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Introduction

The FA20D engine was a 2.0-litre horizontally-opposed (or 'boxer') 4-cylinder petrol engine that was manufactured at Subaru's engine constitute in Ota, Gunma. The FA20D engine was introduced in the Subaru BRZ and Toyota ZN6 86; for the latter, Toyota initially referred to it as the 4U-GSE before adopting the FA20 name.

Key features of the FA20D engine included it:

• Open deck design (i.e. the space between the cylinder bores at the top of the cylinder cake was open);
• Aluminium alloy cake and cylinder head;
• Double overhead camshafts;
• Four valves per cylinder with variable inlet and frazzle valve timing;
• Direct and port fuel injection systems;
• Compression ratio of 12.5:ane; and,
• 7450 rpm redline.

FA20D block

The FA20D engine had an aluminium blend block with 86.0 mm bores and an 86.0 mm stroke for a capacity of 1998 cc. Within the cylinder bores, the FA20D engine had bandage iron liners.

Cylinder head: camshaft and valves

The FA20D engine had an aluminium alloy cylinder head with concatenation-driven double overhead camshafts. The 4 valves per cylinder – two intake and 2 frazzle – were actuated by roller rocker arms which had built-in needle bearings that reduced the friction that occurred between the camshafts and the roller rocker arms (which actuated the valves). The hydraulic lash adjuster – located at the fulcrum of the roller rocker arm – consisted primarily of a plunger, plunger spring, check brawl and bank check ball spring. Through the utilize of oil pressure level and spring strength, the lash adjuster maintained a abiding zero valve clearance.

Valve timing: D-AVCS

To optimise valve overlap and utilize frazzle pulsation to enhance cylinder filling at high engine speeds, the FA20D engine had variable intake and exhaust valve timing, known as Subaru's 'Dual Active Valve Control System' (D-AVCS).

For the FA20D engine, the intake camshaft had a lx degree range of adjustment (relative to crankshaft angle), while the exhaust camshaft had a 54 caste range. For the FA20D engine,

• Valve overlap ranged from -33 degrees to 89 degrees (a range of 122 degrees);
• Intake duration was 255 degrees; and,
• Exhaust elapsing was 252 degrees.

The camshaft timing gear assembly contained advance and retard oil passages, every bit well as a detent oil passage to brand intermediate locking possible. Furthermore, a sparse cam timing oil command valve assembly was installed on the front surface side of the timing chain cover to make the variable valve timing machinery more meaty. The cam timing oil control valve assembly operated co-ordinate to signals from the ECM, controlling the position of the spool valve and supplying engine oil to the advance hydraulic sleeping accommodation or retard hydraulic chamber of the camshaft timing gear assembly.

To alter cam timing, the spool valve would be activated past the cam timing oil control valve assembly via a bespeak from the ECM and move to either the right (to advance timing) or the left (to retard timing). Hydraulic pressure in the advance chamber from negative or positive cam torque (for advance or retard, respectively) would employ force per unit area to the advance/retard hydraulic sleeping accommodation through the advance/retard check valve. The rotor vane, which was coupled with the camshaft, would then rotate in the advance/retard management against the rotation of the camshaft timing gear associates – which was driven by the timing chain – and advance/retard valve timing. Pressed by hydraulic pressure from the oil pump, the detent oil passage would go blocked so that it did not operate.

When the engine was stopped, the spool valve was put into an intermediate locking position on the intake side by spring power, and maximum accelerate country on the frazzle side, to prepare for the next activation.

Intake and throttle

The intake system for the Toyota ZN6 86 and Subaru Z1 BRZ included a 'audio creator', damper and a thin rubber tube to transmit intake pulsations to the cabin. When the intake pulsations reached the sound creator, the damper resonated at certain frequencies. According to Toyota, this design enhanced the engine consecration noise heard in the cabin, producing a 'linear intake sound' in response to throttle awarding.

In contrast to a conventional throttle which used accelerator pedal effort to determine throttle angle, the FA20D engine had electronic throttle command which used the ECM to calculate the optimal throttle valve angle and a throttle control motor to control the bending. Furthermore, the electronically controlled throttle regulated idle speed, traction control, stability control and cruise control functions.

Port and direct injection

The FA20D engine had:

• A straight injection system which included a high-force per unit area fuel pump, fuel delivery pipage and fuel injector assembly; and,
• A port injection system which consisted of a fuel suction tube with pump and approximate assembly, fuel pipe sub-assembly and fuel injector assembly.

Based on inputs from sensors, the ECM controlled the injection volume and timing of each type of fuel injector, according to engine load and engine speed, to optimise the fuel:air mixture for engine weather. According to Toyota, port and direct injection increased performance across the revolution range compared with a port-just injection engine, increasing ability past up to 10 kW and torque by up to 20 Nm.

As per the table below, the injection organization had the following operating weather condition:

• Cold outset: the port injectors provided a homogeneous air:fuel mixture in the combustion bedchamber, though the mixture around the spark plugs was stratified by compression stroke injection from the directly injectors. Furthermore, ignition timing was retarded to raise exhaust gas temperatures so that the catalytic converter could reach operating temperature more than quickly;
• Depression engine speeds: port injection and direct injection for a homogenous air:fuel mixture to stabilise combustion, improve fuel efficiency and reduce emissions;
• Medium engine speeds and loads: direct injection only to utilize the cooling effect of the fuel evaporating every bit it entered the combustion chamber to increment intake air volume and charging efficiency; and,
• Loftier engine speeds and loads: port injection and direct injection for high fuel catamenia book.

The FA20D engine used a hot-wire, slot-in blazon air menstruation meter to measure intake mass – this meter allowed a portion of intake air to menses through the detection area and so that the air mass and flow charge per unit could be measured directly. The mass air flow meter besides had a congenital-in intake air temperature sensor.

The FA20D engine had a pinch ratio of 12.five:one.

Ignition

The FA20D engine had a direct ignition system whereby an ignition gyre with an integrated igniter was used for each cylinder. The spark plug caps, which provided contact to the spark plugs, were integrated with the ignition coil associates.

The FA20D engine had long-reach, iridium-tipped spark plugs which enabled the thickness of the cylinder caput sub-assembly that received the spark plugs to be increased. Furthermore, the water jacket could be extended near the combustion chamber to enhance cooling performance. The triple footing electrode type iridium-tipped spark plugs had 60,000 mile (96,000 km) maintenance intervals.

The FA20D engine had apartment type knock control sensors (non-resonant type) attached to the left and correct cylinder blocks.

Exhaust and emissions

The FA20D engine had a 4-two-1 exhaust manifold and dual tailpipe outlets. To reduce emissions, the FA20D engine had a returnless fuel organization with evaporative emissions control that prevented fuel vapours created in the fuel tank from beingness released into the temper by catching them in an activated charcoal canister.

Uneven idle and stalling

For the Subaru BRZ and Toyota 86, there take been reports of

• varying idle speed;
• rough idling;
• shuddering; or,
• stalling

that were accompanied by

• the 'check engine' light illuminating; and,
• the ECU issuing error codes P0016, P0017, P0018 and P0019.

Initially, Subaru and Toyota attributed these symptoms to the VVT-i/AVCS controllers not coming together manufacturing tolerances which caused the ECU to detect an abnormality in the cam actuator duty cycle and restrict the functioning of the controller. To fix, Subaru and Toyota developed new software mapping that relaxed the ECU's tolerances and the VVT-i/AVCS controllers were later manufactured to a 'tighter specification'.

There have been cases, withal, where the vehicle has stalled when coming to rest and the ECU has issued error codes P0016 or P0017 – these symptoms have been attributed to a faulty cam sprocket which could crusade oil pressure loss. Equally a result, the hydraulically-controlled camshaft could not respond to ECU signals. If this occurred, the cam sprocket needed to be replaced.

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Source: http://www.australiancar.reviews/Subaru_FA20D_Engine.php

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