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Introduction

The FA20D engine was a 2.0-litre horizontally-opposed (or 'boxer') four-cylinder petrol engine that was manufactured at Subaru'southward engine plant 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 pinnacle of the cylinder block was open);
• Aluminium alloy block and cylinder caput;
• Double overhead camshafts;
• Four valves per cylinder with variable inlet and exhaust valve timing;
• Straight and port fuel injection systems;
• Compression ratio of 12.5:1; and,
• 7450 rpm redline.

FA20D cake

The FA20D engine had an aluminium alloy block with 86.0 mm bores and an 86.0 mm stroke for a capacity of 1998 cc. Inside the cylinder bores, the FA20D engine had cast fe liners.

Cylinder head: camshaft and valves

The FA20D engine had an aluminium alloy cylinder caput with chain-driven double overhead camshafts. The 4 valves per cylinder – two intake and ii exhaust – 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 ball and check ball spring. Through the use of oil pressure level and bound force, the lash adjuster maintained a constant zero valve clearance.

Valve timing: D-AVCS

To optimise valve overlap and utilise exhaust pulsation to enhance cylinder filling at high engine speeds, the FA20D engine had variable intake and exhaust valve timing, known equally Subaru's 'Dual Active Valve Command 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 degree 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,
• Frazzle elapsing was 252 degrees.

The camshaft timing gear assembly contained accelerate and retard oil passages, as well as a detent oil passage to make intermediate locking possible. Furthermore, a thin cam timing oil control valve associates was installed on the front surface side of the timing chain cover to make the variable valve timing mechanism more compact. The cam timing oil control valve associates operated according to signals from the ECM, controlling the position of the spool valve and supplying engine oil to the advance hydraulic sleeping room 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 motility to either the right (to advance timing) or the left (to retard timing). Hydraulic pressure level in the advance chamber from negative or positive cam torque (for advance or retard, respectively) would apply force per unit area to the accelerate/retard hydraulic chamber through the advance/retard check valve. The rotor vane, which was coupled with the camshaft, would then rotate in the advance/retard direction against the rotation of the camshaft timing gear assembly – 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 advance land 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 'sound creator', damper and a sparse rubber tube to transmit intake pulsations to the cabin. When the intake pulsations reached the audio 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 application.

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

Port and direct injection

The FA20D engine had:

• A directly injection system which included a high-pressure fuel pump, fuel delivery pipe and fuel injector assembly; and,
• A port injection system which consisted of a fuel suction tube with pump and gauge associates, fuel pipage sub-assembly and fuel injector associates.

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 condition. According to Toyota, port and straight injection increased operation across the revolution range compared with a port-only injection engine, increasing power by upward to 10 kW and torque by upwards to 20 Nm.

As per the tabular array below, the injection system had the following operating conditions:

• Cold get-go: the port injectors provided a homogeneous air:fuel mixture in the combustion chamber, though the mixture around the spark plugs was stratified past compression stroke injection from the direct injectors. Furthermore, ignition timing was retarded to heighten exhaust gas temperatures so that the catalytic converter could reach operating temperature more than chop-chop;
• Low engine speeds: port injection and directly injection for a homogenous air:fuel mixture to stabilise combustion, improve fuel efficiency and reduce emissions;
• Medium engine speeds and loads: straight injection only to utilise the cooling effect of the fuel evaporating as it entered the combustion chamber to increase intake air volume and charging efficiency; and,
• High engine speeds and loads: port injection and direct injection for loftier fuel flow volume.

The FA20D engine used a hot-wire, slot-in type air flow meter to measure intake mass – this meter allowed a portion of intake air to flow through the detection area so that the air mass and catamenia rate could be measured direct. The mass air flow meter also had a born intake air temperature sensor.

The FA20D engine had a compression ratio of 12.5:1.

Ignition

The FA20D engine had a straight ignition arrangement whereby an ignition whorl 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 assembly.

The FA20D engine had long-attain, iridium-tipped spark plugs which enabled the thickness of the cylinder head sub-associates that received the spark plugs to exist increased. Furthermore, the water jacket could exist extended most the combustion chamber to enhance cooling performance. The triple ground electrode type iridium-tipped spark plugs had 60,000 mile (96,000 km) maintenance intervals.

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

Exhaust and emissions

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

Uneven idle and stalling

For the Subaru BRZ and Toyota 86, at that place take been reports of

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

that were accompanied past

• the 'check engine' calorie-free illuminating; and,
• the ECU issuing mistake codes P0016, P0017, P0018 and P0019.

Initially, Subaru and Toyota attributed these symptoms to the VVT-i/AVCS controllers not meeting manufacturing tolerances which caused the ECU to detect an abnormality in the cam actuator duty cycle and restrict the performance 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 subsequently manufactured to a 'tighter specification'.

There have been cases, however, where the vehicle has stalled when coming to residual and the ECU has issued error codes P0016 or P0017 – these symptoms have been attributed to a faulty cam sprocket which could cause oil pressure loss. As a result, the hydraulically-controlled camshaft could non respond to ECU signals. If this occurred, the cam sprocket needed to exist replaced.

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