Subaru Xt 1988 User manual

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~-----------FOREWORD----------~~

This

service

manual

has

been

prepared

provide SUBARU

service

personnel

with

the

necessary

informatio.n

and

data for the correct maintenance

and

repair

SUBARU XT.

The manual includes the procedures for maintenance, disassembling, reassembling, inspection

and

adjustment

components

and

trouble-shooting for guidance

both the

fully

qualified

and

the less-experienced mechanics.

Please

peruse

and

utilize this manual

fully

ensure

complete repair work for satisfying our customers by keeping

their vehicles

optimum condition.

When

replacement

parts during repair work

needed,.,e

sure

use.

SUBARU genuine parts.

All information, illustrations

and

specifications contained in this manual

are

based

on the latest product

information available at the time

publication approval.

reserve

the right

make

changes

at any time

without

prior notice.

FUJI HEAVY INDUSTRIES LTD.

How

use

this manual

This

service

manual

divided into four volumes.

Each

volume consists

Section 1, Section 2, 3,Section

and

Section 6 respectively.

Each

chapter, beginning

with

the Engine section,

basically

made

the following five

areas.

Mechanism

and

function

Specifications

and

service data

3. Component parts

Service

procedure

5. Trouble-shooting

"ABBREVIATION

LIST"

provided at the back

page

quick reference index in

each

volume.

"ALPHABETICAL

INDEX"

also

provided at the last

page

each

volume.

This

service

manual applies

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

FUJI

HEAVY

INDUSTRIES

LTD.

1987

FUJI

HEAVY

INDUSTRIES

LTD.

All

rights reserved.

Not

reptoduced in

whole

part

without

the

prior

written

permission

FUJI

HEAVY

INDUSTRIES

LTD

TOKYO

JAPAN.

TABLE

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

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24fll'.fStue~'

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Clutch

2.~tl

Engine

and

TranPni$SioQ

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·~altfall~ttiisSitnland'·QiffeT·lt!iat;i

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nd:[Un'r~,~~~I.

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4WD&ystem

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ii;;,;

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e·.

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•

Durantent"ltel;

··EngineE~i.IIISY

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.....,

........•.

Wiring·

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

ATF

BILEV

BTDC

Calif.

Carbo

CIP

CTR

CVJ

DIFF

DOJ

DIR

DSPD

ECS

EGR

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

IG-COIL

SWITCH

INT

lIP

LSD

MPFI

PCV

PHV

PIS pulley

RAD

FAN

R-DEF

SAE

SIR

TEMP

GAUGE

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

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

.................................................

.....

1988

•

MODEL

ITEM

Overall length

(in)

Overall

width

(in)

Overall

height

(in)

Front

Max.

(in)

Leg

room

Rear

Min.

(in)

Compartment

Front

(in)

Head

room

Rear

(in)

Shoulder

room

(in)

Wheelbase

(in)

Front

(in)

Tread Rear

(in)

Ground

clearance

lin)

Front

U.S.A. Rear

Total

Curb

weight

Front

Weight Rear

lib)

CANADA

Total

Front

Gross vehicle

weight

Rear

Total

Seating capacity persons

*1:

The

weight

power

steering is included.

"2:

The

weight

power

steering and

power

window

included.

*3:

The

weight

air

conditioner

and cruise

control

is included.

MPFI

5MT

640

(1,410)

435

(965)

1,075

(2,375)

740

11,630)

660

(1,460)

1,400

(3,090)

1800

FWD

MPFI

5MT

4AT

1,255

(49.4)

1,435

(56.5)

1,425

(56.1 )

120

(4.7)

650

705

(1,435) (1,555)

455

(1,000)

(1,005)

1,105

1,160

(2,435)

(2,560)

640

695

(1,405)

(1,525)

445

450

(985)

(995)

1,085

1,145

(2,390) (2,520)

870 870

(1,920) (1,920)

690

(1,520) (1,520)

1,560

(3,440) (3,440)

4WD

FWD

XT6

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)

680

810

(1,500)

(1,785)

510

460

(1,125) (1,010)

1,190

1,270

(2,625)

(2,795)

670

800

(1,4701 (1,765)

500

455

(1,105)

(1,000)

1,170

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)

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)

790

825

(1,740)

(1,820)

510

515

(1,125) (1,135)

1,300

1,340

(2,865) (2,955)

785

820

(1,725) (1,805)

505

510

(1,1151 (1,125)

1,290

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)

'1J

(")

1800

2700

MODEL

FWD

4WD

FWD

4WD

XT6

Full

time

4WD

Full

time

4WD

XT6

MPFI

MPFI MPFI MPFI

ITEM

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

(in)

(3.62

2.64)

Displacement

3 (cu

in)

1,781

(108.68)

2,672

(163.05)

Compression

ratio

9.5:1

Firi

order

1-3-2-4 1-6-3-2-5-4

Ignition

timing

idling

speed

BTDC/rpm

20°

± 2°

/700

20°

± 2°

/800

20°

± 2°

/700

20°

± 2°

/750

Idling

speed

neutral, N

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

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

Torque

Converter

50D20R

(MF)

65D23R

(MF)

(min.)

(amp.)

306

12V

65A

DSPD

3.636

2.105

1.428

1.093

0.885

3.583

"1:

With

gear

neutral

position

(MT)

"P"

position

(AT)

"2:

5-forward

speeds

with

synchromesh and 1-reverse

"3:

Full

automatic,

4-forwards

and l-reverse

111

420

2.785

1.545

1.000

0.694

2.272

50D20R

(MF)

75D23R

(MF)

55D23R

(MF)

75D23R

(MF)

111

306

490

356

490

12V

90A

DSPD

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

'"0

1800

2700

MODEL

FWD

4WD

FWD

4WD

GL GL

XT6

Full

time4WD

Full

time

4WD

XT6

MPFI

MPFI MPFI MPFI

MPFI

MPFI MPFI

ITEM

SMT

4AT

SMT

SIR

4AT

5MTS/R

4AT

Reduction

gear

Final

Type

gear

Hypoid

(Front

drivel

reduction

Reduction

gear

ratio

3.700 3.900

3.700

3.900 3.700

Transfer

Type

gear -Helical -Helical -

Reduction

gear

reduction

Reduction

gear

ratio

1.000

(Rear

drive)

Final

Type

gear -

Hypoid

reduction

Reduction

gear

ratio

3.700

3.900

3.700

Type

Rack

and

pinion

Steering system

Turns,

lock

4.8

3.S

3.2

Minimum

turning

circle

(ft)

9.7

(31.81

[at

tire

10.8

(3S.41

[at

bumper]

10.4

(34.1)

[at

tire]

11.3

(37.11

[at

bumper]

Front

·1

Suspension Rear

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

front

brake

185/70HR13

19S/60R14

85H

Steel

belted

radial, Tubeless

205/60R1487H

""tJ

(')

:!!

(')

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