Subaru DL GL 1984-1994 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Subaru Model: DL / GL Generations Covered: Second Generation (A2/A3 Chassis) Production Years Covered: 1984-1994 Codes Chassis Codes: A2 (DL), A3 (GL) 👋 Introduction Market Position Vehicle Category: Compact/Subcompact Sedans, Wagons, and Hatchbacks Competitive Analysis Key Competitors: Toyota Corolla, Honda Civic, Nissan Sentra, Mazda 323, Mitsubishi Mirage Key Features Subaru Signature Features: Symmetrical All-Wheel Drive (standard on many models/trims), boxer engines, durable construction, strong off-road/all-weather capability for its class. Manual Value Proposition Target Audience: DIY mechanics, Subaru enthusiasts, independent repair shops seeking comprehensive technical data. 📋 Manual Details Coverage Areas Regions Covered: North America (primarily), adaptable for other markets Page Count Estimated Page Count: Over 1000 pages (typical for comprehensive factory service manuals) Manual Type Type: Factory Service and Repair Workshop Manual Language Language: English Format Format: Digital (PDF likely, based on typical aftermarket offerings) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, fuel injection, ignition, cooling, lubrication, emissions control, engine management (ECU diagnostics) Drivetrain Systems: Manual transmission (3-speed automatic and 4/5-speed manual), clutch, driveshafts, front and rear differentials, AWD system (full-time and part-time variants) Chassis Systems: Suspension (front struts, rear independent suspension), steering (rack and pinion), braking system (front discs, rear drums/discs), wheel alignment Electrical Systems: Wiring diagrams, lighting, charging system (alternator, battery), starting system, dashboard instruments, power windows/locks (if equipped), radio, wipers, HVAC controls Body And Interior: Body panels, doors, windows, seats, trim, weatherstripping, corrosion protection, paint codes Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug service, fluid checks and replacements, belt adjustments, brake pad/shoe replacement, tire rotation Diagnostic Procedures: Troubleshooting guides for common drivability issues, electrical faults, and mechanical problems; diagnostic trouble codes (DTCs) where applicable Repair Procedures: Engine overhaul, transmission rebuild, clutch replacement, suspension component replacement, brake caliper service, steering rack repair, electrical component repair Installation Procedures: Component replacement, accessory installation guidelines Emission Control Systems: Detailed explanations of emission control hardware and troubleshooting procedures specific to the era's regulations (e.g., EGR, catalytic converters). Technical Depth Depth Of Information: Comprehensive, covering from basic maintenance to full engine and transmission rebuilds, including detailed diagnostic strategies. 📊 Manual Specifications File Format Digital File Type: Likely PDF, optimized for searchability and printing. Searchability: Searchable text within the PDF for quick access to specific topics. Print Quality Digital Render Quality: High-resolution scans or original digital files ensuring clear text and diagrams. Binding Type Physical Format If Applicable: Not applicable for digital format; typically spiral-bound or perfect-bound for print versions. Paper Type Physical Format If Applicable: Not applicable for digital format; typically heavy-duty paper stock for print versions. Completeness Manual Coverage Scope: Complete factory service information, not a condensed or Haynes-style manual. Covers all aspects of repair and maintenance. ⚙️ Engine Specifications Primary Engine Engine Family: EA Series (EA81, EA82) Engine Configuration: Horizontally Opposed (Boxer) 4-Cylinder Engine Displacement Common: 1.8 Liters (1769cc) and 1.6 Liters (1595cc) Fuel Delivery Common: Carbureted (early models) and Electronic Fuel Injection (EFI/SPI) Performance Horsepower Range: Approximately 70-95 HP, depending on engine variant and market regulations. Torque Range: Approximately 90-115 lb-ft, depending on engine variant. Fuel System Fuel Type: Unleaded Gasoline Engine Codes Common Engine Codes: EA81, EA82, EA82T (turbocharged) 🔧 Transmission Standard Transmission Type Standard: 4-speed Manual Transmission Optional Transmission Type Optional: 3-speed Automatic Transmission, 5-speed Manual Transmission (on some higher trims/later models) Features AWD System Description: Symmetrical All-Wheel Drive (standard on most models). Configurations include: full-time AWD with viscous coupling center differential, part-time 4WD with lockable center differential. Fluid Specifications Manual Transmission Fluid: API GL-5 75W-90 or 80W-90 gear oil Automatic Transmission Fluid: Dexron III (or equivalent) 📐 Dimensions Exterior Length Approximate: 4300 - 4500 mm (varies by body style: sedan, wagon, hatchback) Width Approximate: 1650 - 1680 mm Height Approximate: 1350 - 1450 mm Weights Curb Weight Approximate: 2200 - 2500 lbs (1000 - 1135 kg) Wheel Bolt Pattern Bolt Pattern: 4 x 140mm Center Bore: 56mm 🛡️ Safety Features Ratings Federal Safety Standards Compliance: Compliant with US Federal Motor Vehicle Safety Standards (FMVSS) of the era. Active Features Active Safety Features: Power-assisted front disc brakes, rear drum brakes (later models may offer rear discs), limited-slip differential (on some AWD systems). Passive Features Passive Safety Features: Lap and shoulder belts (front and rear), reinforced chassis structure, impact-absorbing steering column, side-impact beams (later models). 💡 Technology Features Infotainment Audio System Type: Factory AM/FM radio with cassette player, optional upgraded systems. Speaker Configuration: Typically 2-4 speakers, depending on trim level. Driver Assistance Driver Assistance Features: Limited to mechanical systems; advanced electronic driver assistance features were not common in this era. Connectivity Connectivity Options: None (analog systems only). 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 - 5,000 miles (5,000 - 8,000 km) or 6 months, depending on driving conditions and oil used. Air Filter Replacement: Every 15,000 - 30,000 miles (24,000 - 48,000 km) Spark Plug Replacement: Every...
Toyota Corolla, Honda Civic, Nissan Sentra, Mazda 323, Mitsubishi Mirage
Key Features
Subaru Signature Features:
Symmetrical All-Wheel Drive (standard on many models/trims), boxer engines, durable construction, strong off-road/all-weather capability for its class.
Manual transmission (3-speed automatic and 4/5-speed manual), clutch, driveshafts, front and rear differentials, AWD system (full-time and part-time variants)
Chassis Systems:
Suspension (front struts, rear independent suspension), steering (rack and pinion), braking system (front discs, rear drums/discs), wheel alignment
Electrical Systems:
Wiring diagrams, lighting, charging system (alternator, battery), starting system, dashboard instruments, power windows/locks (if equipped), radio, wipers, HVAC controls
Detailed explanations of emission control hardware and troubleshooting procedures specific to the era's regulations (e.g., EGR, catalytic converters).
Technical Depth
Depth Of Information:
Comprehensive, covering from basic maintenance to full engine and transmission rebuilds, including detailed diagnostic strategies.
📊 Manual Specifications
File Format
Digital File Type:
Likely PDF, optimized for searchability and printing.
Searchability:
Searchable text within the PDF for quick access to specific topics.
Print Quality
Digital Render Quality:
High-resolution scans or original digital files ensuring clear text and diagrams.
Binding Type
Physical Format If Applicable:
Not applicable for digital format; typically spiral-bound or perfect-bound for print versions.
Paper Type
Physical Format If Applicable:
Not applicable for digital format; typically heavy-duty paper stock for print versions.
Completeness
Manual Coverage Scope:
Complete factory service information, not a condensed or Haynes-style manual. Covers all aspects of repair and maintenance.
⚙️ Engine Specifications
Primary Engine
Engine Family:
EA Series (EA81, EA82)
Engine Configuration:
Horizontally Opposed (Boxer) 4-Cylinder
Engine Displacement Common:
1.8 Liters (1769cc) and 1.6 Liters (1595cc)
Fuel Delivery Common:
Carbureted (early models) and Electronic Fuel Injection (EFI/SPI)
Performance
Horsepower Range:
Approximately 70-95 HP, depending on engine variant and market regulations.
Torque Range:
Approximately 90-115 lb-ft, depending on engine variant.
Fuel System
Fuel Type:
Unleaded Gasoline
Engine Codes
Common Engine Codes:
EA81, EA82, EA82T (turbocharged)
🔧 Transmission
Standard
Transmission Type Standard:
4-speed Manual Transmission
Optional
Transmission Type Optional:
3-speed Automatic Transmission, 5-speed Manual Transmission (on some higher trims/later models)
Features
AWD System Description:
Symmetrical All-Wheel Drive (standard on most models). Configurations include: full-time AWD with viscous coupling center differential, part-time 4WD with lockable center differential.
Fluid Specifications
Manual Transmission Fluid:
API GL-5 75W-90 or 80W-90 gear oil
Automatic Transmission Fluid:
Dexron III (or equivalent)
📐 Dimensions
Exterior
Length Approximate:
4300 - 4500 mm (varies by body style: sedan, wagon, hatchback)
Width Approximate:
1650 - 1680 mm
Height Approximate:
1350 - 1450 mm
Weights
Curb Weight Approximate:
2200 - 2500 lbs (1000 - 1135 kg)
Wheel Bolt Pattern
Bolt Pattern:
4 x 140mm
Center Bore:
56mm
🛡️ Safety Features
Ratings
Federal Safety Standards Compliance:
Compliant with US Federal Motor Vehicle Safety Standards (FMVSS) of the era.
Active Features
Active Safety Features:
Power-assisted front disc brakes, rear drum brakes (later models may offer rear discs), limited-slip differential (on some AWD systems).
Passive Features
Passive Safety Features:
Lap and shoulder belts (front and rear), reinforced chassis structure, impact-absorbing steering column, side-impact beams (later models).
💡 Technology Features
Infotainment
Audio System Type:
Factory AM/FM radio with cassette player, optional upgraded systems.
Speaker Configuration:
Typically 2-4 speakers, depending on trim level.
Driver Assistance
Driver Assistance Features:
Limited to mechanical systems; advanced electronic driver assistance features were not common in this era.
Connectivity
Connectivity Options:
None (analog systems only).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 5,000 miles (5,000 - 8,000 km) or 6 months, depending on driving conditions and oil used.
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km)
Spark Plug Replacement:
Every 30,000 - 60,000 miles (48,000 - 96,000 km), depending on plug type.
Fluid Specifications
Engine Oil Specification:
API SG/SH SAE 10W-30 or 10W-40 (check owner's manual for exact grade based on temperature).
Coolant Specification:
Ethylene Glycol based antifreeze (50/50 mix with distilled water)
Brake Fluid Specification:
DOT 3 or DOT 4.
Known Issues
Common Wear Items:
Clutch wear, exhaust system rust, wheel bearings, CV joints (especially on AWD models), radiator leaks, head gaskets (less common than later Subaru models, but still a potential issue).
Electrical Quirks:
Flickering dashboard lights, issues with door lock actuators, alternator problems.
Engine Specifics:
Carburetor adjustment/cleaning, fuel pump reliability, timing belt replacement (if applicable to specific engine variant - EA82 typically had timing belts).
📚 Vehicle History
Brand Heritage
Subaru Philosophy:
Subaru has a heritage rooted in aviation and engineering excellence, emphasizing durability, safety, and innovative drivetrain technologies like the boxer engine and AWD.
Model Evolution
Dl Gl Lineage:
The DL and GL models represented Subaru's core passenger car offerings in the 1980s and early 1990s, evolving from the earlier Leone platform.
Key Design Changes:
Significant styling updates occurred in 1985 and 1990, reflecting contemporary automotive design trends while retaining Subaru's functional approach. Introduction of turbocharged variants (GL-10 Turbo) and updated AWD systems.
Production
Manufacturing Location:
Primarily Gunma Plant, Japan.
🏆 Awards & Recognition
Recognitions
Vehicle Reputation:
Known for ruggedness, reliability, and exceptional all-weather capability for their time, particularly the AWD variants.
Automotive Press Mention:
Often praised for their practicality and value, especially by those living in snowy climates.
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