4-1 {S0A1] SPECIFICATIONS S SPECIFICATIONS 6 4-DOOR SEDAN ae Awo. ‘Awo t md Z is TURE. iTEM ‘SMT™? war aate2 | sMT¢3%6 | 4ATSA"S | AATSZ eurrz | AT? 1, DIMENSIONS [overt Tena ron 50789 Over wich ‘rm a 590 665) Overall height om 1360 638) eee Z 1,095 (43.1] top (Moxs_mm | 098 (48.1 room [rear ‘Com: Min. mm (in) eet Pat [aeag [front mini) am GEo [sie Ba a paa | se nea | oS ea) | WE BEM erent | tom Rear _mm (in) 916 (36.0) 910 (35.8) 910 (35.8) “S10 (35.8) | 910 (35.6) | 915 (36.0) Shoulder [Front rom ip 1375 64.1 room. [Rear mm) 1365 63) eibese ‘oe 2.580 101.8) ee Front enm fn) 186 G77) 7.460 (578) [oa a Teor mm (| Taso 7 Minimum food Garena" mm tn) oc) we 2. WEIGHT "705 (1,555) | 746 (1,640) | 795 (1,746) | 755 (1,665) | 780 (1,728) } 600 (1.775) 805 (1,780) | 840 (1,855) rome eg tel] ee | ee ae | aise nae | 7am | aaa | wae ogden [sears | was | ose | asiors | vase | neo | o.s3sie ao ca | Bus 200) | 505 (12501 ] 600 73207 | 605 (7.390) | 625 (1,980) ] 6 (3.360 | 620.265) eee cea Vmec gta aoe |e ao le mn (elem licorice |e HON eee _ few. cer | cutenes | ose | oators | ozzors | cata | aeser | aso Spa} 1a] aso Piss [tae | waz | laos [180 ust ques} G20) | Garo) | Gee | aoe | cay | ary | uo | zz - 1.225 1,275 1,345 1,310 1,345 4,415 1,410 1,045 eas | leer | sen | doors | esses | eizom | joss | catesrs Front ra 00) 340 (2.085), 350 (205) Roar 49 (8) 305 (665) 715018) Foul to 0) 775 (2.890) 7805 4,0) 1; Models for Canada 22, Thoweight ofthe power door lock, power window, air condoner, cruise contol, ABS, cassete player and sunroo! are included inthe CM, 15: The weight of the povier door lock, power window, ait conditioner, ctuise eontiol and cassette player are included in the CAV. “4; The weight of the power door lock, power window and sic conditionar are included in tha C.W. 5; Models fot Canad, the weight of the poster door lock and power window are included in tne CW. | NOTE: When optional parts are installed, the weight indicated in the following table is added to Curb weight Power door lock Cruise control and Ait conditioner ‘and Aes. Survoot AIRGAG powat window cassette playe _| Front (6) (0) 25 (58) 5110) 14 G0) 2120) i101 Rear kg (to) 206) =21-5) 210) 210 14 (30) 206) Total __kg lo) 215) 23 (80) 5110) 14 (90) 23 (60) 705)SPECIFICATIONS [soas}_ 1-1 al wo ‘AWO v is i 13 TURBO eur [ vant] «at [owner [eat [oar] aar . ENGINE [Enoine woe Herron opposed quid eooled, vince, soko gasoline engine Valve arongemart Oveihead comshat ype Bore % Suoke am tia 96.9% 75 (2.015 x 2.95) Displacement ‘em? {cu in)| 2,212 (134.98) [Compression ao 35 ao Fig odor as eee ; "Jods 100 (No toad) ling speed at N or F poskion rd 860% 50 [Ait conditioner ON} Maxim bat Ww PSiom a0 015.400 760 15600 Maximum torque 130 a tkg-m,felbyepm 186 (19.0, 137] at 4,400 eee ELECTRICAL Tonto ting aiding seed ae 0700 15 700 oa WOK: KAGE) Spare | type and manudactrr IIPPONDENSO: Kz0EPRTS CHAMPION: RC7VE-4 erste BVA Tbe BRAT SSORaLMF/AAT; 76O2ILME eatery [Reset copasiy rin SMT: /4AT: 111 Cold ranking empores ae SMT: 258/4AT: 480 }. TRANSMISSION Chtch ype ve [ote [ve [ow | w | re | cso | re ranamission yoo : *6 7 7 ve | 8 8 = [3 tet Sees [aves [aed [ass [soar | say | aes [2705 and tear t ss [tes fer | tore | teie | tse | 1585 eaaaa |e Tyee L100] 1.000 [166 [1.000 | 1.000 | "1.368 | "1.000 ath aor [ose ose | ore | cess |" asoe |" ova | oo sth ore | — = [ems [7 = — [ons | = Reverse cae [ame | 2am | sae | 22m | az | sae |" 227 Feason |i | woeol o at escal | Hotear | — | Helical | Hetear | — [Hote gear [rodvetion | Gear tio x.c00 | 1.000 000] _t.000 | — | 1.000 from Trin [Typs.t oor | “Hrpeld { Mypoid | wypoid | tec Hypoid | Hypoig | Hypoid | Hypoid Fewtuon [Cnemaie [3700 [ a200 [3700 | etn | 3000 [se00 | 2.000 | .000 Transor [Type of goat 7 teat | — = [eter [= Reduzion easton | eduction [Gear aio si 1000 | =| +.000 [= eae Frnat [type ot eae = Hvpod | Hypo | Hvpsia | Hypois_| Hyped feducton [oar raio = aan [3000 | 3200 | a0 | 2.900 | SPD: Dry Single Plate Diaphragm Te: Torque Corvortet 8; S-lorward speods with eynchromesh and 1-revorse 17; Electronically controled fily-automatic, forward speed "a: S:forward speods with synchvomesh and T-roverso — wi "9: Elecronically controlled fuly-autornatic, forward speads end \1ov ts and 1 fh conter ilterential and viscous coupling ee ith hydraulically controlled transfor kehTack are pinion. Tee) my ‘rns, Jock 19 tock Frirmum tutsing ciclo "wall to wall mith Mabie cud = 10.2635) “SUSPENSION Thocprerson srt tyBe, NASON. ‘ol pring st Hp ndependent CO SPU cape surpended power Unit rie wi brake 79s/60Rt5 87H, resy70814 OTH 20 1159, 132) -Franarasion geet OH CtUs a. imp at Taxomate wansmiion uid “EHUS a imp i atterortial goat ol (Cus at imo Find vat Gtforerial goat 10S. emp Foner woatng td “us qe ion a | 70 (74,82) Engine coolant ‘equs at. tne otSPECIFICATIONS _ sr cinncTIONS B: STATION WAGON a a) ro wo. 7 7 i tT ig rem ‘SMT 4AT BAT ‘SMT “4AT @aTe2 4. DIMENSIONS [overan Jength rom (in| 4,620 (181.9) a im “a ral height ‘men (in) 1,300 (54.7) [1.430 (86.3) 1 Feo 590 (35.04 | Front sai a wma | ew, ear — nm (int 960 (37.8), a5 (364) 360 (7.8) [25 20.4) ene | Frm peem oe pala ies 62 ine en 185 (683) teva et woe co - oe 1 ran [2 Seats ex it 1265 63.7) som rae Wess i aaa ron ie Freee oT mami Fon om aa [ena od dence mea ee ‘estes | 2. WEIGHT — = | es De. [ane Las, | aie bid 690 (1,515)"1_|_725 (1,500)"1__|_778 (1.705)"4 690 (1,615)"1 | 740 (1,630) | 795 (1,750)°4 en eta ee ea cao, | enciaia, | aU, | esi | storuioom | em aore pen Sena | aero, | aoe, [ann |daisaae [ee dine ca (ID}| 4 35 (2,830)"1 | 1,330 (2,990)°1 7,390 (3,060)"4 | 1,285 (2,830) 4,400 (3,090)*1 | 1,470 (3,240)* 7 Front Yo) 5 (2018) TS ronal [Beart 380 (2.115) 990 2.300) eel aT EEC “Twos Gunde, a wel tte per doo ard poe window seine nthe “Moana rt ep rt nana coe Bs eet nea teint Fn eee incon ewe wih TE Mate fr care NOTE: When optional parts are installed, the weight indicated in the following table is added to Curb weight. Tower doe ook ci era 220) ny conaionn | aa 0s sumoot | AIROAS sewer into casei inet fox a8 7m 510) rE a Fm foots i 2 Sea 3) 20) 7a 2 Saisie 2) 760 518 188 en TC}garden peed at Nor F postion aie TOFU Nem (egee, fEIEIOM ELECTRICAL 20" at 700 BKREETY Fron ing tna SPOS ‘BTocuom| 3 WOK: BREE pPONDENSO: K2OEPALVT FIANPION: RCTYE ar ean METAR. SOLE ‘Se; QB6/4AT: 480 ‘p9PD: Dry Single Pate Diaphves™ Fer Torque Converter Tes Tern gence wth syne ernes and Yeverse "5 Soma Sy cooled filer ord speeds and Nevers Erecorg spews wih SYREN ES pee arSeuoe aera and Veer coupling Tr Efeicay cored Wa afer orm acai ond Weoverse — Wal viauicay eoroed wransiot ‘euchmana aiast Tana SPECIFICATIONS {soB10} 1-1 ma fs os is T Ts Tew oat wa “at ar war AT 6. STEERING Tee at aa = i 7 mine ee, fate Curb to curb ... 10.2 (33.5) ee E 7, SUSPENSION i Frost ‘Macpherson strut type. Independent eee tt ear ie meee a Sacha ia or a 8, BRAKE eae on eam pas 9. TIRE = re 10. CAPACITY witb Engine ___C(US at ime ath iaaiencise om ‘Lower level (US at Imp at) aelara rae oo OTe Tonto fieamoc|_ob38 |) ta | all aaa tia | ebta | “€(US gt Imp atl paste (US at Imp at) le Dee agin To aed +3; Preumatic suspension with height contro!QUICK REFERENCE INDEX 2) ENGINE SECTION ronal € SUBARL. Saag AND VACUUM FITTING 1992 eR Ee) aad SERVICE MANUAL Pe oa Be aU ae UES aT es ae eee ia Fda) FOREWORD es * Ps Ps co) This service manual has been prepared to pro- fav ame Seno S01) Pod vide SUBARU service personnel with the neces- sary information end data for the correct mainte- nance and repair of SUBARU LEGACY. FUEL SYSTEM Poe) This manual include the procedures for mainte- nance disassembling, reassembling, inspection and adjustment of components and trouble. EXHAUST SYSTEM td ting for guidance of both the fully qualified the less-experienced mechanics. lease peruse and utilize this manual fully. to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum ONE ae ne clei cel) 2-10 condition. When replacement of parts during re- MOUNTING SYSTEM 2a Dair work is needed, be sure to use SUBARU genuine parts. Al information, illustration and_ specifications TRANSMISSION AND contained in this manual are based on the latest DIFFERENTIAL SECTION product informetion available at the time of pub- lication approval Torn 7 Evita y Ne soy FUJI HEAVY INDUSTRIES LTD. Pr taahiaeas aed Ea Al sight reserved. This book ray net be repro- ee MOS Rr ee Mcoacd wwiten permission of FU! HEAVY INDUSTRIES LTD, TOKYO JAPAN. suBKAUCEDand @ are trademarks of FUJEHEAVY INDUSTRIES LTD. r 4 ‘opyright 1991 FUJI HEAVY INDUSTRIES LTD. AWD SYSTEM 3-4SL IMPORTANT SAFETY NOTICE Providing appropriate service and repair is a matter of great importance in the serviceman’s safety maintenance and safe operation, function and performance which the SUBARU vehicle possesses. In case the replacement of parts or replenishment of consumables is required, genuine SUBARU parts Whose parts numbers are designated or their equivalents must be utilized. It must be made well known that the safety of the serviceman and the safe operation of the vehicle would bbe jeopardized if he used any service parts, consumables, special tools and work procedure manuals which are not approved or designated by SUBARU. How to use this manual 1. GENERAL 1» This Service Manual is divided into six volumes by section so that it can be used with ease at work, Refer to the Table of Contents, select and use the necessary section. # Each chapter in the manual is basically made of the following five types of areas. M: Mechanism and function S : Specification and service date © : Component parts W : Service procedure (X 3 Service procedure) (Y : Service procedure) T : Troubleshooting ‘The description of each area is provided with four types of titles different in size as shown below. The Title No. ‘or Symbol prefixes each title in order that the construction of the article and the flow of explanation can be easily understood. [Example of each title] © Area title: W, SERVICE PROCEDURE (one of the five types of areas) © Large ttle (Heading): 1. Oil Pump (to denote the main item of explanation) * Medium title (Section): A. REMOVAL {to denote the type of work in principle) © Smal title (Sub-section}: 1. INNER ROTATOR {to denote a derivative item of explanation)c eG © The Title Index No. is indicated on the top left (or right) side of the page as the book is ‘opened. This is useful for retrieving the necessary portion. (Example of usage) Refer to2-4[W1B4] Area litle Large title Medium litle- Area title Ee Smali title (Sub-section) Medium titie (Section) Large title (Heading) Chapter No. Example of title placement owt TaoT iW SERVICE PROCEDURE (1.General ‘A: PRECAUTION When servicing clutch system, pay stention to the following items. 1) Check the routing of clutch eabie for smoothness, 2) Excessive tighteness of looseness of clutch cable havo a bad influence upon the cable durability. 23) Apply greate suiciently 10 the connecting portion of elutch pedal 4) Apoly grease sulficiently to the release lever portion. 5) Position clutch cable through the center of tovboatd role ‘Adinetment ie done by © In this manual, the following symbols are used. 4 | :Should be lubricated with oil Should be lubricated with grease. CLUTCH mal title 2RELEASE LEVER) Cheek lever pivot por the point of contact with holder for wear, 2.Release Bearing and Lever ‘A: REMOVAL, Sealing point (-) fa Tightening torqueTABLE OF CONTENTS (i) GENERAL SECTION [ ENGINE SECTION 1-1 Specifications Td ke AR 3 General Information 4 Pre-Delivery Inspection Periodic Maintenance Services Special Tools 71 Emision Control System and Vacuum Fitting } 242 On-Car Services | 2-3 Engine 2-4 Engine Lubrication System 2-8 Engine Cooling System Db tee eee eee 2-1 Fuol Injection Systern 2-8 Fuel System 2-8 Exhaust System 2-10 Clutch 2-11. Engine and Transmission Mounting System @ TRANSMISSION AND DIFFERENTIAL SECTION 3-1 Manual Transmission and Differential 3-2 Automatic Transmission and Differential 3-3. Transmission Control System 3-4 AWD System “Sugpension iiesleiand Axles. steering System Brakes Pedal System and Control Cables Hoater and: Ventilator “Air Conditioning System " Body and Exterior ‘Doors and Windows Seats, Seat Belts, and Interior Instrument Panel Supplemental Restraint System Engine Electrical System Body Electrical System Wiring Diagram and Trouble-shootingEMISSION CONTROL SYSTEM AND VACUUM FITTING 2- 1 SUBARU. 1992 SERVICE MANUAL 1. System Application 2. Schematic Drawing 3. General Precautions 4. Crankcase Emission 5. Three-way Catalyst 6: AVF Control System 7. Ignition Control Syst 8. Evaporative Emission Contr: 9. Vacuum Fitting2-1 10700] EMISSION CONTROL SYSTEM AND VACUUM FITTING 1. System Application There are three emission control systems which are as ps ¢€ ‘cate emission control sytem € dust emission control system ¢ Three-way catalyst system © AFF control system © Ignition control system 3} Evaporative emission control system ‘Main components Funetion Crankcase emission contol system Pov valve ‘Draws blow-by gat Into intake manifold from crankcase ‘and burns it together with aitfusl mixture, Amount of blow-by gas to be. drawn in is controle by intake manifold vacuum pressure. Exhaust emission control system Front Oxidizes HC and CO contained in exhaust gases as welll as. caver aim [EE roee-nay cna] ideas Ca ocaves put aigrals Tom Vavous sensors compares OU Elearenic | heey Sign with stead det, ard ora» Sonat for Jonna Sonsc of otful mintre rate sa consol system Or sensor [Detects densi of onvgen contsined in ehaon aes Ait flow soneor [Detects amount of rine a Thorlo sonsor_—[ Dates tae valve positon and His postion Sa Receives varous sonal, compares these elanale wih ecu Stee ana loved timers ard ean 2 gral fa lorition control system ‘optimal contol of igniton timing, (Crank angie sensi Detects engine's revolution speed Cam angle sensor ‘Detects reference signel for combustion eyinder disci Water temperature Emits a coolant temperature signal orc srt ten Knock sensor | Detects a knock signal and sends io ECU. ‘Adsorbs evaporative gas whieh oceure in fuel tank when eee fengine stops, and sends ito combustion chambers for @ {complete burn when engine is started. This prevents HC om boing discharged into atmosphere Purge conwol sole noid vate Receives a signal from ECU and contols purge of evap tative gas adsorbed by canister.[0201] 2-1 EMISSION CONTROL SYSTEM AND VACUUM FITTING 2. Schematic Drawing 1. MPFI Non-TURBO model € asarwivo 2.0 wostis wosnas “gna. aM waninot nana wl 3 UaNVITO IY Bawa yosnas ® Ms 71LIOWHL Saiva OwINOD| nod "ulv SS¥EAS Awa anna vans nwa aions 108 UaLsINvD La 3h WA uano 10H | L Fig. 1EMISSION CONTROL SYS1EM AND VACUUM FILLING 2-1 (0202) 2, MPFI TURBO model 32.082 ASATWAYS wosnas j] mow ree C wosNas s10N¥ WWD lyanya19 wn of AVES), aia dina Tans w & ganva Bano TON Fig. 2EMISSION CONTROL SYSTEM AND VACUUM FITTING 3. General Precautions 1) Know the importance of periodic maintenance s vices. (1) Every service item in the periodic maintenance schedule must be performed. (2) Failing to do even one item can cause the engine to run poorly and increase exhaust emissions. 2) Determine if you have an engine or emission system problem. (1) Engine problems are usually not caused by the emission control systems. (2) When troubleshooting, always check the engine and the MPFl system first. 3) Check hose end wiring connections first. The most frequent cause of problems is simply a bad connection in the wiring or vacuum hoses. Always make sure that connections are secure and correct. 4) Avoid coasting with the ignition turned off and pro- longed engine braking, [0300] 2-1 5} Do not damage parts. (1) To disconnect vacuum hoses, pull on the end, not the middle of the hose. (2) To pull apart electrical connectors, pull on the connector itself, not the wire. (8) Be careful not to drop electrical parts, such as sensors, or relays. If they are dropped on a hatd floor, they should be replaced and not reused, (4) When checking continuity at the wire connector, the test bar should be inserted carefully to prevent terminals from bending. 6) Use SUBARU genuine parts. 7) Record how hoses are connected before discon- necting. (1) When disconnecting vacuum hoses, use tags te sntify how they should be reconnected. (2) After completing a job, double check to see the the vacuum hoses are properly connected. See the "Vacuum connections label” under the hood.2-1_[04A0} EMISSION CONTROL SYSTEM AND VACUUM FITTING 4. Crankcase Emission Control € ‘em A: DESCRIPTION The positive crankcase ventilation (PCV) system is em- ployed to prevent air pollution which will be caused by blow-by gas being emitted from the crankcase, The system consists of a sealed oil filler cap, rocker covers with fresh air inlet, connecting hoses, PCV valve ‘and an air intake duct. At the part throttle, the blow-by gas in the crankcase ‘lows into the intake manifold through the connecting hose of erank case and PCV valve by the strong vacuum of the intake manifold, Under this condition, the fresh air is introduced into the erankcase through connecting hose of rocker cover ‘At wide open throttle, a part of blow-by gas flows into the air intake duct through the connecting hose and is drawn to the throttle chamber, because under this condition, the intake manifold vacuum is not so strong a8 to introduce all blow-by gases increasing with engine speed directly through the PCV valve Aic intake duet 1g. 3 Non-Turbo model eo Fresh ai = Mature of ar an Dlowby exe = Biow-by gas Fig. 4 Turbo model1. 04A0) EMISSION CONTROL SYSTEM AND VACUUM FITTING 4. Crankcase Emission Control occ A: DESCRIPTION The positive crankcase ventilation (PCV) system is em- sloyed to prevent air pollution which will be caused by blow-by gas being emitted from the crankcase. The system consists of a sealed oil filler cap, rocker covers with fresh air inlet, connecting hoses, PCV valve and an air intake duct. At the part throttle, the blow-by gas in the crankcase flows into the intake manifold through the connecting hose of erank case and PCV valve by the strong vacuurn of the intake manifold, Under this condition, the fresh air is introduced into the crankcase through connecting hose of rocker cover. ‘At wide open throttle, @ part of blow-by gas flows into the air intake duct through the connecting hose and is drawn to the throttle chamber, because under this condition, the intake manifold vacuum is not so strong as to introduce all blow-by gases increasing with engine speed directly through the PCV valve. “Turbocharger Fig. 4 Turbo mode! Incake manifold PCV waive and Blowby 69! Blowby so Non-Turbo model‘EMISSION CONTROL SYSTEM AND VACUUM FITTING B: INSPECTION 1) Check the positive crankcase ventilation hoses and connections for leaks and clogging. The hoses may be cleared with compressed air. 2) Check the oil filler cap to insure that the gasket is not, damaged and the cap fits firmly on the filler cap end. 3) Check the PCV valve as the following procedure. (1) Disconnect the hose from the PCV valve. 2) With a finger attaching top of the valve, then lightly open and close the throttle valve (increase and decrease the engine speed a little). (3) The valve is in good condition if @ vacuum is felt by the finger. If not, replace the valve. {4) The valve alone may be checked by sheking it. It normal when you hear it move. Replac to move. To inteke ® manitola {0600} 5. Three-way Catalyst ‘The basic material of three-way catalyst is platinum (Pt) and rhodium (Rh), and a thin film of their mixture is applied onto honeycomb or porous ceramics of an ovel shape (cartier), To avoid damaging the catalyst, only unleaded gasoline should be used. The catalyst is used to reduce HC,'CO and NOx in exhaust gases, and permits simultaneous oxidation and reduction, To obtain an excellent purification efficiency on all components HC, CO and NOx, a balance should be kept among the concentrations of the components. ‘These concentrations vary with the air-fuel ratio. The air-fuel ratio needs to be controlled to @ value within the very narrow range covering around the theoretical (stoichiometric) air-fuel ratio to purify the components efficiently. 6. A/F Control System The eir/luel control system compensates for the basic amount of fuel injection in response to a signal sent from the O, sensor to provide proper feedback control of the mixture. Thus, the theoretical air-fuel ratio is maintained to provide effective operation of the three- way catalyst. The basic amount of fuel injection is preset according to engine speed and loads, as well as the amount of intake air. This system also has a “learning” control function which stores the corrected data in relation to the basic amount of fuel injection in the memory map. Anew air-fuel r correction is automatically added for quick response to the deviation of the air-fuel ratio. Thus, the air-fuel ratio. is optimally maintained under various conditions while stabilizing exhaust gases, improving driving perfor- mance and compensating for changes in sensors’ per- formance quality with elapse of time. Refer to 2-7 "FUEL INJECTION SYSTEM”.7. Ignition Control! System {CU determines the optimal i ___.5 signals sent from various sensors (which monitor the operating conditions of the engine}, and sends a signal to the igniters. ion control system is controlled by the ECU. ition timing accord- 10700] EMISSION CONTROL SYSTEM AND VACUUM FITTING ‘The ECU has @ “learning” control func 1b transient characteristics for responsive ignition timing control. Refer to 2-7 "FUEL INJECTION SYSTEM”. Battery cote 7 Tati wner-S | nnn 3 Crank ange sensor Ignition cot Spark plug e229 Fig. 6EMISSION CONTROL SYSTEM AND VACUUM FITTING fosayy 2. 8. Evaporative Emission Control Gasoline vapor evaporated from the fuel in the fuel tank Sucienn is introduced into the canister located in the engine y' compartment through the evaporation line, and is ab. sorbed on activated carbon in it. A fuel separator is also A: DESCRIPTION incorporated on the tank fuel line, 1 The purge conte! solancid valve is contoted by the and provides optimal purge control according to 1, GENERAL the coolant temperature, engine speed and vehicle speed, ‘The evaporative emission control system is employed to prevent evaporative fuel from being discharged into ambient atmosphere, This system includes a canister, purge control solenoid valve, a fuel separator, their connecting lines etc. — 1 oid valve (Canister purge control? Trae Fue tier cap) {Vacuum relat a. an Fuel separator Rol over valve {4¥90 model onty? | \ cane Ft ont sez Fig. 7 TURBO] ae hameats 56 Thro body ee = {eeu ae) re Fat sepaeoe Ralowervane-y (antec oo) punto pore ‘control valve [ —! canta Fat nk cose Figes) FUEL SEPARATOR The fuel separator is to prevent liquid fuel from flowing ister in case of abrupt cornering, etc. « cap The relief vaive is adopted to prevent the development of vacuum in the fuel tank which may occur in case of "rouble in the fuel vapor line. in normal condition, the filler pipe is sealed at @ and at che packing pressed against the filler pipe end. As vacuum develops in the fuel tank, atmospheric pressure forces the spring down to open the valve; consequently sir is led into the fuel tank controlling the inside pres- sure. spring 10 EMISSION CONTROL SYSTEM AND VACUUM FITTING B: INSPECTION 1) Remove fuel filler cap. 2} Disconnect evaporation hose from canister. Check for unobstructed evaporation line by blowing air into hose. 3) Disconnect purge hose from canister, Blow air through hose to ensure that air does not leak. Be careful not to suck on the hose as this causes fuel evaporating gas to enter your mouth. 4) Check the exterior of the canister to ensure that it is not cracked or scratched.EMISSION CONTROL SYSTEM AND VACUUM FITTING fos02} 2-1 If 9. Vacuum Fi 41, Non-TURBO mor Throttle chamber solenoid valve 2 Front 2.202 Fig. 10. 2'%URBO model Pressure regulator Trrostle chamber ‘To pressure vor se1016 Fig. 11e. ON-CAR SERVICES 2-2 SS SUBARU. 1992 SERVICE MANUAL PNOMAONS Page Foreword Ignition Timing Engine idle Speed . Engine Compression Intake Manifold Vacuum Hydraulic Lash Adjuster . Fuel Injector... . Oxygen (O,) Sensor OOURWANN2-2 [0100] ON-CAR SERVICES 41. Foreword Tis-ahapter describes msjor inspection ond service “= {or the engine mounted on the body. For bres not found inthis chapter, refer to the se Tice procedure secion Inthe oppicable chapter 2. Ignition Timing A: INSPECTION 1) Warm up the engine. 2) Confirm that the idle switch is ON. 3) To check the ignition timing, connect a timing light to #1 cylinder spark plug cord, and illuminate the timing, mark with the timing light. If the timing is not correct, check the ignition control system, (Refer to "2-7 Fuel Injection System’) Ignition timing [BTOC/rpmt; Non-TURBO* 20° 8°/700 TURBO 15° 87/700 * To improve stability, ignition timing while engine is idling is also controlled. For this reason specified igni: tion timing range is increased somewhat, to =8° Fig. 7 3. Engine Idle Speed A: INSPECTION 1) Before checking idle speed; check the following: {1) Ensure that air cleaner element is free from clog- ging, ignition timing is correct, spark plugs are in ‘good condition, an¢ that hoses are connected prop- erly. (2) Ensure that CHECK ENGINE light is off. 2) Warm up the engine. 3) Connect “Select Monitor” and measure engine rpm (Function mode "FO4") ‘a. When Select Monitor is not used, attach the pickup sensor on tachometer (Secondary pickup type) to #1 plug cord. b. This ignition system provides simultaneous ignition for #1 and #2 plugs. It must be noted that some tachometers may register twice that of actual engine speed, 4) Check idle speed when unloaded (with headlights, heater fan, rear defroster, radiator fan, air conditioner, ete. OFF). Idle speed (No load and gears in neutral position}: 700+ 100 rpm 5) Check idle speed when loaded. (Turn air conditioner ‘switch “ON" and operate compressor for at least one minute before measurement.) Idle speed (A/C switch “ON”): 850250 rpm Hf idle spe: Troubleshooting chart under System”. is outside specifications, refer to General "2-7 Fuel InjON-CAR SERVICES fo4ao] 2-2 4, Engine Compression A: MEASUREMENT 1} After warming up the engine, turn off the ignition- starter switch 2) Make sure that the battery is fully charges. 3) Remove all the spark plugs. 4) Disconnect connectors from fuel injector. 5) Fully open the throttle valve, 6) Check the starter motor for satisfactory performance and operation 7) Crank the engine by means of the starter motor, and a read the maximum value on the gauge when the pointer is steady, Hold the compression gauge tight against the spark plug hole, 8) Perform at least two measurements per cylinder, ‘and make sure that the velues are correct, Compression (200 — 300 rpm and fully open throttle) Non TURBO Standard 1,079 — 1,275 kPa (11.0 — 13.0 kg/em*, 156 — 185 psi) * Limit 883 kPa (9.0 kg/cm’, 128 psi) Difference between cylinders 196 kPa (2.0 kg/cm*, 28 psi) TuRBO ‘Standard 981 — 1,177 kPa {10.0 — 12.0 kg/em*, 142 — 171 ps Limit ‘785 kPa (B.0 kg/em®, 114 psi) Difference between cylinders 196 kPa (2.0 kg/em*, 28 psi)2 [5A0} i. Intake Manifold Vacuum @ EASUREMENT ) Warm up the engine. } Disconnect the vacuum hose and install the vacuum Iauge to the hose fitting on the manifold. }) Keep the engine at the idle speed and read the “acum gauge indication. 3y observing the gauge needle movement, the internal, condition of the engine can be diagnosed as described 1 Table below. ON-CAR SERVICES Vacuum pressure Non-TURBO More then —66.7 kPa (—500 mmitg, —19.69 inka) TURBO More than —65.3 kPe (490 mmtig, —19.29 inHg) ing, A/C “OF! (Diagnosis of engine condition by measurement of manifold vecuum ‘Vacuum gauge indication 7. Needle is steady but lower than normal position. This tendency becomes more evident as ongine temperature (ses Possible engine condition Leakage around intake manifold gasket or throttle chamber gasket. 7, When engine speed is reduced slowly from higher ‘Stops temporary when iis lowering ot becomes steady ebove ermal position. 286, neste [Back pressure 100 high oF exhoust muller clogged. 3. Needle intermittently drops to position lower than normel post Leakage eround cylinder. 7, Needle drope suddenly end iniermktently from normal position. Sticky valves. ', When engine speed Is gradually increased, noodle begins to vi brate rapidly 8t certain speod, and then vibrstion increases a= engine speed increases [Weak or broken valve springs. TE Needle vibrates above and below normal position In narrow range [Botective ignition aystom or Uworte chamber idle adjustmentENGINE tmzoo} 2-3 6. Hydraulic Lash Adjuster 7. Cam Shaft ‘The hydraulic lash adjuster is built into each rocker arm The cam nose part is finished with “chil on the valve side, A total of sixteen lash adjusters are employed. treatment to increase wear resistance and anti-scuffing property. ‘The right- hand camshaft is supported by three journals inside the cylinder head while the left-hand camshaft is supported by four journals. The flanges of these cam White voles ate open shafts are also supported by the camshaft support ends to receive thrust force. + tion free lof vate sem | White valves are closed lengine 22.000 Fig. 6 Sowrnal Journal Porton tlc by tus free igh hn ronon atteted byron free e2oei Fig. 63. M800] ENGINE 3. Cylinder Head “gmbustion chambers in the cylinder head are com- ter plug, pentroof types which feature a wide ‘area for increased combustion efficiency. ‘our Valves (two intake and two exhaust), which are irranged in a cross-flow design, are used per cylinder. The cylinder head gasket is made from carbon material not asbestos), Its core is metal provided with metal hooks to increase resistance to both heat and wear. ‘The inner side of grommets used in the cylinder bore are reinforced with wire to withstand both high com- bustion pressure and temperature. ‘The cylinder head of the turbocharged engine utilizes the same basic design as that described above, except that pipes to lubricate and cool the turbocharger are provided. Intake valve tntoke port ee i 7 ambunion cner tHE POM SF Oxo aa exhaust valve Exhaust val Exhaust port Exhaust por 9. Cylinder Block ‘The cylinder block is made from aluminum die casting. ‘The cylinder perimeter has an open-deck design which is lightweight, highly rigid and has superb cooling efi- ciency. ‘The cylinder block of the turbocharged engine is a closed deck type to increase rigidity. The cylinder liners are made from cast iron and are dry types which are totally cast with aluminum cylinder ‘block. Five main journal block designs are employed to increase stiffness and quiet operation. The oll pump is located in the front center of the cylinder block and the water pump is located at the front of the right-cylinder bank. At the rear of the right-cylinder block is a separa- tor which eliminates oil mist contained in the blow-by gas. myENGINE [M1100] 10. Crankshaft The crankshaft is supported by five bearings to provide high rigidity and strength. The corners of the crankshaft journals and webs, as well as the erank pins and webs, are finished with fillet-roll work to increase stiffness. The five crankshaft bearings are made from aluminum alloy and the No. 3 bearing is provided with a flanged metal to receive thrust force. ” 2 8 Fig. & 11. Piston ‘The piston skitt has e “slipper” design to reduce weight, and sliding, The oil control ring groove utilizes @ slit design. The piston pin is located in an offset position. The Nos. J and 3 pistons are offset in the lower direction while the Nos. 2 and 4 pistons are offset in the upper direction. The piston head is recessed for both the intake and exhaust valves, It also has symbols used to identify the location and the direction of installation. Three piston rings are used for each piston-two com- Pression rings and one oil ring. The top piston ring has an inner-bevel design and the second piston ring has an interrupt design to reduce oil consumption, Identification mack (Piston sie) Location mark (Engi tor soe) Ieentitication mar, Fig. 9 Location mark (Engine tront sige) TOP ‘Secon ring Idonttiation mark Piston size} Alewerrupe Upper rit Sescer Oit tng Lower ratENGINE SUBARU. 1992 SERVICE MANUAL M_ MECHANISM AND FUNCTION General Timing Belt .. . Belt Tension Adjuster. Belt Cover 1 2 3 4 5. Valve Rocker ASSY 6. Hydraulic Lash Adjuster 7. Cam Shaft 8. Cylinder Head 9, Cylinder Block ... 10. Crankshaft 11, Piston : i S_ SPECIFICATIONS AND SERVICE DATA A: SPECIFICATIONS, : B: SERVICE DATA sennnssunnnunsnnnneins : © COMPONENT PARTS 1, Timing Belt 2. Cylinder Head and Camshaft... 3. Cylinder Head and Valve ASSY .. 4, Cylinder Block ... 5. Cranksheft and Piston W SERVICE PROCEDURE .... 1. General Precautions 2. Timing Belt 3. Valve Rocker ASSY 4, Camshaft 5. Cylinder Head 6. Cylinder Block .. T TROUBLESHOOTING 1. Engine Trouble in General 2, Engine Noise esse ODOR RWONTES3_ M100} M MECHANISM AND FUN neral ~dbaru 2200ce engine is made from aluminum alloy and is horizontally opposed. itis @ 4-stroke cycle, water-cooled, SOHC 16-valve engine. The fuel system alizes an MPF! (multiple fuel injection) design. A summary of the major construction and function Features is 2s-ollows: # The cylinder head is a center-plug type that utilizes pentroof combustion chambers. The four-valve design is provided with two intake valves and two exhaust valves per eylinder. The intake and exhaust ports are arranged in a cross-flow design. ENGINE CTION ‘© The valve rocker arm has a builtin hydraulic lash adjuster which eliminates the need for valve clearance adjustment. ‘© A ingle timing belt drives two camshafts on the left and right banks and the oil pump on the right bank. Belt tension is automatically adjusted to eliminate mainte- nance. ‘© The crankshaft is supported by five bearings to pro- vide high rigidity and strength © The cylinder block is made from aluminum die cast which is integrated with cast-iron cylinder liners. eee a ae ae le Hydraulic lsh austor a Intake valve 5 SE ne mam Connecting toc Rocker shaft supporter 3 rs © SI i f Rocker cover Exhurt valve a H Leama ve oct locker shaft ‘Spork plug Leytinder hood 82076 iENGINE IM3oo] 2-3 ————— ee Ones: 2. Timing Belt ‘Asingle timing belt drives two camshafts (one in the left bank and one in the right bank}. The back of the belt also drives the water pump. ‘The timing belt teeth have a specially designed round profile to provide quiet operation. The timing belt is composed of a strong and inflexible core wire, a wear- resistant canvas and heat- resistant rubber material A hydraulic belt-tension adjuster constantly maintains specified belt tension to properly drive the camshefts, 8 well as to provide a “maintenance-tree” advantage. ‘Timing indicator (For ting mark of crankihat pulley). ‘camanate rocket RH PET | cranks sprocke belt cover, Fig. 2 3. Belt Tension Adjuster The belt tension adjuster provides a constant value of tension for the timing belt. Proper belt tension is main- tained using @ rod to push the tension pulley. The location of the tensioner pulley shaft center is offset in relation to the center of the pulley’s outside diameter. ‘The tensioner adjuster rod provides a rotary movement for the tensioner pulley by both tension of the spring housed in the adjuster. 1) Belt tension action The tensioner adjuster rod is moved to the left by the force of the main spring. This causes silicon oil (which is held to constant pressure by compression-spring ten- sion inside the reservoir chamber) to push the check ball so that silicon oil flows into the oil-pressure cham- ber. Crankshett sprocket V sgt No.2 141 piston is tat TOC when piston position mark on aligrad with mark on eylinder block, {#7 piaton i et at TOC on comoretion stroke when pinton- Position mark on camuhatt sprocket i aigned with mark on, Pinon Potion mark ‘Camshaft sprocket LH Water pump pully 2077 The momentum which forces the adjuster rod out aets upon the tensioner arm so that the pulley is turned counterclockwise. Thus, timing belt tension is properly maintained. 2) Balance to belt tension When the timing belt reaction force is balanced by the main spring tension (to push the adjuster rod), the arm is held stationary to maintain constant belt tension. When the timing beit reaction force increases to such an extent that the belt will be too tight, a small quantity of oil in the oil-pressure chamber gradually returns to the reservoir chamber via the adjuster body-to-rod clear ance, This return of oil continually moves the rod until ‘the reaction force of the timing belt balances with mai spring force and oll pressure inside the oil-pressure chamber. Thus, belt tension is constantly maintained.3_IM400} ENGINE “Tension am © Verne Fig. 3 4. Belt Cover The belt cover is made of synthetic resin molding which is lightweight and heat resistant. Ithas a totally enclosed design thet utilizes rubber packing at the mating surface of the cylinder block. This eliminates the chance of dust and water from entering the interior. Cc design is utilized by placing rubber mounting In the cylinder block and belt cover to prevent the transmission of noise and vibration The front belt cover has a graduated line for ignition- timing confirmation. ‘compression spring {Siicon oft) Out seat 2.078 5. Valve Rocker ASSY ‘A metal bushing is press-fitted to the rocker arm at the rocker shaft location and a sintered alloy chip casting is used at the frictional surface of the cam. The valve side of the rocker arm is provided with a hydraulic lash adjuster to maintain 2 “zero” valve clear- ance, as well as to provide quiet operation end eliminate valve clearance adjustment. The rocker arm on the exhaust valve side has a “Y"- letter design and operates two exhaust valves. The rocker shaft has an oil passage in it. Each shaft end is provided with a built-in relief valve. Figt portion vite eerie Wave washer © ©} Oo ‘supporter O ©) xhauat vave Supporter rocker sr ) e004 4ON-CAR SERVICES 3. Hydraulic Lash Adjuster A; INSPECTION ) Disconnect blow-by hose. }) Remove plug cap. ) Disconnect connectors from fuel injectors. Fig. 5 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 location) to check that there is no air in it. When 1sh adjuster, valve rocker moves when pushed with fingers. Fig. 6 6) If air is in lash adjuster, remove valve rocker ASSY from engine and bleed air completely. B: BLEEDING AIR FROM VALVE LASH ADJUSTER 1) Remove valve rocker ASSY. [osao} 2-2 Fig. 7 2) Manually remove lash adjusters where air is rapped. 1 lash adjuster is difficult to remove manually, use pliers. 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 @ 2 mm (0.08 in) dia rod, push check ballin Engine cit B Posh check bat! on seat suioe (4995870001, 7 Hycraulic tah adjuster 52.215] Fig. 8 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 air is completely bled out. if plunger does not properly lock (when pushed), re- place lash adjuster with 9 new one. 7) Fill rocker arm's oil reservoir instell ash adjuster. Do not rotate lash adjuster during installation. 8) Temporarily and equally tighten bolts Dthrough @. Do not allow dowel pin to catch valve rocker ASSY. th engine oil and