Subaru 1600 User 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 mainte-
nance is needed, be su : ~ e to use SUBARU
genuine parts.
All information, illustrations and specifica-
tions contained in this manual are based on
the latest product infonnation available at
the time
of publication approval.
FUJI HEAVY INDUSTRIES LTD.
TA B 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.
__________ __ ____ ~ ________________ ~ _____ .~1 __________ ~ __ ~ ____________ ~ __________ __
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 ofmanufacture 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
othru 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 Safetycartificationplate
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 informa-
tion 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
numberplate 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· -180
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 120I 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
productsmay 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

GENERAL INFORMATION
1-8. Opening Engine Hood
1) Engine hood can be lifted slightly
by pulling engine hood lock release
located at the lower area
of instrument
panel.
I
I
I\
OM-S02
Fig. 1-11 Engine hood lock release
2) Push up safety catch with hood
pushed down slightly and unlock it.
OM-S03
Fig. 1·12 Re/68sing hood lock
3) Lift hood and unfasten stay from
holder and
put the top of stay into the
stopper on hood.
A1·064
Fig. 1·13 Setting the stay
4) If engine hood needs to be opened
wider than normal position, remove
stay and set
it as shown in figure.
1-9. Lifting Points and Procedure·
1. Pantoaraph Jack
• Mark shows each pantograph jack
setting positions.
OM·61S6
Fig. 1-15 Lifting points
NOTE:
I. Never get under the vehicle while it
is supported only by the jlck.
Always use safety stands to support
body when you have to get under
the Clr.
b. Block the wheels dilgonilly by
wheel chocks.
c. Make sure the jack is set at the
correct position on the fllnge of
side sill.
1-10
A4·161
Fig. 1-14 Setting the stay
5) When clOSing engine hood, detach
stay with hood lifted slightly.
Mter setting stay on holder, lower
hood.
Then push down the front end
of
hood to lock it.
NOTE:
Make sure thlt the hood is locked
completely before driving.
Fig. 1-16 Settingjack

GENERAL INFORMATION
2. Garaa. Jack
~ IJUIJ
Fig. 1·17 A1-076
A1-077
Fig. 1·18
3. Lift
E:3
a
FRONT
A1-078
Fig. 1-20
- ,.
A ph
NOTE:
a. When jacking up the vehicle, place
chocks to hold wheels.
b. After jacking up the vehicle with
garage jack, be sure to support the
vehicle with safety stands for
safety.
c. Mike sure the stands are set at the
correct position on the flange of
side sill. (The same setting positions
as those of pantograph jack)
Correct position
Fig. 1-19
d. For rear lifting points of 4WO,
apply garage jack under rear dif·
ferential.
NOTE:
Be sure to lift vehicle at the same four
positions as those of pantograph jack.

GENERAL INFORMATION
1·10. Towing Hooks
Towing hooks are provided in front
and rear ends
of vehicle.
Front
Rear
Right
Hatchback
Sedan •
Hardtop
Station
Wagon
•
BRAT
• : installed
- : not installed
• Front
Front towing hOOk..!
Fig. 1-21
Left Right Left
• • -
• • -
....
....
----
OM-439
• Rear
(Hatchback, Sedan and Hardtop)
Fig. 1-22
(Station Wagon and BRAT)
Fig. 1-23
A1-012
NOTE:
When towing the vehicle, pay atten-
tion to the following.
a. Before towing the car, make certain
that the parking brake is released
and transmission is in neutral.
b. Never turn the ignition key to the
"LOCK" position while the car is
being towed.
c. When the Automatic transmission
vehicle is being towed with the
front wheels on the ground, place
the selector lever in "N" position
and do not exceed 30 km/h (20
MPH).
Whenever towing the car more than
10 km (6 miles) distance, tow the
car with the front wheels raised off
the ground. In case of an inopera-
tive transmission, always tow it
with the front wheels raised off the
ground.
d. Avoid towing another car with
front towing hooks.
e. Not only towing hooks but also
other body parts might be damaged
if pulling too quickly the rope
winded round the hooks and if
pulling strongly the rope side ways
against the hook.
f. Never use tie down tabs for towing.

CHAPTER~
PERIODIC MAINTENANCE SERVICES
Page
2-1. SCHEDULE OF MAIN-rENANCE SERVICES ................. 2- 2
2-2.
PROCEDURES OF MAINTENANCE SERVICES .............. 2- 3
1. Inuke and Exhaust Valve Clearances . . . . . . . . . . . . . . . . . . . .. 2- 3
2. Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . .. 2- 4
3. Cylinder Head Nuts, Bolts and Intake Manifold Bolts .......... 2- 4
4. Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2- 5
5. Engine Oil Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2- 6
6. Engine Coolant ................................... 2- 6
7. Cooling System, Hoses and Connections. . . . . . . . . . . . . . . . . .. 2- 6
8. Engine I die Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . .. 2- 6
9. Choke Mechanism Lubrication ......................... 2- 7
10. Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2- 7
11. Fuel and Evaporative System Hoses and Connections .......... 2- 7
12. Air Filter Elements (Air Cleaner, P .C.V. Air Filter) . . . . . . . . . . .. 2- 9
13. Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2- 9
14. Transmission Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2- 9
15. Engine Oil, Transmission Gear Oil and Differential
Gear Oil for Leaks ................................. 2-10
16. Automatic Transmission Fluid ......................... 2-10
17. Differential Gear Oil (Automatic Transmission) .. . . . . . . . . . . .. 2-11
18. Rear Differential Gear Oil (4WD Vehicle) ................ .. 2-11
19. Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-12
20. Disc Brake Pad and Disc. . . . . . . . . . . . •. . . . . . . . . . . . . . . .. 2-13
21. Brake lining and Drum. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-13
22. Brake System for Leaks or Damage ...................... 2-14
23. Brake System, Parking Brake and Brake Servo System Operations. .. 2-14
24. Cups and Dust Seals of Master Cylinder and Wheel Cylinders ..... 2-15
25. Lubricate Front Disc Caliper. . . . . . . . . . . . . . . . . . . . . . . . . .. 2-15
26. Vacuum Hose and Check Valve of Brake Servo System ......... 2-16
27. Clutch and Hill Holder Systems. . . . . . . . . . . . . . . . . . . . . . . .. 2-16
28. Steering System, Front and Rear Axle Boots . . . . . . . . . . . . . . .. 2-17
29. Power Steering System .............................. 2-18
30. Suspension (Ball Joint and Dust Cover) . . . . . . . . . . . . . . . . . . .. 2-20
31. Grease on Front and Rear Wheel Bearings . . . . . . . . . . . . . . •. .. 2-20
32. Wheel Alignment ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2. -21
33. Retighten Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-21
SlIBARU
34. Headlight Aiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-22
35. Lubricate .Hinges and Locks of Doors, Hood and Trunk lid .. . . .. 2-23
2-3.
SPECIAL TOOLS ........•........................... 2-23

PERIODIC MAINTENANCE SERVICES
2-1. Schedule of Maintenance Services
Symbols used A
R
I
P
E
(I) or (R)
Adjust
Replace
Inspect, correct
or replace ifnecessary
Perform
Item
for emission control sYstem
Recommended service for safe vehicle operation
MAINTENANCE INTERVAL
[Number of months or km (miles) whichever occurs fust)
MAINTENANCE ITEM
7.5 15
22.5 30
37.5 45
52.5
1.6
12 24
36
48 60
72
84
1<1;
+.
37.5 45 52.5
E 1 Intake and exhaust
valve clearance e I 1
tel II
E 2 Drive belt
(I)
n
E 3 Retighten cylinder head nuts and manifold bolts P
E 4
Engine oil R R R R R R R
E 5
Engine oil filter R R R R R R R
E 6
Engine coolant (I) (R)
(I)
E 7
Cooling system, hoses and connections
(I)
E 8
Engine idle speed
I
E 9 Choke mechanism lubrication P
E 10
Fuel filter
(R) (R) (R)
E
11
Fuel and evaporative system hoses and connections
(I)
E 12 Air filter elements (air cleaner, PCV air filter) R I
E
13
Spark plugs
R
14
Transmission oil 1 R I
15
Ensine oil, transmission gear oil and differential
gear oil for leaks I 1 1
16
Automatic transmission fluid
I R I
17 Differential gear oil (automatic transmission) I I I R I I I
18
Rear differential gear oil (4WD vebicle)
I R 1
19
Brake fluid R R R
ffi
Disc brake pad and disc
I I 1 I I L I
Brake liningand drum I
22
Brake system for leaks or damage
1 I I I
23
Brake sYstem, parking brake and brake servo system I 1 I
operation
24
Cups and dust sealS of master cylinder and wheel cylinders R
25 Lubricate front disc caliper
~
P
p-
P
26 Vacuum hose and check valve ofbrake servo system I
;=f.
21
Qutch and hill-holder systems A I I I I I
28 s.teering sYstem, front and rear axle boots I I I I I I I
2-2
60
96
60
I
(I)
R
R
(R)
~
P
(R)
(I)
R
R
R
I
R
R
R
R
I
I
I
I
R
P
I
I
I

~ .. ~
29
30
31
32
33
34
35
PERIODIC MAINTENANCE SERVICES
Months 7.5 15
22.5 30
MAINTENANCE ITEM
xl000km
1.6
12 24
36
48
xlOOO miles 1 7.5
15
22.5
30
Power steering system I
Suspension (ball joint and dust cover) I I
Grease on front and rear wheel bearings I
Wheel alignment I
Retighten wheel nuts
P P P
Headlight aiming I
Lubricate hinges and locks of doors, hood and p p
trunk lid
NOTE:
When operating your vehicles under any of following conditions, change the
engine oil every 6,000 km (3,150 miles) or 3 months whichever occurs first.
• Operation in extremely cold Mather
• Repeated short trips
• Driving on dusty roads
2·2. Procedures of Maintenance Services
37.5 45 52.5
60 72
84
n5
45 52.5
I
I
P
p
To maintain the best perfonnance of
vehicle and to drive safely, periodic
maintenance services must be per-
fonned at least at the designated
intervals and strictly in the correct
procedures.
Standard ofValve clearance (when engine is cold)
And also use the SUBARU genuine
parts whenever replacing parts.
At the specified intervals, inspect,
replace
or adjust each item as follows.
1. Intake .nd Exhaust
Valve Clearances
NOTE:
It is not necessary to adjust valve
dearances on hydraulic lifter equipped
models.
1) Bring piston of cylinder to the top
dead center at compression stroke.
l~
Intake
I Exhaust
All models except those Hydraulic lifter
with hydraulic lifter equipped models
0.23 -0.27 mm
Omm
(0.009 -0.011 in)
(0 in)
0.33 -0.37 mm
Omm
(0.013 -0.015 in)
(0 in)
4) Tighten locknuts.
Torque
14-18N·m
(1.4 1.8 kg-m.
10 - 13 ft-lb)
60
96
60
I
I
I
P
I
p
2) Insert a thickness gauge between
valve stem and rocker ann to measure
the valve clearance.
ST'031
5) Adjust each valve clearance ac-
cording to the follOWing sequence.
3) To adjust the clearance, use Valve
Clearance Adjuster (498767000).
Loosen locknuts and turn adjusting
screws to obtain the specified valve
clearance.
Fig. 2-1 Adjusting valve clearances Cylinder number
#1 ... #3 ... #2 ... #4
I
i
I

PERIODIC MAINTENANCE SERVICES
6) Rechec k the valve clearances on
both sides after rotating crankshaft
several times.
NOTE:
a. Adjust the valve clearances when
the engine is cold with its coolant
temperature between 20 and 40"C
(68 and 104"F).
b. When making the adjustment with-
in the first maintenance interval,
retighten the cylinder head nuts in
advance.
2. Drive Belt
• Alternator belt
I
i Alternator belt tension
13
14 mm (0.51 0.55 in)/
98 N
(10 kg, 22lb)
Crank·
shaft
13
(0.51
Fig. 2·2 Alternator belt tension
OM 101
I) Inspect alternator belt tension,
and adjust
it if necessary as follows.
Loosen alternator mounting bolt and
change alternator installing position
so
as to obtain the specified belt tension.
Fig. 2·3 Tightening.alternator
mounting bolt
2) Wipe off any oil or water on belt
and pulleys.
3) Replace belt if crack or other
damage
is found.
NOTE:
When replacing belt with new one,
adjust its tension to 10 mm (0.39 in)!
98 N (10 kg, 22Ib).
•
Oil pump belt for power
steering
Oil pump belt tension .~
15 20mm(0.59-0.79in)/ .
98N(IOkg,22lb)
Power steering pump
98 N (10 kg, 221b)
:,.
. 15 20mm
I (0.59 -0.79 in)
Idler
Fig.24 Oil pump belt tension
for power steering
I) Inspect oil pump belt tension for
power steering and adjust it if neces-
sary as follows.
( I) Loosen lock bolt installing idler
after taking out idler cap, and then
turn adjust bolt
so as to obtain the
specified belt tension.
A3·186
Fig. 2·5 Turning adjust bolt
(2) Retighten idler lock bolt anJ in·
stall idler cap.
2-4
I
~··--·-I--------l
20 - 29 N·m
Torque ~ 3 k
( • g.l1J
. (Idler lock bolt) 14 _ 22 n.lb) i
L ... __ .. ___ __. _________ ~
NOTE:
a. When installing idler cap, turn it
while pushing. If not available to do
so, apply grease on lip of idler cap
and try to install it again.
b. Make sure to install idler cap
securely by turning it.
2) Wipe off any oil or water on belt,
pulley and idler.
3) Replace belt if crack or other
damage
is found.
3. Cylinder Head Nuts,
Bolts and Intake
Manifold Bolts
1) Remove both sides of valve rocker
covers.
2) Loosen the tlHee bolts securing
the intake manifold on the;l:l #3
cylinder head by 60°. The other
manifold bolts 011 the #2
#4 cy·
linder head side should be intact.
J) Loosen No.1 nut on cylinder
head by around 60° and apply suf.
ficlent engine
oil to its thread portion
as shown in figure.
After repeating 4 to 5 times of
loosening and tightening operation in
the range of 60°, retighten the No.1
nut to the specified torque.
NOTE:
Do not loosen the nut more than 90°,
since water leak might occur.
Apply engine oil ,,)~0
'0'''0
,\'1
Repeat
4 to 5
times.
A3·111
Fig. 2·6 Loosening nut and applving
engine oil

PERIODIC MAINTENANCE SERVICES
64N·m
(6.5 kg-m,47
4) Retighten all nuts in the se-
quence shuwn in figure with same
manner.
A3-119
Fig. 2·7 Tightening sequence for
cylinder head nuts and bolts
NOTE:
a. As a rule, retightening operation
should be carried out when engine
is in cold condition below 40°&
(104°F).
b. Use Socket Wrench (499987006)
to retighten No.1 and No.9 nuts.
c. Use Socket Wrench (899988607)
to retighten No. 4 and 5 bolts.
d. Retightening procedure for the
nuts should be carried out one
by one.
5) After tightening all nuts, reo
tighten No. 1 nut again to the speci·
fied torque without loosening.
6) Also tighten all nuts on another
side cylinder head
with the same
manner.
7) Retighten the intake manifold
bolts
on the #1 -#3 cylinder head
side
to the specified torque.
Torque
18 -22 N·m
(1.8 -2.2 kg·m,
13 16 ft-lb)
8) Adjust
the intake and exhaust
valve clearances when engine
is cold.
(Except hydraulic lifter equipped
models)
0.23 -- 0.27 mm
Intake valve . (0.009 -O.Qll in)
r. .: 0,33 -0.37 mm
lEXhaust valve I(0.013 0.Ql5 in)
9) Install the rocker covers.
! Torque 3 - 4 N·m
(0.3 0.4 kg·m,
2.2 -2.9 ft·lb)
4. Engine Oil
I) Drain engine oil by loosening
engine oil drain plug.
A3-007
Fig.2-8 Drainingengine oil
2) Open engine oil filler cap for
quick draining the engine oil.
OM-514
Fig.2-9 Engine oil filler cap
3) Tighten engine oil drain plug after
draining engine
oiL
25 N·m
(2.5 kg-m, 18 ft·lb)
4) Fill engine oil through filler pipe
up to upper point on level gauge. Make
sure
that vehicle is placed level when
checking oil level.
Use engine oil of
proper quality and viscosity, selected
in accordance with the next table.
API
SAL VI~i.'osi!y No. and Applicable Temperature
Clas-
ITlM
sili~a-
lion (OF I
30"
0"
30"
60° 90"
("0 34"
_III"
U"
16" 'pc,
I30.
20W-4U. 2UW·SO .
fngilll: oil
SE
I
IOW-3I1, lOW-40, lOW-50 I
SF
<
SIY-JII
I
(SW-30 oil is not recommended for sustained high speed driving.)
The proper viscosity helps car get good
cold and
hot starting by reducing
viscous friction and thus increasing
cranking speed.
NOTE:
Each oil manufac1Urer has its own base
oil and additives.
Thus, do not mix two or more oils of
different brands.
2-5
OM·745
Fig. 2-10 Checking engine oil level

Engine oil capacity
1800 cc
1600 cc
Engine Engine
Upper 4.0
II 3.S!!
(4.2 USqt )
C.7 USqt )
level 3.S Irnpqt
3.1lmpqt
Lower
3.0 II
2.s!!
level
(3.2 USqt ) (2.6 USqt )
2.6lmpqt 2.2lmpqt
5) Close engine oil filler cap.
6) Start
engine and warm it up for a
time.
7) After stop engine, recheck the oil
level.
If necessary, add the engine oil up to
upper point on level gauge.
s. Engine Oil Filter
1) Remove oil nIter with an oil fIlter
wrench.
2) Get a new oil fIlter and apply a
thin coat of engine oil to the seal
rubber.
3) Install oil fIlter by turning it with
hand, being careful not
to damage
seal rubber.
4) Tighten more approximately two
thirds tum after the seal rubber con·
tacts the oil pump case. Do
not
tighten excessively, or oil may leak.
5) After installing oil fIlter, run
engine and make sure that no oil
is
leaking around seal rubber.
NOTE:
The filter element and filter case are
permanently joined; therefore, interior
cleaning is not necessary.
6. Engine Coolant
• Inspecting
Inspect that the coolant level is above
level plate by removing radiator cap.
Top up coolant
to level plate if the
coolant level is 10 mm (0.39 in) or
more below it.
PERIODIC MAINTENANCE SERVICES
OM-519
Fig.2·11 Inspecting coolant level
NOTE:
a. The radiator is of the pressurized
type. Do not attempt to open the
radiator cap immediately after the
engine has been stopped.
b. The SUBARU Coolant containing
anti-freeze and anti-rust agents is
especially made for SUBARU en-
gine, which has an aluminum crank-
case. Always use SU BARU Coolant,
since other coolant may cause cor-
rosion.
• Replacing
1) Put heater control knob on instru·
ment panel
to heat position.
2) Loosen coolant drain cock after
installing hose onto drain plug, and
drain coolant.
Fig.2·12 Draining coolant
3) Open radiator cap for quick drain-
ing coolant.
4) Tighten drain cock firmly.
5) Fill the SUBARU coolant up to
level plate.
2-6
Coolant capacity
1800 cc
1600 cc
Engine Engine
Approx. Approx.
5.5 Q 5.3 Q
e.8 US qt )
4.8 Imp
qt
(S.6US
q
t)
4.7 Imp qt
6) Install radiator cap and close
firmly.
7) Start engine and warm it up for a
time.
8) Stop engine, and wait until the
engine temperature is decreased.
9) Inspect the coolant level.
If necessary, add coolant up to level
plate.
7. Cooling System,
Hoses and
Connections
1) Check the components of· the
cooling system and each connection
for leak.
2) If the coolant temperature ex·
ceeds 86.5 to 89.SoC (188 to 193°F)
while radiator
is not so hot, check
thermostat.
3)
If thermostat does not open
at 86.5 to 89.SoC (188 to 193°F),
replace
it with a new one.
4) If electric fan does not operate
with coolant temperature above 93
to 97°C (199 to 207°F), check
thermoswitch or fan motor.
5) If radiator hoses are damaged,
replace with new ones.
6) If by-pass hoses or overflow tube
are clogged, clean the inside of hoses
or tube with cleaning oil.
8. Engine Idle Speed
NOTE:
Inspection of engine idle speed should
be carried out after inspection of
intake and exhaust valve clearances.
(Except hydraulic lifter equipped
models)