1985-1996 Subaru Brat Service & Repair Manual

Brought to you by SachaLnn There’s A LITTLE DEVIL IN US ALL!

SUBARU 1979-1989 SEDANS- WAGONS COUPES- UTILITY 2WD- 4WD

CONTENTS INTRODUCTION. ........................ 7 TOOLS-EQUIPMENT-SAFETY......... 8 Tools and equipment 8 Safety ........................................ 10 LUBRICATION AND MAINTENANCE 11 Specifications 11 How to grease and oil change 11 Service schedule 14 Lubrication chart 19 Maintenance chart 20 WHEELS AND TYRES 21 Specifications ........ • ........................ 21 How to change a road wheel 21 Tyre wear trouble shooting 23 Care and maintenance 24 ENGINE TUNE-UP. .. .................... 25 Tune-up specifications 25 Tune-up operations ............................. 25 ROADSIDE TROUBLE SHOOTING. ... 33 Trouble shooting ............................... 33 To check ignition and electrical systems 33 To check fuel system 35 To check mechanical system. .................... 36 ENGINE 38 PART 1. ENGINE MECHANICAL TROUBLE SHOOTING. ................................. 38 PART 2. OVERHEAD VALVE (OHV) ENGINE .. 41 Specifications ; ..................... 41 Description 43 Engine assembly ............................... 43 Rocker assemblies and pushrods 46 Inlet manifold 47 Engine sump and oil pump pick up ................ 48 Camshaft and cam followers 49 Cylinder heads 50 Oil pump ..................................... 53 Pistons, connecting rods and cylinder bores 54 Crankshaft and main bearings 60 Flywheel/drive plate ............................ 62 Engine mountings .............................. 63 Exhaust system ................................ 64 PART. 3 OVERHEAD CAMSHAFT (OHC) ENGINE ..................................... 66 Specifications 66 Description c • • • • • • • • • • • • • • • • • • • • • • 67 Engine assembly ............................... 68 Camshaft drive belts. ........................... 71 Camshafts, rocker arms and tappets 75 Inlet manifold 76 Cylinder heads 77 Engine sump and oil pump pick up ................ 80 Oil pump ..................................... 81 Pistons, connecting rods and cylinder bores 82 Crankshaft and main bearings 88 Flywheel/drive plate ................... 90 Engine mountings. ............................. 91 Exhaust system ................................ 92 COOLING SySTEM...................... 93 Specifications 93 Cooling system trouble shooting. ................. 93 Description 94 Radiator ...................................... 95 Cooling fan and thermoswitch .................... 97 Thermostat 98 Water pump ................................... 99 Water pump drive belt. .................... .. .. . 100 Heater assembly. .............................. 100 FUEL SYSTEM 104 Specifications 104 Fuel system trouble shooting. .................... 104 Air cleaner .................................... 106 Carburettor 107 Electromagnetic plunger fuel pump 116 Electromagnetic diaphragm fuel pump ............. 117 Fuel filter. .................................... 119 Fuel tank ..................................... 119 Throttle cable 120 CLUTCH 121 Specifications 121 Clutch trouble shooting 121 Description 122 Clutch unit. ................................... 123 Clutch release mechanism ....................... 124 Clutch pedal 125 Clutch cable. .................................. 125 Clutch adjustments ............................. 126 MANUAL TRANSAXLE .................. 127 Specifications 127 Transaxle trouble shooting 128 Description 132 Transaxle assembly 135 Transaxle controls 141 Axle shafts 148 Propeller shaft 150 AUTOMATIC TRANSAXLE 152 Specifications 152 transaxle trouble shooting. ............. 152 DescrIptIon 153 Transmission fluid 153 Brake band 154 Kicdown solenoid 155 Vacuum modulator. ............................ 155 Four wheel drive transfer solenoid 155 Automatic four wheel drive switch 156 Neutral safety switch 156 Selector lever and linkage 157 Transaxle assembly 159 REAR AXLE ............................... 162 Specifications 162 Rear axle trouble shooting. ...................... 162 Description 164 Axle shafts 165 Differential assembly. .......................... 166 Differential mounting rubber bushes 168 STEERING ................................ 170 PART 1. STEERING TROUBLE SHOOTING.... 170 PART 2. CONVENTIONAL STEERING In Specifications In Description 1n Steering gear assembly 1n Non-adjustable steering column 174 Tilt adjustable steering column. .................. 176 Intermediate shaft 178

Contents .. PART 3. POWER STEERING.................. 179 Specifications 179 Description 179 Preliminary inspection and testing ................ 179 In car adjustment and minor repairs 180 Power steering pump 181 Power steering gear assembly 183 Steering column 184 Intermediate shaft 184 FRONT SUSPENSION.. .. .. .. .. .. .. . 185 Specifications 185 Front suspension trouble shooting 185 Description 186 Front hub ..................................... 187 Suspension unit. ............................... 188 Ball joint 190 Suspension control arm. ..... .. .. .. .... .. .. .. .. . 190 Radius rod .................................... 190 Stabiliser bar. ................. .. .... .. .. ...... 191 Steering angles and ground clearance 191 REAR SUSPENSION. .................... 194 PART 1. REAR SUSPENSION TROUBLE SHOOTING. ................................. 194 PART 2. TORSION BAR REAR SUSPENSION.. 195 Specifications 195 Description 195 Torsion bar and trailing link. .................... 195 Shock absorber. ............................... 196 Trailing arm 197 Rear hub 197 PART 3. COIL SPRING REAR SUSPENSION... 198 Specifications 198 Description 198 Trailing link 198 Trailing arm 198 Suspension unit. ............................... 199 Rear hub 200 BRAKES 203 Specifications 203 Brakes trouble shooting ......................... 203 Description 206 Master cylinder ................................ 206 Front disc brake assembly. ..• ................... 208 Rear drum brake assembly 212 Brake servo unit 214 Handbrake. ................................... 215 Brake pedal. .................................. 216 Proportioning valve............................. 217 Hill holder valve (HHV) 217 Hydraulic system 218 ELECTRICAL SYSTEM. ................. 219 Specifications 219 Battery and charging system trouble shooting 219 Battery and starting system trouble shooting 221 Lighting system trouble shooting 221 Turn signal lamp trouble shooting 222 Ignition system trouble shooting. ................. 223 Test equipment and some applications. ............ 223 Battery .. ..................................... 224 Alternator 225 Starter motor. ................................. 229 Breaker point distributor. ....................... 232 Electronic distributor ............. 235 Switches and controls ........................... 239 Steering wheel and horn control ............ 242 Instrument cluster. ............................. 242 Speedometer cable 244 Heater blower motor 244 Lamp units 245 Windscreen wipers. ............................ 251 Rear wipers 252 Fuses and fusible links. ......................... 253 How to wire up a trailer ......................... 254 Wiring diagrams ............................... 256 EMISSION CONTROL. .................. 272 Introduction ................................... 272 Positive crankcase ventilation (PCV) system 272 Evaporative control system 273 Air preheat system 277 Exhaust gas recirculation (EGR) system. .......... 277 Coasting by-pass system 280 Air injection system 281 Catalytic converter 282 BODy 283 PART 1. BODY COMPONENTS ............... 283 Windscreen and rear glass. ...................... 283 Front doors 283 Rear doors ................................. 286 Engine bonnet ................................. 289 Luggage compartment lid - Sedan and Coupe 290 Tailgate - Station Wagon 291 Tailgate - Utility 293 Radiator grille ................................. 294 Centre console. ................................ 294 Vehicle cleaning 294 PART 2. BODY REPAIRS ..................... 297 Introduction ................................... 297 Safety .................................. 297 Tools, equipment and materials 297 Rust repairs ................................... 302 Panel damage 305 Panel replacement 308 Plastic body fillers 309 Fundamentals of spray painting 310 Preparing for painting 313 Spray painting. ................................ 316 Spray gun and spray pattern trouble shooting. ...... 318 Paint difficulties - Causes and cures. ............ 319 Finishing off (except enamel finishes) 323 CONVERSION TABLES 325 SUPPLEMENT 327 Lubrication, maintenance and engine tune-up " 328 Overhead camshaft engine 328 Fuel system 328 Front suspension 328 Rear suspension 328 Emission control 328

INTRODUCTION This workshop manual has been researched and written by automotive engineers for the practically-minded car owner who wishes to maintain his vehicle in a safe, reliable and serviceable condition and, at the same time, reduce running and maintenance costs. A vehicle of the type covered by this manual was taken into our workshop where the repair methods described were proven in practice. To ensure that the reader can readily identify the components and operations described in the text, detailed photographs and illustrations were produced during the workshop research for inclusion throughout this manual. Each section contains step by step procedures for the removal and installation of components and, where applicable, detailed instructions for their testing, overhaul and adjustment. For the technically minded, comprehensive specificatiol1s are given at the beginning of each section. The importance of regular lubrication and maintenance is stressed in an easy to follow service schedule. Performing services at the intervals specified also gives the opportunity of identifying any minor faults before they get worse. A cracked fan belt, deteriorated water hose or faulty tyre is better dealt with in the convenience of your own garage rather than risk an expensive and inconvenient breakdown. Particular emphasis is also placed on the value of trouble shooting as the identification of the trouble source can often be more of a problem than the cure. If used correctly, the information included on the majority of trouble causes and remedies should greatly assist in the saving of the time and possible unnecessary expenditure. This manual will bring within the scope of many readers numerous tasks on the vehicle which can be tackled with confidence. The cost of the manual may well be recovered on the first occasion it is put to usc, and the personal satisfaction of a job well done is the inevitable bonus. Inexperienced operators should not attempt to carry out a particular service operation before completely reading the appropriate section, or other sections which may be referred to, in the manual.

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1985-1996 Subaru Brat Service & Repair Manual

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