Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Distributor

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REMOVAL & INSTALLATION



1.2L Engine
ENGINE NOT ROTATED
  1. Disconnect the negative battery cable.
  2.  
  3. Unfasten the distributor wire harness.
  4.  
  5. Remove the high tension wire from the coil.
  6.  
  7. If any vacuum lines are attached to the distributor, tag, then disconnect them.
  8.  
  9. Tag then remove each individual spark plug wire at the spark plug.
  10.  
  11. Remove the distributor cap from the distributor body, by loosening the retaining screws.
  12.  
  13. Paint alignment marks on the rotor, distributor body and cylinder head at the base of the distributor.
  14.  
  15. Loosen and remove the retaining bolts which secure the distributor to the cylinder head.
  16.  
  17. Carefully lift the distributor out of the cylinder head. Remove the gasket at the base of the distributor and discard.
  18.  

To install:
  1. Before installing the distributor into the cylinder head, place a new gasket on the base of the distributor.
  2.  
  3. Align the paint marks on the rotor and distributor body.
  4.  
  5. Align the paint marks on the distributor body and cylinder head, then carefully insert the distributor into the hole in the cylinder head.
  6.  
  7. Install the distributor retainer bolts, and tighten.
  8.  
  9. Install any vacuum hoses removed, as well as the wire harness to the distributor.
  10.  
  11. Install the distributor cap on the distributor body and tighten the retaining screws. Connect the plug wires to the correct spark plugs. Attach the high tension wire from the distributor cap to the coil.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine and allow it to reach normal operating temperature, then check the ignition timing. Adjust the timing if needed. Refer to the procedure in General Information & Maintenance .
  16.  

ENGINE ROTATED

See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: Align the matchmarks on the distributor body

If the engine has been cranked, disassembled, or the timing otherwise lost, proceed as follows:

  1. Remove the plastic dust cover from the timing port on the flywheel housing.
  2.  
  3. Remove the No. 1 spark plug. Use a wrench on the crankshaft pulley bolt (on manual transmission cars place transmission in NEUTRAL) and slowly rotate the engine until the TDC 0 mark on the flywheel aligns with the pointer on the transaxle/transmission. While turning the engine place your finger over the No. 1 spark plug hole, when you feel air escaping past your finger the piston is on the compression stroke and when the marks align the piston is at TDC (top dead center).
  4.  
  5. An alternate method is to remove the bolts that hold the valve cover to expose the valves on No. 1 cylinder. Rotate the engine so that the valves in No. 1 cylinder are closed and the TDC 0 mark on the flywheel lines up with the pointer.
  6.  
  7. Align the small depression on the distributor drive pinion with the mark on the distributor body. This will align the rotor with the No. 1 spark plug terminal on the distributor cap. Make sure the base gasket is located in the proper position.
  8.  
  9. Align the matchmarks you have made on the distributor body with those on the engine block and install the distributor in the engine. Make sure the drive is engaged.
  10.  
  11. Install the hold-down bolt(s) finger-tight.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine and adjust the ignition timing.
  16.  

1.6L, 1.8L and 2.7L Engines

See Figures 2, 3 and 4

Click image to see an enlarged view

Fig. Fig. 2: Remove the distributor cap-1.8L engine shown



Click image to see an enlarged view

Fig. Fig. 3: Paint alignment marks on the distributor body, rotor and cylinder head



Click image to see an enlarged view

Fig. Fig. 4: With the hold-down bolt removed, lift out the distributor

ENGINE NOT ROTATED
  1. Disconnect the negative battery cable.
  2.  
  3. Unfasten the distributor wire harness.
  4.  
  5. Remove the high tension wire from the coil.
  6.  
  7. If any vacuum lines are attached to the distributor, tag, then disconnect them.
  8.  
  9. Tag then remove each individual spark plug wire at the spark plug.
  10.  
  11. Remove the distributor cap from the distributor body by loosening the retainer screws or unfastening the two clips.
  12.  
  13. Paint alignment marks on the rotor, distributor body and cylinder head at the base of the distributor.
  14.  
  15. Loosen and remove the retaining bolt , or bolts depending on model which secure the distributor to the cylinder head.
  16.  
  17. Carefully lift the distributor out of the cylinder head. Remove the gasket at the base of the distributor and discard.
  18.  

To install:
  1. Before installing the distributor into the cylinder head, place a new gasket on the base of the distributor.
  2.  
  3. Align the paint marks on the rotor and distributor body.
  4.  
  5. Align the paint marks on the distributor body and cylinder head, then carefully insert the distributor into the hole in the cylinder head.
  6.  
  7. Install the distributor retainer bolts, or bolts depending on model, and tighten.
  8.  
  9. Install any vacuum hoses removed, as well as the wire harness to the distributor.
  10.  
  11. Install the distributor cap on the distributor body and secure Connect the plug wires to the correct spark plugs. Attach the high tension wire from the distributor cap to the coil.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine and allow it to reach normal operating temperature, then check the ignition timing. Adjust the timing if needed. Refer to the procedure in General Information & Maintenance .
  16.  

ENGINE ROTATED

See Figure 1

If the engine has been cranked, disassembled, or the timing otherwise lost, proceed as follows:

  1. Remove the plastic dust cover from the timing port on the flywheel housing.
  2.  
  3. Remove the No. 1 spark plug. Use a wrench on the crankshaft pulley bolt (on manual transmission cars place transmission in NEUTRAL) and slowly rotate the engine until the TDC 0 mark on the flywheel aligns with the pointer. While turning the engine place your finger over the No. 1 spark plug hole, when you feel air escaping past your finger the piston is on the compression stroke and when the marks align the piston is at TDC (top dead center).
  4.  
  5. An alternate method is to remove the bolts that hold the right (passenger's) side valve cover and remove the cover to expose the valves on No. 1 cylinder. Rotate the engine so that the valves in No. 1 cylinder are closed and the TDC 0 mark on the flywheel lines up with the pointer.
  6.  
  7. Align the small depression on the distributor drive pinion with the mark on the distributor body. This will align the rotor with the No. 1 spark plug terminal on the distributor cap. Make sure the O-ring is located in the proper position.
  8.  
  9. Align the matchmarks you have made on the distributor body with those on the engine block and install the distributor in the engine. Make sure the drive is engaged.
  10.  
  11. Install the hold-down bolt(s) finger-tight.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine and adjust the ignition timing.
  16.  

2.2L, 2.5L and 3.3L Engines

The 2.2L, 2.5L and 3.3L engines do not use a distributor.

DISASSEMBLY



1.2L Engines

See Figures 5 and 6

Click image to see an enlarged view

Fig. Fig. 5: Disassembled 1.2L engine's distributor-carbureted version



Click image to see an enlarged view

Fig. Fig. 6: Disassembled 1.2L engine's distributor-fuel injected version

  1. Remove the distributor from the engine.
  2.  
  3. Remove the rotor of the distributor body.
  4.  
  5. Remove the rubber packing at the base of the rotor, if equipped.
  6.  
  7. Remove the harness from the holder on the distributor body. Disconnect the ground strap as necessary.
  8.  
  9. On the carbureted model, place two standard screwdrivers under the reluctor and pry upward to remove.
  10.  
  11. On the carbureted model, remove the screws which secure the breaker assembly and remove the assembly. On fuel injected models, remove the screws which secure the generator assembly and remove the assembly including the harness.
  12.  

Do not disassemble the breaker or generator assemblies.

Nippondenso Model 100291 Distributor

See Figure 7

Click image to see an enlarged view

Fig. Fig. 7: Disassembled Nippondenso 100291 distributor

This distributor was installed in many 1.6L and 1.8L engines.

  1. Remove the rotor from the distributor.
  2.  
  3. Remove the vacuum controller by removing the snapring and screw.
  4.  
  5. Remove the screw plate which secures the breaker plate in position.
  6.  
  7. Remove the igniter by loosening the screws.
  8.  
  9. Remove the breaker plate.
  10.  
  11. Unfasten the dust cover. Be careful not to break the cover.
  12.  
  13. Remove the governor spring using needle nose pliers. Remove the snapring, then remove the flyweight. Be careful not to deform the governor spring.
  14.  
  15. Remove the cap from the top of the governor shaft and remove the screw. Pull out the governor shaft and signal rotor.
  16.  
  17. Remove the roll pin from the spiral gear using a punch.
  18.  
  19. Slide the governor shaft from the housing.
  20.  

Hitachi Model D4R84 Distributor

See Figure 8

Click image to see an enlarged view

Fig. Fig. 8: Disassembled Hitachi D4R84 distributor

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the distributor from the engine
  4.  
  5. Remove the cap by detaching the spring clip or removing the attaching screws.
  6.  
  7. Remove the rotor and remove the carbon point from the cap.
  8.  
  9. Remove the vacuum controller by removing the screws.
  10.  
  11. Remove the harness by disconnecting the control unit terminals.
  12.  
  13. Pry the reluctor off the shaft using small pry bars.
  14.  
  15. Remove the retaining screws and remove the breaker plate.
  16.  
  17. Remove the screws attaching the control unit to the breaker plate. Remove the control unit.
  18.  
  19. Remove the screws attaching the stator and separate the magnet from the stator.
  20.  
  21. Remove the O-ring and toll pin from the spiral gear. Remove the spiral gear from the distributor shaft.
  22.  
  23. Remove the distributor shaft from the housing.
  24.  
  25. Remove the governor springs from the shaft.
  26.  
  27. Remove the governor weights from the shaft.
  28.  

Hitachi D4P84 and D6P84 Distributors

These distributors were installed on late model 1.8L fuel injected and all 2.7L fuel injected engines.

Subaru does not recommend disassembly of the Model D4P84 or D6P84 distributors. If component replacement is necessary, the distributor should be replaced as an assembly.

INSPECTION



1.2L Engine
  1. Check the carbon point for free movement in the cap.
  2.  
  3. Measure the carbon point length with calipers. Minimum length is 0.39 in. (10mm). Replace if not within specification.
  4.  
  5. Check all terminals for corrosion or damage. Clean as necessary.
  6.  
  7. Check the rotor head for deformity or corrosion. Replace as necessary.
  8.  
  9. Check the reluctor for deformity, damage and free play. Replace as necessary.
  10.  
  11. Check the stator for damage or bending. Replace as necessary.
  12.  
  13. Check the breaker plate frictional section for free movement. Lubricate as required.
  14.  

Nippondenso Model 100291 Distributor

See Figure 9

Click image to see an enlarged view

Fig. Fig. 9: Use an ohmmeter to test the signal generator

  1. Inspect the distributor base for any clogging of the breather hole.
  2.  
  3. Check all components for signs of cracking, burn marks or other damage.
  4.  
  5. Using a vacuum pump or equivalent, check the canister plunger to make sure it functions with vacuum.
  6.  
  7. Use an ohmmeter to check the signal generator. Connect the meter to the wire harness, and check the resistance. The correct resistance should be 130-190 ohms.
  8.  

Hitachi Model D4R84 Distributor
  1. Replace the reluctor if damaged and the stator if bent or scratched.
  2.  
  3. Replace the breaker plate if it binds or does not move smoothly.
  4.  
  5. With the shaft held stationary, manually turn the reluctor counterclockwise. It is working properly if it returns to the original position when released. If not, replace.
  6.  
  7. Apply a vacuum to the vacuum controller using a hand vacuum pump. If it does not hold vacuum, replace it.
  8.  

ASSEMBLY



1.2L Engine

See Figures 10, 11 and 12

Click image to see an enlarged view

Fig. Fig. 10: Proper alignment of breaker plate-carbureted 1.2L engine's distributor



Click image to see an enlarged view

Fig. Fig. 11: Proper alignment of generator plate-fuel injected 1.2L engine's distributor



Click image to see an enlarged view

Fig. Fig. 12: Air gap measurement

  1. Assembly is the reverse of disassembly. Install the breaker assembly by aligning the mark on the plate with that on the housing.
  2.  
  3. Connect the lead wires to their proper locations.
  4.  
  5. Adjust the air gap between the reluctor and the stator to 0.008-0.016 in. (0.2-0.4mm). Loosen the stator screw to adjust the gap.
  6.  

Nippondenso Model 100291 Distributor

See Figures 13 and 14

Click image to see an enlarged view

Fig. Fig. 13: Proper signal generator alignment



Click image to see an enlarged view

Fig. Fig. 14: Adjusting the air gap

  1. Assembly is the reverse of disassembly. Lubricate and install the governor shaft and spiral gear. Select washers that will give a gear-to-housing clearance of 0.0059-0.0197 in. (0.15-0.50mm). Install the roll pin and stake it in place.
  2.  
  3. Install the signal rotor by aligning the matchmark scribed on the notch with that of the spiral gear.
  4.  
  5. Install the breaker plate, evenly fitting the set springs into the housing.
  6.  
  7. Adjust the air gap between the signal generator and the signal rotor to 0.008-0.016 in. (0.2-0.4mm).
  8.  
  9. Install the vacuum controller, dust cover, rotor and cap.
  10.  
  11. Install the distributor into the engine, start the engine and check the timing.
  12.  

Hitachi Model D4R84 Distributor

See Figures 15, 16 and 17

Click image to see an enlarged view

Fig. Fig. 15: Proper roll pin and rotor shaft alignment



Click image to see an enlarged view

Fig. Fig. 16: Alignment of distributor for roll pin installation



Click image to see an enlarged view

Fig. Fig. 17: Air gap adjustment

  1. Assembly is the reverse of disassembly. Apply a coat of grease to the shaft bearing and sliding surface for the breaker plate.
  2.  
  3. Install the governor and weights and springs. Attach the springs to the hook pins.
  4.  
  5. Position the cutout section of the rotor shaft and roll pin holes in line.
  6.  
  7. Using a new roll pin, install the spiral gear so that its alignment mark is aligned with the mark on the housing when the cutout section of the rotor shaft faces the No. 1 cylinder mark on the cap.
  8.  
  9. Align the breaker plate with the retaining screw hole during installation.
  10.  
  11. Press the roll pin into place in parallel with the cutout section of the reluctor.
  12.  
  13. Connect the harness to the control unit.
  14.  
  15. After properly assembling the parts, measure the air gap between the reluctor and stator with a feeler gauge. The air gap should be 0.012-0.020 in. (0.3-0.5mm). If not within specification, adjust the stator to gain specified clearance.
  16.  

 
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