1985-1991 Subaru XT Service & Repair Manual

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~-----------FOREWORD----------~~ This service manual has been prepared to provide SUBARU service personnel with the necessary informatio.n and data for the correct maintenance and repair of SUBARU XT. The manual includes the procedures for maintenance, disassembling, reassembling, inspection and adjustment of . components and trouble-shooting for guidance of both the fully qualified and the less-experienced mechanics. Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicles in optimum condition. When replacement of parts during repair work is needed,.,e sure to use. SUBARU genuine parts. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication approval. We reserve the right to make changes at any time without prior notice. FUJI HEAVY INDUSTRIES LTD. How to use this manual This service manual is divided into four volumes. Each volume consists of Section 1, Section 2, 3,Section 4, 5, and Section 6 respectively. Each chapter, beginning with the Engine section, is basically made up of the following five areas. 1. Mechanism and function 2. Specifications and service data 3. Component parts 4. Service procedure 5. Trouble-shooting "ABBREVIATION LIST" is provided at the back page of quick reference index in each volume. "ALPHABETICAL INDEX" is also provided at the last page in each volume. This service manual applies to SUBARU XT, and explains all equipments including factory options. Therefore, you may find some explanations for equipments not installed on the vehicle. SUBARU, 8 and ~ are registered trademarks of FUJI HEAVY INDUSTRIES LTD. © Copyright 1987 FUJI HEAVY INDUSTRIES LTD. All rights reserved. Not to be reptoduced in whole or in part without the prior written permission of FUJI HEAVY INDUSTRIES LTD .. TOKYO JAPAN. .- ,.

J' TABLE OF CONTENTS [] GENERAL SECTION 1-1 Specifications 1-2 * * * * * * * * * * * * 1-3 General Information 1-4 Pre-Delivery Inspection 1-5 Periodic Maintenance Services 1-6 Special Tools 2;"1 .ERti$$iotl··C~QttO,I.S~~."~bl·vii~I\1'i\=<Rt.I"II~··' ',"" 2-2.,O"tE~(:~'.t~lC:~<, . . ······'i, ,.,<"i;;/icr",jb!.) ,. 2.83 ···~~li,fI~.<.,;, ',." .•....••.•... , ..•.•••...•.. ' •..•.. / .•.... ';:;)1' N·,····'·<.j:f .... ,.!::;::.~::;:;;~::;:~;:~~~1~,.,;}' m. ",j" 2 .... 6 ************ .;j~!"f;7<,r~~;,'w~ti~~SySt~Rl .. 24fll'.fStue~' . . .. ,2~9E.xhau$l$ysteJti . 2~'D Clutch 2.~tl Engine and TranPni$SioQ l\IIoulltfA9Svstt" . :', - - :.,,:. '" :" ',,', :: ·~altfall~ttiisSitnland'·QiffeT·lt!iat;i ..••• ·Automati~Tf."i$s nd:[Un'r~,~~~I. · ·tra~sn\im~n'COftttQt . . "'<':,. 4WD&ystem .' ,'c421'SuSP~~si.h;.,;;< :'.i; ii;;,; ..... , ·4 4 =a 2 !t h e e e·. 'r~l~ng$'~~e'Xm~' "'".""'''' ",':"" ;;.:.';.;.r",;!, ~ .. '. .• '. . \ii, In. .. "'; ... ' ?'i:,.·'· ',~. . 4~Brikes ..,.i,.:;+ .... :'''~ 4~5 .... pedaISy$t.mJnd;c,.~l1t,.i~ftt"); j~~; :;=~!r-~na~:r~~~i~en,·i':ii'~" ,.,';'" ','. .- ;·SOdVarntExt.ft,,:r i.;; Df,lOt$'~~'Wi,JloW$ :····~~i;Se~~,8.~~"~.;.t.~r~~·:i'; . • Durantent"ltel; . ,. . ··EngineE~i.IIISY •• m .8ody£'eC~~~~~~·,. ....., ........•. Wiring· II i81mriand;Trojbte~$hootin •• ;·:;

SUBARU 1988 SrERV~CE MAINJUJAlL QUICK REFERENCE INDEX . [j] GENERAL SECTION SPECIFICATIONS 1 - 1 • • • • • • • • • • • • 1-2 GENERAL INFORMATION 1-3 PRE-DELIVERY INSPECTION 1 -4 PERIODIC MAINTENANCE SERVICES 1 -5 SPECIAL TOOLS 1 -6

AIC ACC AIC pulley ALT pulley API Approx ASSY ASV AT ATF BILEV BJ BP BTDC Calif. Carbo CP CIP CTR CVJ CW DIFF DOJ DIR DSPD ECS EGR FF drive FMVSS ABBREVIATION LIST Air Conditioner Accessory Air Conditioner compressor pulley Alternator pulley American Petroleum Institute Approximately Assembly Air Suction Valve Automatic Transmission Automatic Transmission Fluid Bi-Ievel Bell Joint British Petroleum Before Top Dead Center California Carburetor Complete Crankshaft Pulley Center Constant Velocity Joint Curb Weight Differential Double Offset Joint Dual-range Dry Single Plate Diaphragm Electric Control System Exhaust Gas Recirculation Front wheel drive (2WD) Federal Motor Vehicle Safety Standards GVWR HI HP IG-COIL IG SWITCH INT lIP LH LO LSD MPFI MT PCV PHV PIN PIS pulley RAD FAN R-DEF RH SAE SIR TC TEMP GAUGE TP VGR Gross Vehicle Weight Rating High (Speed) Horse Power Ignition Coil Ignition Switch Intermittent (Wiper) Idler Pulley Left-hand Low (Speed) Limited Slip Differential Multi Point Fuel Injection Manual Transmission Positive Crankcase Ventilation Pressure Holding Valve Parts Number Power Steering oil pump pulley Radiator Fan Rear Defogger Right-hand Society of Automotive Engineers Inc. Single-range Torque Converter Temperature Gauge Theft Prevention Variable Gear Ratio VIN Vehicle Identification Number W/height control With height control W/P pulley Water Pump pulley

INDEX Air Cleaner ........... ...................................................... 1-4- 9 Air Filter Elements (Air cleaner, PCV air filter) ..................................... 1-5-16 Automatic Transmission Fluid ................................. 1-5-19 Automatic Transmission Fluid (ATF) Level .......... 1-4-24 Battery Fluid Level and Battery Installation ................... ................................................ 1-4- 6 Brake Fluid .... ............................................... .............. 1-5-20 Brake Fluid Level and Brake Piping Installation .............. ............................................... ...... 1-4- 5 Brake Lining and Drum ......... .................................. 1-5-24 Camshaft Drive Belt ..................... ........... ........... ...... 1-5- 6 Clutch and Hill-holder System .......................... ...... 1-5-28 Coolant Level and Cooling Fan Installation ......... 1-4- 6 Disc Brake Pad and Disc/Front and Rear Axle Boots .................. .................. ............................. 1-5-22 Door Operation, Door lock and Regulator .......... 1-4- 4 Drive Belt(s) [Except Camshaft] (Inspect drive belt tension) ...................................... 1-5- 3 Driving Test ................................................... ............. 1-4-21 Engine Oil .... .............................. ........... ............ .......... 1-5- 9 Engine Oil Filter ...................... ....... ....... ..... ............... 1-5-11 Engine Oil Level ........................................................ 1-4- 7 Exhaust Pipe and Muffler .... .............. ........... ........... 1-4-16 External Appearance and Equipment ......... ........... 1-4-27 Fuel .............................................................................. 1-3-13 Fuel System for Leakage ............... ............... .......... 1-4-16 Fuses ........................................................................... 1-4-13 General Precautions ..................... ............................ 1-3- 2 Grease on Front and Rear Wheel Bearings ....... 1-5-38 Height Control System ..... Air (Pneumatic) Suspension Vehicle .............. 1-4-18 Hood Operation ............ .................................... ......... 1-4- 3 Identification Number and Label Locations ........... 1-3- 9 Inspect Brake Line and Check Operation of Parking and Service Brake System ............... ........ 1-5-25 Installation of Steering Components ..................... 1-4-15 Jack Installation ......................................................... 1-4-10 Lifting, Towing and Tie-down Points ..................... 1-3-18 Lights and Switches ................................................. 1-4-13 Lubricants ................................................................... 1-3-13 Operation of Indicator Lights and Gauges .......... 1-4-19 Power Steering Fluid Level..................................... 1-4-25 Precautions in Handling a Full-Time 4WD Vehicle ............. ................... ................ ......... ................ 1-3- 3 Replace Engine Coolant and Inspect Cooling System, Hoses and Connections ............ 1-5-12 Replace Fuel Filter and Inspect Fuel System Hoses and Connections .................. 1-5-15 Sealants and Adhesives .................. ......................... 1-3-16 Seat Adjuster and Seat Belts ................................ 1-4-11 Spark Plug .................................................................. 1-5-17 Steering and Suspension .......... .............. ..... ........... 1-5-30 Tachometer, Radio, Clock, etc. .............................. 1-4-20 Theft Prevention ........................................................ 1-3-11 Tightening Torque of Standard Bolts and Nuts ..................................................................... 1-3-17 Tilt/Telescopic Steering Column ............................. 1-4-18 Toe ............................................................................... 1-4-25 Transmission and Differential Gear Oil Level ...... 1-4- 8 Transmission/Differential (Front and rear) Lubricants (Gear oil) ................................................ 1-5-18 Trunk lid, Rear Gate and Fuel Lid Operation ..... 1-4- 4 Underside .......................................... .......................... 1-4-26 Vehicle Identification Numbers (V.I.N.) .................. 1-3- 7 Water Leakage ........................................................... 1-4-27 Wheel Nuts for Looseness and Tire Inflation Pressure ...................................................................... 1-4-11 Windshield Washer and Windshield Wipers ......... 1-4-10

SPECIFICATIONS !55i1..l~1==I1..I XT . ................................................. ~~ ..... 1988

• XT MODEL ITEM Overall length mm (in) Overall width mm (in) Overall height mm (in) Front Max. mm (in) Leg room Rear Min. mm (in) Compartment Front mm (in) Head room Rear mm (in) Shoulder room mm (in) Wheelbase mm (in) Front mm (in) Tread Rear mm (in) Ground clearance mm lin) Front U.S.A. Rear Total Curb weight Front Weight Rear kg lib) CANADA Total Front Gross vehicle weight Rear Total Seating capacity persons *1: The weight of power steering is included. "2: The weight of power steering and power window is included. *3: The weight of air conditioner and cruise control is included. DL MPFI 5MT *1 640 (1,410) *1 435 (965) *1 1,075 (2,375) - - - 740 11,630) 660 (1,460) 1,400 (3,090) 2 1800 FWD GL GL MPFI MPFI 5MT 4AT 1,255 (49.4) 1,435 (56.5) 1,425 (56.1 ) 120 (4.7) *2 650 *2 705 (1,435) (1,555) *2 455 *2 455 (1,000) (1,005) *2 1,105 *2 1,160 (2,435) (2,560) *1 640 *1 695 (1,405) (1,525) *1 445 *1 450 (985) (995) *1 1,085 *1 1,145 (2,390) (2,520) 870 870 (1,920) (1,920) 690 690 (1,520) (1,520) 1,560 1,560 (3,440) (3,440) 4WD FWD GL XT6 MPFI MPFI 5MT SIR 4AT 4,510 (177.6) 1,690 (66.5) 1,330 (52.4) 1,255 (49.4) 1,100 (43.3) 665 (26.2) 950(37.4) 875 (34.4) 1,340 (52.8) 2,465 (97.0) 1,420 (55.9) 1,445 (56.9) 155 (6.1) 125 (4.9) *2 680 *3 810 (1,500) (1,785) *2 510 *3 460 (1,125) (1,010) *2 1,190 *3 1,270 (2,625) (2,795) *1 670 *3 800 (1,4701 (1,765) *1 500 *3 455 (1,105) (1,000) *1 1,170 *3 1,255 (2,575) (2,765) 885 925 (1,950) (2,040) 745 695 (1,640) (1,530) 1,630 1,620 (3,590) (3,570) 4 2700 4WD Full time 4WD Full time 4WD XT6 XT6 MPFI MPFI 5MT SIR 4AT 1,335 (52.6) 1,435 (56.5) 1,440 (56.7) 165 (6.5) *3 790 *3 825 (1,740) (1,820) *3 510 *3 515 (1,125) (1,135) *3 1,300 *3 1,340 (2,865) (2,955) *3 785 *3 820 (1,725) (1,805) *3 505 *3 510 (1,1151 (1,125) *3 1,290 *3 1,330 (2,840) (2,930) 945 945 (2,080) (2,080) 750 750 (1,660) 11,660) 1,695 1,695 (3,740) (3,740) en '1J m (") " (") ~ o z

1800 2700 MODEL FWD 4WD FWD 4WD DL GL GL GL XT6 Full time 4WD Full time 4WD XT6 XT6 MPFI MPFI MPFI MPFI MPFI MPFI MPFI ITEM 5MT 5MT 4AT 5MT SIR 4AT 5MT SIR 4AT Horizontally opposed, liquid cooled, 4-cylinder, Horizontally opposed, liquid cooled, 6-cylinder, Engine type 4-stroke gasoline engine with multi-point 4-stroke gasoline engine with multi-point fuel injection fuel injection Valve arrangement Overhead camshaft type Bore x stroke mm (in) 92 x 67 (3.62 x 2.64) Displacement cm 3 (cu in) 1,781 (108.68) 2,672 (163.05) Compression ratio 9.5:1 F i ri ng order 1-3-2-4 1-6-3-2-5-4 Ignition timing at idling speed BTDC/rpm *1 20° ± 2° /700 20° ± 2° /800 20° ± 2° /700 20° ± 2° /750 Idling speed at neutral, N or P position rpm 700 ± 100 800 ± 100 700 ± 100 750 ± 100 (BPR6ES-ll (or BPR5ES-l1, BPR7ES-ll) .......... NGK Spark plug Type and manufacturer For U.S.A.: W20EPR-U11 (or W16EPR-Ul1, W22EPR-Ul1) ..... Nippondenso RN9YC-4 (or RN 11 YC-4) ...................... Champion For Canada: RN9YC-4 (or RN11 YC-4) .............. ........ Champion Maximum output HP/rpm 97/5,200 145/5,200 Maximum torque N·m (kg-m, ft-Ibllrpm 139 (14.2, 103) /3,200 211 (21.5,156)/4,000 Type Battery Reserve capacity Cold cranking ampere Alternator Clutch type Transmission type 1st 2nd 3rd Gear ratio 4th 5th Reverse DSPD: Dry Single Plate Diaphragm TC Torque Converter 50D20R (MF) 65D23R (MF) (min.) 78 (amp.) 306 12V - 65A DSPD *2 3.636 2.105 1.428 1.093 0.885 3.583 "1: With gear in neutral position (MT) or "P" position (AT) "2: 5-forward speeds with synchromesh and 1-reverse "3: Full automatic, 4-forwards and l-reverse 111 420 TC *3 2.785 1.545 1.000 0.694 - 2.272 50D20R (MF) 75D23R (MF) 55D23R (MF) 75D23R (MF) 78 111 99 111 306 490 356 490 12V - 90A DSPD TC DSPD TC *2 *3 *2 *3 3.545 2.785 3.545 2.785 2.111 1.545 1.947 1.545 1.448 1.000 1.366 1.000 1.088 0.694 0.972 0.694 0.871 - 0.780 - 3.416 2.272 3.416 2.272 en '"0 m o " o ~ o z

1800 2700 MODEL FWD 4WD FWD 4WD DL GL GL GL XT6 Full time4WD Full time 4WD XT6 XT6 MPFI MPFI MPFI MPFI MPFI MPFI MPFI ITEM SMT SMT 4AT SMT SIR 4AT 5MTS/R 4AT Reduction gear Final Type of gear Hypoid (Front drivel reduction Reduction gear ratio 3.700 3.900 3.700 3.900 3.700 Transfer Type of gear - Helical - Helical - Reduction gear reduction Reduction gear ratio - 1.000 - 1.000 - (Rear drive) Final Type of gear - Hypoid - Hypoid reduction Reduction gear ratio - 3.700 - 3.900 3.700 Type Rack and pinion Steering system Turns, lock to lock 4.8 3.S 3.2 Minimum turning circle m (ft) 9.7 (31.81 [at tire I , 10.8 (3S.41 [at bumper] 10.4 (34.1) [at tire] 11.3 (37.11 [at bumper] Front ·1 *2 ·1 Suspension Rear *3 *4 *3 Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Brake Rear Drum brake (Leading & trailing type) Disc brake Parking brake Size 165SR13 Tire Type *1: MacPherson strut type, Independent, Coil spring *2: MacPherson strut type, Independent, Pneumatic suspension (CANADA: with height control) *3: Semi-trailing arm type, Independent, Coil spring "4: Semi-trailing arm type, Independent, Pneumatic suspension (CANADA: with height control) Mechanical on front brake 185/70HR13 19S/60R14 85H Steel belted radial, Tubeless *2 *4 205/60R1487H en ""tJ m (') :!! (') ~ o z

1985-1991 Subaru XT Service & Repair Manual

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