ‘These phenomena reveal malfunction of hot air control system. If these phenomena should occur, check the hot sir control system for the following items before carrying out inspection of the carburetor. ON-CAR SERVICES (5 ‘Ate intake duct ‘Vacuum motor Ait control valve “Ferperature sensor Ae intake hose Exhaust pipe \Vecuum hose Intake manifold Carburater Fig. 16 2. VACUUM HOSES Check each hose for cracks and proper connections. 3. VACUUM MOTOR stopped, remove air intake duct, 1) With the en and check to 5% position. ‘The air control valve is in correct position if its under hood air inlet is Open and hot air inlet is closed. Check the condition of the air control valve - 2) Disconnect the vacuum motor inlet vacuum hot ‘and connect another hose to the inlet to apply vacuum to the vacuum motor. Vacuum can be applied by suck- ing at the hose end. Check to see if the air control valv correct position. { Solel iectast cia estesON-CAR SERVICES ion of the sir control vaive is the reverse of that described in 1) above. The air control valve is in correct position if the under hood air inlet is closed, and ‘the hot air inlet i yen. 3) With the hot air inlet in open position, as described in 2), pinch the vacuum hose with fingers so that the ai does not enter the vacuum motor. In this condition, {010B0] 2-2 check that the air control valve maintains the condition described in 2} for more than 30 seconds, and that the hot air inlet is open. If the diaphragm spring actuates the air control valve by its spring force to open the under hood air inlet within 30 seconds, replace the vac- uum motor as an ASSY since this may have resulted from air leak at the vacuum motor diaphragm. ‘Operation of air control valve end sensor valve A tompertre ecuum on vacuum mot de | i cont vate operation | Sngor ave operation Selon 205 80 mee 38% | aiaon Below 22°C (72°F) Closed TAoow Hwa TOmmne, | ygpaveameacn cebiena as 7 San ae al Roe 6 18H = God edinion oom 4, TEMPERATURE SENSOR Check temperature sensor for proper function by pro- ceeding as follows. Be sure to keep the engine cold before starting this test, 1) With the engine stopped, check the position of the air control valve. In this case, underhood air inlet should be open. Use a mirror for inspection as 3-1). 2) Start the engine and keep it idling. Immediately after engine starting, check the air control valve for correct position as described above. In this case, the correct Position of the air control valve is the reverse of 4-1); the underhood air inlet is closed, and the hot air inlet is open. 3) Check that the air control valve gradually moves to open the underhood air inlet as the engine warms up. ‘When the environmental temperature around the tem- perature sensor is low, spend more time for engine warming up operation to facilitate smooth operation of the air contro! vaive. 5, RUBBER PLATE Check the rubber plate for stickiness. 6. AIR INTAKE HOSE Check the air intake hose for damage and its connec- tions for leaks. 10. Idle Compensator (Carbure- tor model) ‘A: FUNCTION The idle compensator detects temperature of the intake air and, when the air temperature is high, it draws part of outside air directly into the intake manifold, thereby preventing air-fuel mixture from becoming rich and improving combustion characteristics at idle engine idle compensator Bimetat Fig. 18 B: INSPECTION Check whether vaive opens when idle compensator of air cleaner case is heated by a hair drier or the like. Check if vaive is in closed position with temperature under 60°C (140*F).