Haynes Subaru 1600 & 1800 Owners Workshop Manual 1850104344, 9781850104346

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at Terr ¥| DaveYey. © HA YNES.

Subaru Owners Workshop Manual Larry Holt and John H Haynes Member of the Guild of Motoring Writers

Models covered All Subaru 1600 & 1800 Series 2 models (inc. MV) with 2WD and 4WD 1595. CC, L781. sc Does not cover L-Series or XT range

ISBN 1 85010 434 4 © Haynes Publishing Group 1983, 1988 All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder. Printed in England

(995-70N7)

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& 1800 ‘79 to ‘87 owners

manual. — (Owners Workshop

Manuals).

Automobiles — Maintenance and repair

|. Title

Newbury Park California 91320

Subaru Inc

ll. Haynes, J. H.

TL152

ISBN 1-85010-434-4

lll. Series

Acknowledgments Thanks are due to Fuji Heavy Industries Ltd. of Japan, who gave us permission to reproduce certain illustrations and provided technical information.

The Champion Sparking Plug Company of spark plug conditions.

provided the illustrations

About this manual /ts purpose The purpose of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done even if you choose to get it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. It is hoped that you will use the manual to tackle the work yourself. For many simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after having done the job yourself.

Using the manual The manual is divided into Chapters. Each Chapter is divided into numbered Sections, which are headed in bold type between horizontal lines. Each Section consists of consecutively numbered paragraphs.

Introduction

The two types of illustrations used (figures and photographs), are referenced by a number preceding their captions. Figure reference numbers denote Chapter and numerical sequence in the Chapter; i.e. Fig. 12.4 means Chapter 12, figure number 4. Figure captions are followed by a Section number which ties the figure to a specific portion of the text. All photographs apply to the Chapter in which they appear, and the reference number pinpoints the pertinent Section and paragraph; i.e. 3.2 means Section 3, paragraph 2. Procedures, once described in the text, are not normally repeated. When it is necessary to refer to another Chapter, the reference will be given as Chapter and Section number; i.e. Chapter 1/16. Cross references given without use of the word ‘Chapter’ apply to Sections and/or paragraphs in the same Chapter. For example, ‘see Section 8’ means in the same Chapter. Reference to the left or right side of the vehicle is based on the assumption that one is sitting in the driver's seat facing forward. Even though extreme care has been taken during the preparation of this manual, neither the publisher nor the author can accept responsibility for any errors in, or omissions from, the information given.

to the Subaru

The Subaru line of vehicles, manufactured by Fuji Heavy Industries Ltd. of Japan, is one of the most versatile of all vehicles currently available. Although Subaru models have been available in both the US and UK for a number of years, this OWM is involved with only those vehicles produced in 1980 and later. Models built prior to 1980 are the subject of another Haynes manual. Subaru vehicles can be purchased in a number of forms and trim levels. In North America the most popular versions include 2-door and 4-door hatchbacks, station wagons and the unique pick-up truck called

the Brat. The UK has a similar line of saloons, hardtop coupes and the MV pick-up truck. One feature which helps to separate Subaru from other vehicle

manufacturers is the use of four-wheel drive (4WD), available on most models. Subaru is the worldwide innovator in 4WD passenger cars. As mentioned above, in addition to body form, Subarus can be purchased in a variety of trim levels with many options. Optional equipment includes items such as a digital display instrument panel and the revolutionary Hill-holder device which prevents the vehicle from rolling backward when accelerating from a stop on a hill.

Contents Page

Acknowledgments

2

About this manual

2

Introduction to the Subaru

é

General dimensions

8

Use of English

9

Buying parts

10

Vehicle identification numbers

11

Maintenance

12

Automotive

techniques, tools and working facilities chemicals and lubricants

18

Jacking and towing

19

Safety first!

20

Troubleshooting

21

Chapter 1 Tune-up and routine maintenance

28

Chapter 2 Engine

:

57

Chapter 3 Cooling, heating and air conditioning systems

88

Chapter 4 Fuel and exhaust systems

99

Chapter 5 Engine electrical systems

120

Chapter 6 Emissions control systems

:

134

Chapter 7 Transmissions

145

Chapter 8 Driveline

170

Chapter 9 Brakes

181

Chapter

10

Chassis electrical system

202

Chapter

11

Suspension and steering systems

246

Chapter

12

Bodywork

270

Ee RR ee Chapter 13 Supplement:

I Conversion factors a Index

298

Revisions and information on later models

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General

dimensions

For modifications, and information applicable to later models, see Supplement at end of manual Length (overall) Hatchback

156.9 in (3985 mm)

(DL-2WD)

Hatchback (GL-2WD) Hatchback (All 4WD)

157.9

in (4010

157.3

in (3995 mm)

mm)

Sedan: andi hardtop (DIL) \ cscs cccosssscccestecceosutc teeter athe ake eee nner aes

167.3 in (4250 mm)

pedan and hardtop (GL))......csaca:sssssccatsnsevceseessuans settreteety esceemretees. ts.vrei eeee

168.1

Station: wagon:

168.5 in (4280 mm) 169.3 in (4300 mm)

(DL=2WD)).c:Sc...cecscccuereecs: toned tee astee ESE, ocat vccsttodes

in (4270 mm)

Station: wagon (GE-2WD))..cc..N..