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    Subaru DL GL 1984-1994 Service Repair Manual

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    This manual provides comprehensive service and repair information for 1984-1994 Subaru DL and GL models, chassis codes A10 and A20, equipped with EA71, EA81, and EA82 engine codes. These vehicles,...
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    Tipo: Car
    Proveedor:
    SKU: 89119
    This manual provides comprehensive service and repair information for 1984-1994 Subaru DL and GL models, chassis codes A10 and A20, equipped with EA71, EA81, and EA82 engine codes. These vehicles, available as 2-door coupes, 4-door sedans, and 5-door station wagons, are known for early reputation for reliability, durability, and capable 4-wheel drive systems. Featuring horizontally opposed Boxer engines and offering both front-wheel drive and all-wheel drive configurations, these Subarus represented a practical and robust option in the compact car segment of their time, building upon heritage. This service manual, written in English, offers in-depth guidance on all major vehicle systems. It covers engine mechanical and management, manual and automatic transmissions, drivetrain, suspension, steering, brakes, and the electrical system. Additionally, it details body and chassis repair, HVAC systems, and provides essential procedures for preventive maintenance, troubleshooting, component testing, and repair, including critical torque specifications and alignment data. With over 1500 pages of detailed instructions, diagrams, and wiring schematics, this manual is an indispensable resource for owners, mechanics, and technicians seeking to maintain, diagnose, and repair these models effectively.
    🏷️ Basic Information
    Identification
    Make:
    Subaru
    Model:
    DL / GL
    Model Years Covered:
    1984-1994
    Codes
    Chassis Codes:
    A10 (DL), A20 (GL)
    Engine Codes:
    EA71, EA81, EA82
    👋 Introduction
    Market Position
    Segment:
    Compact/Subcompact Sedans and Wagons (historically).
    Unique Selling Proposition:
    Subaru's early reputation for reliability, durability, and capable 4-wheel drive (on select models).
    Competitive Analysis
    Competitors:
    Toyota Corolla, Honda Civic, Nissan Sentra, Mazda 323.
    Key Features
    Engine Layout:
    Horizontally opposed (Boxer) engines, providing a lower center of gravity.
    Drivetrain Options:
    Available with front-wheel drive (FWD) and full-time/selectable 4-wheel drive (4WD).
    📋 Manual Details
    Coverage Areas
    Documentation Scope:
    Comprehensive service and repair coverage for 1984-1994 Subaru DL and GL models.
    Page Count
    Estimated Page Count:
    Over 1500 pages (typical for factory service manuals of this era).
    Manual Type
    Type:
    Factory Authorized Service Manual / Repair Manual
    Language
    Language:
    English
    Format
    Format:
    PDF Download
    📖 Manual Coverage
    Systems Covered
    Engine Mechanical:
    Detailed disassembly, inspection, repair, and reassembly procedures for all engine variants (EA71, EA81, EA82).
    Engine Management:
    Fuel injection (MPFI, SPFI), ignition system, emissions control, diagnostics, and component testing.
    Transmission Manual:
    Service and repair for 4-speed and 5-speed manual transmissions, including clutch operation.
    Transmission Automatic:
    Service and repair for 3-speed and 4-speed automatic transmissions, including hydraulic control and torque converter.
    Drivetrain:
    Front-wheel drive and Subaru's legendary 4-wheel drive system (Symmetrical AWD), including differentials, CV joints, and prop shafts.
    Suspension:
    Front and rear suspension systems (MacPherson struts, independent rear suspension), shock absorbers, springs, bushings, and alignment specifications.
    Steering:
    Manual steering and power steering systems, including steering column, rack and pinion, and hydraulic components.
    Brakes:
    Front disc brakes, rear drum brakes (some models may have rear discs), hydraulic system, parking brake, ABS (optional on later models).
    Electrical System:
    Battery, charging system (alternator), starting system (starter motor), lighting, instruments, switches, relays, fuses, and wiring diagrams.
    Body And Chassis:
    Body panel repair, door mechanisms, glass, interior trim, seat removal, and frame specifications.
    HVAC:
    Heating, ventilation, and air conditioning system diagnosis and repair.
    Procedures Included
    Preventive Maintenance:
    Detailed schedules for oil changes, filter replacements, fluid checks, belt inspections, and tune-ups.
    Troubleshooting:
    Systematic diagnostic procedures for common and uncommon issues, including symptom-based troubleshooting guides.
    Repair And Rebuild:
    Step-by-step instructions for component removal, repair, and reinstallation.
    Component Testing:
    Specifications and procedures for testing various electrical and mechanical components using multimeters and specialized tools.
    Torque Specifications:
    Accurate torque values for all critical fasteners, ensuring proper assembly and preventing component failure.
    Wheel Alignment:
    Specifications for camber, caster, and toe adjustments, crucial for tire wear and handling.
    Technical Depth
    Depth:
    Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls.
    Diagnostics:
    Advanced diagnostic information, including troubleshooting charts and pinpoint tests for electrical and mechanical faults.
    Diagrams:
    Detailed exploded views, assembly diagrams, and comprehensive electrical wiring schematics.
    📊 Manual Specifications
    File Format
    Format:
    PDF
    Searchability:
    Likely text-searchable, enabling quick access to specific information.
    Print Quality
    Quality:
    High-resolution scans ensuring clarity of text and diagrams.
    Binding Type
    Binding:
    Not applicable (digital format).
    Paper Type
    Paper:
    Not applicable (digital format).
    ⚙️ Engine Specifications
    Primary Engine
    Engine Option 1:
    1.8L EA81 SOHC 4-cylinder Boxer
    Engine Option 1 Power:
    ~73 hp @ 4800 rpm
    Engine Option 1 Torque:
    ~90 lb-ft @ 2800 rpm
    Engine Option 2:
    1.8L EA82 SOHC/DOHC 4-cylinder Boxer (some turbocharged variants available)
    Engine Option 2 Power:
    ~90-100 hp (naturally aspirated), ~115 hp (turbocharged)
    Engine Option 2 Torque:
    ~100-105 lb-ft (naturally aspirated), ~130 lb-ft (turbocharged)
    Engine Option 3:
    1.6L EA71 SOHC 4-cylinder Boxer (early models)
    Engine Option 3 Power:
    ~71 hp @ 5200 rpm
    Engine Option 3 Torque:
    ~82 lb-ft @ 3200 rpm
    Performance
    Fuel Induction:
    Carburetor (early models) or Multi-Point Fuel Injection (MPFI) / Single-Point Fuel Injection (SPFI) on later models.
    Emission Controls:
    Catalytic converter, EGR system, and other emissions control technologies as mandated by regulations.
    🔧 Transmission
    Standard
    Transmission Type Standard:
    4-speed manual transmission
    Optional
    Transmission Type Optional 1:
    5-speed manual transmission
    Transmission Type Optional 2:
    3-speed automatic transmission
    Transmission Type Optional 3:
    4-speed automatic transmission
    Features
    Drivetrain Coupling:
    Manual transmissions often featured a clutch-activated 4WD system or full-time AWD. Automatic transmissions typically came with full-time AWD.
    📐 Dimensions
    Exterior
    Body Styles:
    2-door Coupe, 4-door Sedan, 5-door Station Wagon.
    Wheelbase:
    Approximately 96.5 inches (2450 mm)
    Length:
    Approximately 162-175 inches (4115-4445 mm), varies by body style.
    Width:
    Approximately 64.2-65.6 inches (1630-1665 mm).
    Height:
    Approximately 53.5-56.5 inches (1360-1435 mm), varies by body style.
    Weights
    Curb Weight:
    Approximately 2000-2400 lbs (907-1089 kg), varies by model and drivetrain.
    Gross Vehicle Weight Rating:
    Varies by model, typically around 3000-3400 lbs (1361-1542 kg).
    🛡️ Safety Features
    Ratings
    Crash Test Performance:
    Minimal official crash test data readily available for this era, but generally considered reasonably safe for its time.
    Active Features
    Braking System:
    Front disc brakes, rear drum brakes. Some later models offered optional ABS.
    Drivetrain Stability:
    Subaru's Symmetrical AWD system provided enhanced traction and stability in various conditions.
    Passive Features
    Seat Belts:
    Standard 3-point front seat belts, lap belts in rear.
    Head Restraints:
    Standard front head restraints.
    💡 Technology Features
    Infotainment
    Audio System:
    Basic AM/FM radio with cassette player was common. Optional upgrades might have included more speakers or graphic equalizers.
    Driver Assistance
    ABS:
    Anti-lock Braking System (ABS) was an optional feature on later models, typically on higher trim levels or 4WD variants.
    Connectivity
    Connectivity Features:
    Limited to analog systems; no modern connectivity features like Bluetooth or USB were available from the factory.
    🔧 Maintenance
    Service Intervals
    Oil Change Interval:
    Typically every 3,000-5,000 miles (4,800-8,000 km) or 6 months, whichever comes first. Consult manual for specific recommendations based on driving conditions.
    Air Filter Replacement:
    Every 15,000-30,000 miles (24,000-48,000 km), or as needed based on inspection.
    Spark Plug Replacement:
    Every 30,000-60,000 miles (48,000-96,000 km), depending on plug type.
    Coolant Flush:
    Every 2-3 years or 30,000-50,000 miles (48,000-80,000 km).
    Timing Belt Replacement:
    Crucial for EA82 engines. Typically every 60,000 miles (96,000 km) or 4-5 years. Failure can cause catastrophic engine damage.
    Fluid Specifications
    Engine Oil Type:
    API SG or SH, SAE 10W-30 or 10W-40 recommended for most conditions. Consult manual for precise viscosity based on temperature.
    Engine Oil Capacity:
    Approximately 4.0-4.5 quarts (3.8-4.3 liters) with filter change for most EA81/EA82 engines.
    Coolant Type:
    Ethylene glycol based antifreeze, typically a 50/50 mix with distilled water. Use Subaru-specific coolant if available.
    Transmission Fluid Manual:
    API GL-4, SAE 75W-90 or 80W-90 gear oil.
    Transmission Fluid Automatic:
    Dexron II or equivalent automatic transmission fluid.
    Brake Fluid Type:
    DOT 3 or DOT 4 brake fluid.
    Power Steering Fluid:
    ATF Dexron II or equivalent.
    Known Issues
    Engine Reliability:
    Generally reliable, but head gasket leaks (especially on EA82), timing belt failures (if not replaced), and carburetor issues can occur.
    Rust Corrosion:
    Susceptible to rust, particularly in the rocker panels, wheel wells, and underbody, common for vehicles of this age.
    Electrical System Aging:
    Older wiring harnesses, connectors, and components may degrade, leading to intermittent electrical issues.
    Cv Joint Wear:
    CV joints on 4WD models can wear out, causing clicking noises during turns.
    📚 Vehicle History
    Brand Heritage
    Manufacturer Origin:
    Subaru is a division of Subaru Corporation (formerly Fuji Heavy Industries), a Japanese multinational corporation.
    Model Evolution
    Generation:
    These models represent the second generation of Subaru's front-wheel-drive/4WD cars, evolving from earlier models like the Leone.
    Design Language:
    Boxy, utilitarian design characteristic of 1980s and early 1990s automotive styling.
    Production
    Production Period:
    1984-1994 (for this specific generation/manual coverage).
    Manufacturing Locations:
    Primarily Japan.
    🏆 Awards & Recognition
    Recognitions
    General Reputation:
    Subaru models from this era built a reputation for durability and capability, especially the 4WD variants, earning loyalty among owners.
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