SUBARU EA81 Engine Workshop Repair Manual

SUBARU 1600 I BOO FORE WORD 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 1600 and 1800 series. This manual completely covers the proce. dures . for maintenance, disassembling, reas- sembling, inspection and adjustment of com- ponents and troubleshooting for gUidance of both the fully qualified and the less-experi- enced mechanics. . Please peruse and utilize this manual fully to ensure complete maintenance and repair work for satisfying our customers by keeping their vehicles in op-timum condition. When replacement of parts during maintenance is needed , be su :~e to use SUBARU genuine parts. All information, illustrations and specifications contained in this manual are based on the latest product infonnation available at the time of publication approval. FUJI HEAVY INDUSTRIES LTD. TAB LE OF CONTENTS - · ·AU, -8- and fI are trademarks of FUJI HEAVY INDUSTRIES LTD. © Copyright 1982 FUJI HEAVY INDUSTRIES LTD. Not to be reproduced in whole or in part without the prior written permission of FUJI HEAVY INDUSTRIES LTD., TOKYO JAPAN.

CHAPTER'iJ GENERAL INFORMATION p. 1- 1. GENERAL SPECIFICATIONS ................................................................ 1- 2 1- 2. VEHICLE IDENTIFICATION NUMBERS (V.I.N.) ................................. 1- 4 1. Applicable V.I.N. of This Manual. ......................................................... 1- 4 2. The Meaning of V.I.N. .......................................................................... 1- 6 1- 3. IDENTIFICATION NUMBERS ................................................................ 1- 6 1. Vehicle Identification Number .............................................................. ··1- 6 2. Engine Serial Number ••••••••••••••••••••••••••••••••••••••••••••••••••.••••.•.••••••••••••••••• 1- 8 3. Transmission Serial Number ................................................................. 1- 6 . ~'""t 1- 4. LARE LS .................................................................................................... 1- 8.~'·" 1. Safety Certification Plate ..................................................................... 1- i 2. Vehicle Emi.ion Control Information Labels ...................................... 1- 6 3. Emission Data Label (California Models Only) ................. ~~ ............... 1- 6 4. VehicleldentiflCltion Number Plate ............................. L ........... ~t .• "'\;; '''''.1_ 5. Color Code Label ..•.......... •••.•.... •.•..•.•.•.••.•.... •...••..••.•••.••.••..••.•..•.•.•.... •. 1- 1 1- 6. RECOMMENDED LUBRICANTS ........................................................... 1- 7 1- 6. RECOMMENDED SEALANTS, ADHESIVES AND .~'. ,. GREASES .••••.••••••••••••••.•••••••.•••••••••••••.•••••••••••••••••••••••••••••••••••••••••••••••••••••• 1- 8 1- 7. TIGHTENING TORQUE OF STANDARD BOLTS AND NUTS ......... 1- 9 , 1- 8. OPENING ENGINE HOOD .................................................................... 1-10 1- 9. LIFTING POINTS AND PROCEDURE ................................................. 1-10 1. Pantograph Jack .................................................................................. 1-10 2. GarageJack ......................................................................................... 1-11 3. Lift ...................................................................................................... 1-11 1-10. TOWING HOOKS ................................................................................... 1-12 • B·.I1I1

- ~ -----~----.-----~--~~-~-~."........,--........ --.---~--~-~~~-~-~----.~-~- 1600 1800 STD 4MT Overall length mm 3985 (in) (156.9) Overall width mm 1610 (in) (63.4) Overall height mm 1365 (in) (53.7) r mm 1700 Compartment Length (in) (66.9) I ['~~-"] two_u ··CalJ0 space at four .. Is Width ~~ 1345 ~ ··CalJ°space (53.0) is BRAT - rear CUlO bed only H'gh mm 1115 el t (in) (43.9) Wheelbase mm 2380 (in) (93.7) Front mm 1330 (in) (52.4) Tread Rear mm 1345 (in) (53.0) Minimum road clearance mm 165 (in) (6.5) - .': Between rear end of seat and rear gate .': Between back panel and rear gate Hatchback DL GL 4WD STD 5MT 5MT AT 4MT 3985 4010 3995 (156.9) (157.9) (157.3) 1610 1615 1620 (63.4) (63.6) (63.8) 1365 1365 1410 (53.7) (53.7) (55.7) 1700 1700 1700 (66.9) (66.9) (66.9) 1345 1345 1345 (53.0) (53.0) (53.0) 1115 1115 1115 (43.9) (43.9) (43.9) 2380 2380 '2370 (93.7) (93.7) (93.3) 1330 1330 1310 (52.4) (52.4) (51.6) 1345 1345 1345 (53.0) (53.0) (53.0) -- 165 165 205 (6.5) (6.5) (8.1) 1600 1800 Sedan 4WD DL GL GL 5MT Dfr 5MT AT 3995 4250 4270 (157.3) (167.3) (168.1) 1620 1610 1615 (63.8) (63.4) (63.6) ---- I------ 1415 1365 1365 (55.7) (53.7) (53.7) 1700 1750 1750 (66.9) (68.9) (68.9) 1345 1345 1345 (53.0) (53.0) (53.0) 1115 1115 1115 (43.9) (43.9) (43.9) 2370 2460 2460 (93.3) (96.9) (96.9) 1335 1330 1330 (52.6) (52.4) (52.4) 1370 1345 1345 (53.9) (53.0) (53.0) 210 165 165 (8.3) (6.5) (6.5) -- - 1600 1800 Hardtop Station Wagon -- DL GL DL GL 4WD 4WD DL GL 5MT 5MT 5MT AT 5MT AT 4MT Dfr AT 4250 4270 4280 4300 4285 4285 4285 (167.3) (168.1) (168.5) (169.3) (168.7) (168.7) (168.7) 1610 1615 1610 1615 1620 1620 1620 (63.4) (63.6) (63.4) (63.6) (63.8) (63.8) (63.8) 1350 1350 1390 1390 1440 1445 1445 (53.1) (53.1) (54.7) (54.7) (56.7) (56.9) (56.9) ·'1500 ·'1500 ·'1500 ·'1500 .' 1500 1750 1750 (59.1) (59.1) (59.1) (59.1) (59.1) (68.9) (68.9) .2 785 .2 785 .2 785 .2 785 .2 785 (30.9) (30.9) (30.9) (30.9) (30.9) ·'1290 ·'1290 ·'1290 ·'1290 .11290 1345 1345 (50.8) (50.8) (50.8) (50.8) (50.8) (53.0) (53.0) .11320 .21320 .11320 .21320 .21320 (52.0) (52.0) (52.0) (52.0) (52.0) 1105 1105 .3 860 .3 860 .3 860 .l 860 .3 860 (43.5) (43.5) (33.9) (33.9) (33.9) (33.9) (33.9) 2460 2460 2455 2455 2445 2445 2445 (96.9) (96.9) (96.7) (96.7) (96.3) (96.3) (96.3) -- 1330 1330 1325 1325 1310 1335 1335 (52.4) (52.4) (52.5) (52.5) (51.6) (52.6) (52.6) 1345 1345 1345 1345 1340 1365 1365 (53.0) (53.0) (53.0) (53.Q) (52.8) (53.7) (53.7) 165 165 175 175 205 210 205 (6.5) (6.5) (6.9) (6.9) (8.1) (8.3) (8.1) ----._.r'r~ ----...,., • I -- - BRAT 4WD 4WD D 1\ .. \ DL GL ~ I 4MT Dfr AT I 4425 4425 4425,1 (174.2) (174.2) (174.2) 1635 1635 1635 I (64.4) (64.4) (64.4) 1445 I 1440 1445 (56.7) (56.9) (56.9) en " 3 - ... _. n • Co) ,. m _. Z •• 960 •• 960 •• 960 (37.8) (37.8) (37.8) 0 m ::I ::D » .. r- ·$1610 ·'1610 ·'1610 (63.4) (63.4) (63.4) Z ." 0 ::D 1300 1300 1300 (51.2) (51.2) (51.2) 3: ~ 0 Z - - 2445 2445 2445 (96.3) (96.3) (96.3) 1310 1335 1335 (51.6) (52.6) (52.6) 1340 1365 1365 (52.8) (53.7) (53.7) 205 210 210 (8.1) (8.3) (8.3)

1600 1800 1600 1800 1600 1800 Hatchback Sedan Hardtop Station Wagon 4WD 4WD GL DL GL DL GL 4WD 4WD STD DL GL STD GL DL DL GL 4MT 5MT 5MT 4MT Dfr 5MT 5MT 5MT 5MT 5MT 5MT 4MT Dfr AT AT AT AT AT .. I 603 .. I 610 .. I 615 .. I 612 kg 583 587 (1330) 592 615 587 (1345) 592 (1335) 599 (1350) 603 622 631 Front (lb) (1285) (1295) (1305) (1355) (1295) (1305) (1320) (1330) (1370) (1390) . .. , 615 .. 1 624 .. 1 626 .. , 624 Curb weight * (1355) (1375) (1380) (1375) f"~~GL4) ' .. I 359 .. I 383 .. I 374 .. I 435 GLF models ··SMTofDL kg 347 347 (790) 384 399 379 (845) 365 (825) 422 (960) 469 469 474 model and Rear (Ib) (765) (765) (845) (880) (835) (805) (930) (1035) (1035) (1045) ATofGL& .. , 367 .. 1 387 .. , 379 .. , 442 !C GLF models (810) (855) (835) (975) ~ .. I 962 .. I 993 .. I 989 .. 11048 w lit; (2120) (2190) (2180) (2310) Total kg 930 934 976 1014 966 957 1021 1072 1091 1105 (Ib) (2050) (2~0) .. 2 982 (2150) (2235) (2130) ..21011 (2110) .. , 1005 (2250) "'1066 (2365) (2405) (2435) (2165) (2230) (2215) (2350) Front kg 803 803 803 780 780 803 803 803 803 803 803 780 780 796 (Ib) (1770) (1770) (1770) (1720) (1720) (1770) (1770) (1770) (1770) (1770) (1770) (1720) (1720) (1755) Gross Rear kg 658 658 658 680 680 658 658 658 658 744 762 789 789 796 Vehicle weight (lb) (1450) (1450) (1450) (1500) (1500) (1450) (1450) (1450) (1450) (1640) (1680) (1740) (1740) (1755) Total kg 1461 1461 1461 1461 1461 1461 1461 1461 1461 1547 1565 1569 1569 1592 (Ib) (3220) (3220) (3220) (3220) (3220) (3220) (3220) (3220) (3220) (3410) (3450) (3460) (3460) (3510) - - _. __ .- * Vehicle with optional eqUipment is out of this specifications. __________ __ ____ ________________ _____ __________ __ ____________ __________ __ 4WD DL 4MT 596 (1315) 391 (860) 987 (2175) 780 (1720) 789 (1740) 1569 (3460) BRAT 4WD GL Dfr AT 617 626 (1360) (1380) 401 406 (885) (895) 1018 1032 (2245) (2275) 780 780 (1720) (I 720) 789 789 (1740) (1740) 1569 1569 (3460) (3460) C) m Z m ::D » r - Z ." o ::D i: ~ o z )

GENERAL INFORMATION 1·2. Vehicle Identification Numbers (V.I.N.) 1. Applicable V.I.N. of This Manual • 1600 cc Engine 2-Door Hatchback STD 2-DoO£ Hatchback DL 4-Door Sedan DL Hardtop DL • 1800 cc Engine 2-DoO£ Hatchback GL 2·Door Hatchback GL 2-Door Hatchback 4WDSTD 2-DoO£ Hatchback 4WDGL 4-Door Sedan GL 4·Door Sedan GL Hardtop GL Hardtop GL Station Wagon DL Station Wagon GL Station Wagon GL Station Wagon 4WDDL Station Wagon 4WDGL Station Wagon 4WDGL BRAT 4WDDL BRAT 4WDGL BRAT 4WDGL Abbreviations used 4MT: 4-speed manual transmission SMT: S·speed manual transmission AT: Automatic transmission (4MT) (SMT) (SMT) (SMT) (SMT) (AT) (4MT) (4MT. Dual-range) (SMT) (AT) (SMT) (AT) (SMT) (SMT) (AT) (4MT) (4MT, Dual-range) (AT) (4MT) (4MT, Dual.range) (AT) 1-4 J F 1 J F 1 J F 1 J F 1 J F 1 J F 1 J F 2 J F 2 J F 1 J F 1 J F 1 J F 1 J F 1 J F 1 J F 1 J F 2 J F 2 J F 2 J F 2 J F 2 J F 2 A F 2 1 B X D A 1 A F 2 2 B X D B 1 A B 2 2 B X DB 2 A W 2 2 B X D B 3 A F 4 3 B X D B 1 A F 4 3 B X D C 1 A F 5 1 B X D D 1 A F 5 3 B X D E 1 A B 4 3 B X D B 2 A B 4 3 B X D C 2 AW 4 3 B X DB 3 AW 4 3 B X DC 3 AM 4 2 B X DB 4 AM 4 3 B X DB 4 AM 4 3 B X DC 4 AM 5 2 B X DD 4 AM 5 3 B X DE 4 AM 5 3 B X DF 4 AT 5 2 BX DD 5 AT 5 3 BX DE 5 AT 5 3 B X DF 5 0 o 0 0 1 and after 0 o 0 0 1 and after 0 0 o 0 1 and after 0 0 0 0 1 and after 0 0 o 0 1 and after 0 0 o 0 1 and after 0 0 o 0 1 and after 0 0 o 0 1 and after 0 0 o 0 1 and after 0 0 o 0 1 and after o 0 0 0 1 and after 0 0 o 0 1 and after o 0 o 0 1 and after o 0 0 0 1 and after o 0 o 0 1 and after o 0 o 0 1 and after o 0 0 0 1 and after o 0 o 0 1 and after o 0 o 0 1 and after o 0 o 0 1 and after o 0 o 0 1 and after

GENERAL INFORMATION 2. The Meaning of V.I.N • ..------------------------:------ Maker identifier ,.---------------------- Vehicle attribute _---= --------- -- Vehicle identification ..--""'---." .-, _---lL--_-., I' ----'-----, JFIAF2 BXDAIOOOOI [ Sequential number 100001 and after 200001 and after 300001 and after 400001 and after 500001 and after Hatchback 4-Ooor Sedan Hardtop Station Wagon BRAT Plant of manufacture and transmission type A: Gunma manufacture - 4MT B : Gunma manufacture - 5MT C : GUnma manufacture - AT D: Gunma manufacture - 4WD 4MT E : Gunma manufacture - 4WD 4MT, Dual-range F : Gunma manufacture - 4WD AT Model year D: 1983 Check digit o thru 9 and X, varies Weight class B: 3,000 to 4,000 lb GVWR Model 1 2 : 3 : Standard model DLmodel GLmodel Series and engine type 1 : 1300 cc engine 2 1600 cc engine 3 1600 cc engine 4WD 4 1800 cc engine 5 1800 cc engine 4WD Body type F : Hatchback B : 4-Ooor Sedan W: Hardtop M: Station Wagon T : BRAT Line restraint type A : Fuji Subaru line and seat belts B : Fuji Subaru line and air bag Type of vehicle 1 : Passenger vehicle 2 : Multipurpose passenger vehicle Manufacturer and make Fuji Heavy Industries Ltd. SUBARU t-5

I GENERAL INFORMATION ~1·3. Identification Numbers 1. Vehicle Identification Number The vehicle identification number is stamped on the bulkhead panel of the engine compartment. Fig. 1·1 V.I.N. location 2. Enaine Serial Number The engine serial number is stamped on the righ t side of the crankcase at the front. 1·4. Labels 1. Safety Certification Plate Safety certification plate is stuck near the driver's side door striker. Fig. 1-4 Safety cartification plate OM·442 Fig. 1·2 Engine serial number location 3. Transmission Serial Number The transmission number label is stuck on the right upper surface of main case (MT) or converter housing (AT). 2. Vehicle Emission Control Information Labels Vehicle emission control information labels are stuck under the engine hood. High altitude label Certification label (Altitude kit equipped vehicle only) Vacuum connections lIbel OM.819 Fig. 1-5 Vehicle emission control labels 1-6 Fig. 1-3 NOTE: tA-075 Engine, transmission and vehicle identification numbers are used for factory communications such as Technical information, Service bulle- tins and other information. 3. Emission Data Label (California Models Only) Fig. '·6 Emission data label

GENERAL INFORMATION 4. Vehicle Identification 5. Color Code Label Number Plate Fig. '-7 Vehicle identification number plate Fig. ,-8 Colorcade label 1-5. Recommended Lubricants OM·820 API SAE viscosity No. and Applicable Temperature CIa.· ITEM aficl- lion ("P) -30" 0° 30" 60" 90" ("C) -34· -18 0 0" 16· 32° J-. 40 130, 20W40, 20W-SO y • Engine oil SE I lOW·30. lOW40. lOW-SO I - < SW-30 SF I (SW-30 is not recommended for sustained high speed drivillll.) 3 .• Transmission and differential GL-S I 90 gear oil • 4WD rear differential gear oil I SSW < 80W I NOTE: Each oil manufacturer ha its baa oil and additives. Thus do not mix two or more brands.

GENERAL INFORMATION P:1-6. Recommended Sealants, Adhesives and Greases f -----=--- Recommended Application Equivalent Fuji Bond C Mating surfaces of crank and transmission Dow Coming's (pIN 004403004) cases, plugs, etc. No. 7038 Fuji Bond D Cover gasket of water pump (Fuji Bond C (PIN 004403005) can be used instead), etc. 1. Sealant Three Bond 1215 Flywheel bolts, mating surface of fly· Dow Corning's (PIN 004403007) wheel housing. No. 7038 Three Bond 120 I Cylinder head gaskets (Super Three Bond Dow Coming's (PIN 004403008) 50 can be used for the same purpose). No. 3145 Starcalking B·33A Sealing against water and dust entry Butyl Rubber (pIN 000018901) through weatherstrips, grommets, etc. Sealant Cemedine 5430L Weatherstrips and other rubber parts, 3M's plastics and textiles except soft vinyl EC·I770 - parts. EC·1368 Soft vinyl parts, and other parts subject 3M's EC·776 Cemedine 540 to gasoline, grease or oil. EC·847 - e.g. trim leather, gear shift boot, door EC·1022 (Spray 2. Adhesive inner remote cover, etc. Type) Cemedine 3000 Bonding metals, glass, plastic and rubber Armstrong's parts. Repairing slightly tom weather- Eastman - strips, etc. 910 Starseal U- 70 for Weatherstrips securing windshield to body Essex Chemical USA & Canada panels to meet the requirements of Motor Corp's - Vehicle Safety Standard. Urethane E FX clutch grease Splines of transmission main shaft. (P IN 000040901) Molylex No.2 CVJ and DOJ joints of axle shafts. (PIN 623029980) PBC Stopper plugs of the front disk brake (pIN 003607000) caliper. Silicone KS64 Brake caliper body (piston, spindle (pIN 003606010) adjuster O·ring), battery terminals, 3. Grease distributor, hood latch, etc. Control cables and carburetor linkages Silicolube G·30M subject to cold weather, water·pump (P IN 004404002) impeller, door latch, striker, battery terminals, etc. ABK 100 Contacting surfaces of drum brake shoes (pIN 003602000) and shoe clearance adjuster. Niglube RX·2 Disk brake caliper (lever, connecting link (pIN 003606000) and spindle head). Valiant grease M·2 ~teering gearbox (Both manual and power (pIN 003608001) teering) NOTE: The adhesives in the above table are not avail ble from our parts department. Some of them and their equivalent products may be purchased from your local ven, ors.

GENERAL INFORMATION 1·7. Tightening Torque of Standard Bolts and Nuts (1) ENGINE & TRANSMISSION Unit· N·m (kg.m, ft·lb) 5T 7T 9T lOT Dia. x Pitch (mm) 1.03 - LS2 1.52 - 2.01 2.50- 2.99 2.99 - 3.48 4 x 0.75 (0.105 - 0.155, (0.155 - 0.205, (0.255 - 0.305, (0.305 - 0.355, 0.76 - 1.12) 1.12 - 1.48) 1.84 - 2.21) 2.21 - 2.57) 2.50- 2.99 2.9 - 3.9 4.9 - 5.9 5.4-6.4 5 x 0.9 (0.255 - 0.305, (0.30 - 0.40, (0.50 - 0.60, (0.55 - 0.65. 1.84 - 2.21) 2.2 - 2.9) 3.6 -4.3) 4.0 - 4.7) 4.4 - 5.4 5.9 -6.9 9.37 - 10.84 10-12 6 x 1.0 (0.45 - 0.55, (0.60 - 0.70. (0.955 - 1.105, (1.0 - 1.2. 3.3 -4.0) 4.3 - 5.1) 6.91 - 7.99) 7 -9) 12 -14 14.2-17.2 23 - 26 25 -28 8 x 1.25 (1.2 - 1.4, (1.45 - 1.75, (2.3 - 2.7, (2.5 - 2.9, 9 -10) 10.5 - 12.7) 17 - 20) 18 - 21) 25 - 28 30-36 46-54 49.5 - 58.4 lOx 1.25 (2.5 - 2.9, (3.1 - 3.7, (4.7 - 5.5, (5.05 - 5.95) 18 - 21) 22 - 27) 34- 40) 36.5 -43.0) 41 -49 53 -63 84 -98 88 -106 12 x 1.5 (4.2 - 5.0, (5.4 - 6.4. (8.6 - 10.0, (9.0 - 10.8, 30-36) 39 -46) 62 - 72) 65 -18) 11-84 88 - 106 139 - 165 147 - 175 14 x 1.6 (7.2 - 8.6, (9.0 -10.8, (14.2 - 16.8, (15.0 - 17.8, 52 - 62) 65 -18} 103 - 122) !O8 - 129) (2) BODY Unit· N·m (kg·m ft.lb) , Dia.(mm) 4T 7T 9T 1.1 2.6 4 (0.17 - 0.27, 1.2 - 2.0) ~ 2.9 - 5.9 5 (0.30 - 0.60, 2.2 -4.3) 5.4 - 9.3 Qt:::"b 6 (0.55 - 0.95, 4.0 - 6.9) 12.7 - 22.6 22.6 -42.2 31.4 - 51.0 ~ 8 (1.30 - 2.30, (2.30 - 4.30, (3.20 - 5.20, 9.4 - 16.6) 16.6 - 31.1) 23.1 - 37.6) 275 -41.1 51.0 - 86.3 62.8 - 101.9 10 (2.80 - 4.80, (5.20 - 8.80, (6.40 - 11.00, TC·002 20.3 - 34.7) 37.6 - 63.7) 46.3 -79.6) 52.0 - 85.3 88.3 - 156.9 117.7 - 196.1 12 (5.30 - 8.70, (9.00 - 16.00, (12.00 - 20.00, Fig. '·9 38.3 - 62.9) 65.1 - 115.7) 86.8 - 144.7) 1.2 - 2.2 ~ 4 (0.12 - 0.22, 0.9 - 1.6) 2.5 -4.4 ~ 5 (0.25 -0.45, 1.8 - 3.3) ~ 4.4 7.4 6 (0.45 - 0.75, 3.3 - 5.4) TC·OO3- 9.8 -17.7 17.7 - 31.4 23.S - 39.2 8 (1.00-1.80, (1.80 - 3.20, (2.40 - 4.00, Fig. 1-10 7.2 - 13.0) 13.0 - 23.1) 17.4 - 28.9) Including bolt or nut with 22.6 - 36.3 37.3 -66.7 48.1 - 83.4 washer or spring washer 10 (2.30 - 3.70, (3.80 - 6.80, (4.90 - 8.50, only 16.6 - 26.8) 27.5 -49.2) 35.4 - 61.5) 39.2 - 64.7 68.6 - 117.7 88.3 - 147.1 12 (4.00 - 6.60, (7.00 - 12.00, (9.00 - 15.00, 28.9 - 47.7) 50.6 - 86.8) 65.1 - IOS.5) Note: The mark is embossed on the bolt head as follows: 4T 4 9T--9 5T 5 IOT---1O 7T 7

SUBARU EA81 Engine Workshop Repair Manual

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