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1991 Subaru XT & XT6 Service Repair Manual 91
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Basic Information Identification Make: Subaru Model: XT / XT6 Year: 1991 Introduction Market Position Positioning: The 1991 Subaru XT and XT6 represented Subaru's entry into the personal luxury/sports coupe market,...
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| Basic Information | |
| Identification | |
| Make: | Subaru |
| Model: | XT / XT6 |
| Year: | 1991 |
| Introduction | |
| Market Position | |
| Positioning: | The 1991 Subaru XT and XT6 represented Subaru's entry into the personal luxury/sports coupe market, focusing on distinctive styling and its signature AWD system. This manual is essential for owners and technicians working on these unique vehicles. |
| Competitive Analysis | |
| Competitors: | Competed with vehicles like the Toyota Celica, Mitsubishi Eclipse, and Ford Probe, offering a unique AWD advantage and distinctive 'Brat-like' styling cues in its lineage. |
| Key Features | |
| Features: | Aerodynamic 'wedge' styling, optional 'turbo' engine (XT), Symmetrical All-Wheel Drive, unique interior design, pop-up headlights. |
| Manual Details | |
| Coverage Areas | |
| Systems Covered: | Engine Mechanical, Engine Fuel & Emission Control, Engine Electrical, Drivetrain (AWD System), Transmission (Manual & Automatic), Suspension, Steering, Brakes, Body Electrical, Climate Control, Body & Chassis, Wiring Diagrams, Maintenance, Troubleshooting, Diagnostics |
| Page Count | |
| Pages: | Approximately 1500+ |
| Manual Type | |
| Type: | Factory Service Manual (FSM) / Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | Printed Paperback |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Cylinder head, valve train, pistons, connecting rods, crankshaft, engine assembly, lubrication system, cooling system |
| Engine Fuel Emission: | Fuel injection system (MPI), throttle body, exhaust system, emissions control systems (catalytic converter, EGR), fuel pump, fuel filter |
| Engine Electrical: | Ignition system, starter motor, alternator, battery, ECU (Engine Control Unit) and sensor diagnostics |
| Drivetrain: | Subaru's Symmetrical All-Wheel Drive (AWD) system, front and rear differentials, driveshafts, CV joints |
| Transmission: | 4-speed Automatic Transmission (4EAT) and 5-speed Manual Transmission, clutch system, torque converter, transmission fluid specifications and service |
| Suspension: | Front suspension (struts, control arms), rear suspension (struts, trailing arms), springs, shock absorbers, wheel alignment specifications |
| Steering: | Power steering system, steering rack, steering column, universal joints, steering fluid specifications |
| Brakes: | Front and rear disc brakes, brake master cylinder, brake lines, ABS (Anti-lock Braking System) components and diagnostics, brake fluid specifications |
| Body Electrical: | Lighting system, wipers, power windows, door locks, mirrors, horn, interior and exterior lamps, fuse box, relay locations |
| Climate Control: | Air conditioning system (R-12 refrigerant), heating system, blower motor, controls, refrigerant charging specifications |
| Body Chassis: | Body panels, doors, hood, trunk lid, interior trim, bumpers, chassis components, structural integrity |
| Wiring Diagrams: | Complete, detailed wiring schematics for all vehicle systems |
| Procedures Included | |
| Maintenance: | Oil changes, filter replacements (oil, air, fuel), spark plug replacement, coolant flush, brake fluid service, transmission fluid service, belt inspection and replacement |
| Troubleshooting: | Diagnostic procedures for common and complex issues, symptom-based troubleshooting charts |
| Repair: | Detailed step-by-step instructions for component removal, installation, and repair for all major systems |
| Diagnostics: | Engine diagnostic codes (OBD-I equivalent), sensor testing, component testing procedures |
| Technical Depth | |
| Depth: | Comprehensive from basic maintenance to complete engine and transmission overhauls, including electrical system troubleshooting and component-level repair. |
| Manual Specifications | |
| File Format | |
| Format: | Printed, bound manual |
| Print Quality | |
| Quality: | High-quality printing with clear diagrams and text |
| Binding Type | |
| Binding: | Perfect bound or stitched binding for durability |
| Paper Type | |
| Paper: | Durable, semi-gloss paper stock suitable for workshop use |
| Engine Specifications | |
| Primary Engine | |
| Engine Xt: | 2.7L EA82T (Turbocharged) Boxer-4 |
| Engine Xt6: | 3.0L ER27 Boxer-6 |
| Performance Xt | |
| Horsepower Xt: | 115 hp @ 5200 rpm (Naturally Aspirated) / 130 hp @ 4800 rpm (Turbocharged) |
| Torque Xt: | 124 lb-ft @ 2800 rpm (Naturally Aspirated) / 144 lb-ft @ 2400 rpm (Turbocharged) |
| Performance Xt6 | |
| Horsepower Xt6: | 145 hp @ 5600 rpm |
| Torque Xt6: | 166 lb-ft @ 4000 rpm |
| Fuel System | |
| Fuel System Type: | Multi-Point Fuel Injection (MPI) for both engines |
| Fuel Type | |
| Fuel Requirement: | Unleaded gasoline (87 octane recommended for naturally aspirated, 91 octane recommended for turbo/XT6) |
| Engine Code Xt | |
| Engine Code: | EA82T |
| Engine Code Xt6 | |
| Engine Code: | ER27 |
| Transmission | |
| Standard | |
| Transmission Xt Standard: | 5-Speed Manual Transmission |
| Transmission Xt6 Standard: | 4-Speed Automatic Transmission (4EAT) with AWD |
| Optional | |
| Transmission Xt Optional: | 4-Speed Automatic Transmission (4EAT) with AWD |
| Features | |
| AWD System: | Full-time Symmetrical All-Wheel Drive with viscous coupling center differential (manual) or electronic control (automatic). |
| Fluid Specifications Automatic | |
| Atf Type: | Subaru ATF HP / Dexron III (refer to manual for exact specification) |
| Fluid Specifications Manual | |
| Mtf Type: | GL-5 Gear Oil (refer to manual for viscosity) |
| Dimensions | |
| Exterior Length | |
| Length: | Approximately 177 inches |
| Exterior Width | |
| Width: | Approximately 67 inches |
| Exterior Height | |
| Height: | Approximately 51 inches |
| Wheelbase | |
| Wheelbase: | Approximately 97.2 inches |
| Weights | |
| Curb Weight: | Approximately 2800 - 3100 lbs (depending on model and features) |
| Cargo | |
| Cargo Space: | Trunk space suitable for coupes of the era, folding rear seats for extended cargo. |
| Tire Size | |
| Tire Specifications: | Commonly 205/60R14 or 205/55R15 (verify with specific trim/options) |
| Wheel Bolt Pattern | |
| Bolt Pattern: | 5x100mm |
| Safety Features | |
| Ratings | |
| NHTSA Rating: | Era-appropriate safety features; specific NHTSA ratings may not be readily available for this specific model year and variant. |
| Active Features | |
| Active Safety: | Anti-lock Braking System (ABS) optional on some trims. |
| Passive Features | |
| Passive Safety: | Three-point seatbelts, front crumple zones, reinforced passenger compartment, driver-side airbag (optional/standard on some trims). |
| Technology Features | |
| Infotainment | |
| Infotainment System: | Factory original AM/FM stereo with cassette player, optional CD player. Manual details speaker replacement and head unit removal/installation. |
| Driver Assistance | |
| Driver Assistance Features: | Limited by era; primary driver assistance is the AWD system for enhanced traction. |
| Connectivity | |
| Connectivity Features: | No modern connectivity features (Bluetooth, USB). Manual covers basic antenna and wiring for aftermarket additions. |
| Maintenance | |
| Service Intervals Oil | |
| Oil Change Interval: | Every 3,750 miles or 3 months (refer to manual for specific conditions) |
| Service Intervals Filters | |
| Filter Replacement Intervals: | Air filter: 15,000 miles or 12 months; Fuel filter: 30,000 miles (replace more frequently in dusty conditions). |
| Service Intervals Spark Plugs | |
| Spark Plug Replacement: | Every 30,000 miles (NGK, Denso, or equivalent recommended) |
| Service Intervals Coolant | |
| Coolant Flush Interval: | Every 30,000 miles or 24 months |
| Fluid Specifications Engine Oil | |
| Engine Oil Type: | SAE 10W-30 or 10W-40 API SG/SH (refer to manual for climate suitability) |
| Fluid Specifications Coolant | |
| Coolant Type: | Ethylene Glycol based coolant, 50/50 mix with distilled water |
| Fluid Specifications Brake Fluid | |
| Brake Fluid Type: | DOT 3 or DOT 4 brake fluid |
| Known Issues | |
| Common Problems: | Head gasket leaks (especially on EJ series, though less common on EA82T/ER27), turbocharger issues (on XT Turbo), suspension wear, electrical gremlins, AC system leaks (R-12), |
| Specific Issues: | Dashboard cracking, window regulator failure, rust on common areas (wheel arches, sills). |
| Vehicle History | |
| Brand Heritage | |
| Subaru Heritage: | Subaru, a division of Subaru Corporation (formerly Fuji Heavy Industries), has a long history of pioneering All-Wheel Drive technology, originating in aerospace. Known for its boxer engines and durable vehicles. |
| Model Evolution | |
| Xt Evolution: | The XT (Leone Coupe/Van in some markets) was introduced in 1985, with the XT6 variant featuring the unique 6-cylinder boxer engine. The 1991 model year represents the final iteration before production ended. |
| Production | |
| Production Years: | Subaru XT: 1985-1991; Subaru XT6: 1987-1991 |
| Manufacturing Location | |
| Location: | Japan |
| Awards & Recognition | |
| Recognitions | |
| Automotive Awards: | While specific awards for the 1991 XT/XT6 are not widely documented, Subaru's reputation for AWD and durability was well-established by this period. The XT was noted for its futuristic design for its time. |