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1990 Subaru Justy Service Repair Manual 90

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🏷️ Basic Information Identification Make: Subaru Model: Justy Year: 1990 Generation Generation Code: KJ Codes Chassis Code: KJ8 👋 Introduction Market Position Target Audience: Professional mechanics, DIY enthusiasts, and Subaru Justy owners seeking to perform maintenance and repairs. Competitive Analysis Value Proposition: Cost-effective alternative to expensive OEM paper manuals, providing comprehensive information for all repair and maintenance needs. Key Features Content Breadth: Over 80 separate PDF sections covering all aspects of the vehicle. Accessibility: Works on Mac and Windows via Adobe Acrobat Reader. 📋 Manual Details Coverage Areas Covered Models: All 1990 Subaru Justy Models Page Count Estimated Page Count: >1000 Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format Type: Digital (PDF Sections) 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, diagnosis, tuning, emissions control, cooling system, lubrication system, fuel system (carburetor/injection), ignition system, starting system, charging system Drivetrain Systems: Front-wheel drive (FWD), All-wheel drive (AWD) system components, differentials, axles, CV joints Transmission Systems: Manual transmission (gearbox, clutch, linkage), automatic transmission (if applicable, likely not for 1990 base model) repair and adjustment Suspension Steering Systems: Front and rear suspension components, shock absorbers, springs, steering gearbox, power steering (if equipped), steering column, wheel alignment specifications Brake Systems: Front disc brakes, rear drum brakes (typical for the era), brake fluid specifications, hydraulic system repair, parking brake system Electrical Systems: Wiring schematics (comprehensive), lighting systems, instrument cluster, power windows/locks (if equipped), starter motor, alternator, battery, fuses, relays, diagnostic connectors Body And Chassis Systems: Body panel removal and installation, interior trim, doors, windows, locks, hinges, glass replacement, chassis lubrication, rust prevention Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, tire rotations, brake inspections, battery maintenance, tune-ups Repair Procedures: Engine rebuilds, clutch replacement, transmission overhaul, brake caliper/wheel cylinder service, suspension component replacement, electrical component diagnosis and replacement, exhaust system repair Diagnostic Procedures: Troubleshooting common symptoms, using diagnostic tools, interpreting fault codes (if applicable), electrical system diagnostics Installation Procedures: Installation of replacement parts, accessory installation guidelines (if covered) Technical Depth Depth Level: Comprehensive: Covers routine maintenance, troubleshooting, component-level repair, and full system overhauls. Detail Level: Detailed diagrams, step-by-step instructions, torque specifications, clearances, and diagnostic flowcharts. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text within PDF files Print Quality Printability: Printable pages as needed Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 3-Cylinder, 4-Stroke, SOHC Engine Code: EK33 (typical for this generation) Displacement: 1.0 L (997 cc) Bore X Stroke: 74.7 mm x 77.0 mm (typical) Compression Ratio: 9.5:1 (typical) Performance Horsepower: Approx. 55-60 hp @ 6000 rpm (market dependent) Torque: Approx. 56-60 lb-ft @ 3600 rpm (market dependent) Fuel System Fuel Delivery: Carburetor (likely Hitachi or Mikuni twin-choke) or Electronic Fuel Injection (EFI) depending on market and trim. Fuel Type: Unleaded Gasoline Fuel Pump Pressure: Refer to manual for specific EFI models, typically 35-45 psi. Ignition System Ignition Type: Distributorless Ignition System (DIS) or distributor-based system with electronic control. Spark Plug Type: NGK DCPR7E or equivalent (check manual for exact spec) Spark Plug Gap: 0.032 in (0.8 mm) (typical) 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transmission Optional Transmission Type: ECVT (Electronically Controlled Continuously Variable Transmission) - Optional in some markets. Features Gear Ratios: Refer to manual for specific ratios (e.g., 1st Gear: ~3.54, 2nd Gear: ~2.05, 3rd Gear: ~1.38, 4th Gear: ~1.03, 5th Gear: ~0.85, Reverse: ~3.42, Final Drive: ~4.11) Transmission Fluid Type: API GL-4 SAE 75W-90 Gear Oil (manual transmission) or Subaru ATF-HP (ECVT - if equipped). 📐 Dimensions Exterior Length: Approx. 3670 mm (144.5 in) Width: Approx. 1580 mm (62.2 in) Height: Approx. 1360 mm (53.5 in) Wheelbase: Approx. 2300 mm (90.6 in) Ground Clearance: Approx. 150 mm (5.9 in) Weights Curb Weight: Approx. 780-850 kg (1720-1875 lbs) depending on drivetrain. 🛡️ Safety Features Ratings Crash Test Data: Limited data available for this era and model; NTHSA/IIHS ratings from this period are often incomplete or not comparable to modern standards. Active Features Braking System: Front ventilated disc brakes, rear drum brakes. Anti-lock Braking System (ABS) was not typically available on this model. Passive Features Restraints: Seat belts (manual adjustment, 3-point front, 2-point rear bench typical). Chassis Design: Unibody construction with crumple zones (basic for the era). 💡 Technology Features Infotainment Audio System: Basic AM/FM stereo radio with cassette player. Aftermarket upgrades common. Driver Assistance ABS: Not typically equipped with Anti-lock Braking System (ABS). Connectivity Connectivity Features: Limited to basic radio functionality; no advanced connectivity options like Bluetooth or USB. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 miles or 6 months, whichever comes first (typical recommendation). Air Filter Replacement: Every 15,000-20,000 miles or as needed based on inspection. Spark Plug Replacement: Every 30,000 miles (check manual for specific plug type and interval)....
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1990 Subaru Justy Service Repair Manual 90
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Justy
Year:
1990
Generation
Generation Code:
KJ
Codes
Chassis Code:
KJ8
👋 Introduction
Market Position
Target Audience:
Professional mechanics, DIY enthusiasts, and Subaru Justy owners seeking to perform maintenance and repairs.
Competitive Analysis
Value Proposition:
Cost-effective alternative to expensive OEM paper manuals, providing comprehensive information for all repair and maintenance needs.
Key Features
Content Breadth:
Over 80 separate PDF sections covering all aspects of the vehicle.
Accessibility:
Works on Mac and Windows via Adobe Acrobat Reader.
📋 Manual Details
Coverage Areas
Covered Models:
All 1990 Subaru Justy Models
Page Count
Estimated Page Count:
>1000
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Format Type:
Digital (PDF Sections)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, diagnosis, tuning, emissions control, cooling system, lubrication system, fuel system (carburetor/injection), ignition system, starting system, charging system
Drivetrain Systems:
Front-wheel drive (FWD), All-wheel drive (AWD) system components, differentials, axles, CV joints
Transmission Systems:
Manual transmission (gearbox, clutch, linkage), automatic transmission (if applicable, likely not for 1990 base model) repair and adjustment
Suspension Steering Systems:
Front and rear suspension components, shock absorbers, springs, steering gearbox, power steering (if equipped), steering column, wheel alignment specifications
Brake Systems:
Front disc brakes, rear drum brakes (typical for the era), brake fluid specifications, hydraulic system repair, parking brake system
Electrical Systems:
Wiring schematics (comprehensive), lighting systems, instrument cluster, power windows/locks (if equipped), starter motor, alternator, battery, fuses, relays, diagnostic connectors
Body And Chassis Systems:
Body panel removal and installation, interior trim, doors, windows, locks, hinges, glass replacement, chassis lubrication, rust prevention
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, tire rotations, brake inspections, battery maintenance, tune-ups
Repair Procedures:
Engine rebuilds, clutch replacement, transmission overhaul, brake caliper/wheel cylinder service, suspension component replacement, electrical component diagnosis and replacement, exhaust system repair
Diagnostic Procedures:
Troubleshooting common symptoms, using diagnostic tools, interpreting fault codes (if applicable), electrical system diagnostics
Installation Procedures:
Installation of replacement parts, accessory installation guidelines (if covered)
Technical Depth
Depth Level:
Comprehensive: Covers routine maintenance, troubleshooting, component-level repair, and full system overhauls.
Detail Level:
Detailed diagrams, step-by-step instructions, torque specifications, clearances, and diagnostic flowcharts.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text within PDF files
Print Quality
Printability:
Printable pages as needed
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 3-Cylinder, 4-Stroke, SOHC
Engine Code:
EK33 (typical for this generation)
Displacement:
1.0 L (997 cc)
Bore X Stroke:
74.7 mm x 77.0 mm (typical)
Compression Ratio:
9.5:1 (typical)
Performance
Horsepower:
Approx. 55-60 hp @ 6000 rpm (market dependent)
Torque:
Approx. 56-60 lb-ft @ 3600 rpm (market dependent)
Fuel System
Fuel Delivery:
Carburetor (likely Hitachi or Mikuni twin-choke) or Electronic Fuel Injection (EFI) depending on market and trim.
Fuel Type:
Unleaded Gasoline
Fuel Pump Pressure:
Refer to manual for specific EFI models, typically 35-45 psi.
Ignition System
Ignition Type:
Distributorless Ignition System (DIS) or distributor-based system with electronic control.
Spark Plug Type:
NGK DCPR7E or equivalent (check manual for exact spec)
Spark Plug Gap:
0.032 in (0.8 mm) (typical)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Transmission
Optional
Transmission Type:
ECVT (Electronically Controlled Continuously Variable Transmission) - Optional in some markets.
Features
Gear Ratios:
Refer to manual for specific ratios (e.g., 1st Gear: ~3.54, 2nd Gear: ~2.05, 3rd Gear: ~1.38, 4th Gear: ~1.03, 5th Gear: ~0.85, Reverse: ~3.42, Final Drive: ~4.11)
Transmission Fluid Type:
API GL-4 SAE 75W-90 Gear Oil (manual transmission) or Subaru ATF-HP (ECVT - if equipped).
📐 Dimensions
Exterior
Length:
Approx. 3670 mm (144.5 in)
Width:
Approx. 1580 mm (62.2 in)
Height:
Approx. 1360 mm (53.5 in)
Wheelbase:
Approx. 2300 mm (90.6 in)
Ground Clearance:
Approx. 150 mm (5.9 in)
Weights
Curb Weight:
Approx. 780-850 kg (1720-1875 lbs) depending on drivetrain.
🛡️ Safety Features
Ratings
Crash Test Data:
Limited data available for this era and model; NTHSA/IIHS ratings from this period are often incomplete or not comparable to modern standards.
Active Features
Braking System:
Front ventilated disc brakes, rear drum brakes. Anti-lock Braking System (ABS) was not typically available on this model.
Passive Features
Restraints:
Seat belts (manual adjustment, 3-point front, 2-point rear bench typical).
Chassis Design:
Unibody construction with crumple zones (basic for the era).
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM stereo radio with cassette player. Aftermarket upgrades common.
Driver Assistance
ABS:
Not typically equipped with Anti-lock Braking System (ABS).
Connectivity
Connectivity Features:
Limited to basic radio functionality; no advanced connectivity options like Bluetooth or USB.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first (typical recommendation).
Air Filter Replacement:
Every 15,000-20,000 miles or as needed based on inspection.
Spark Plug Replacement:
Every 30,000 miles (check manual for specific plug type and interval).
Coolant Flush Interval:
Every 30,000 miles or 2 years.
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 10W-30 or 10W-40 (check owner's manual for climate-specific recommendations).
Engine Oil Capacity:
Approx. 3.5 quarts (3.3 liters) with filter change.
Coolant Type:
Ethylene Glycol based coolant, typically a 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Common Wear Items:
Clutch wear, exhaust system rust, CV joint boots, suspension bushings, carburetor issues (if equipped), ignition coil failure.
Electrical Gremlins:
Aging wiring harnesses and connectors can lead to intermittent electrical issues.
Rust Prone Areas:
Wheel arches, rocker panels, and chassis components can be susceptible to rust, especially in areas with harsh winters.
📚 Vehicle History
Brand Heritage
Subaru Philosophy:
Subaru has a long history of producing reliable and durable vehicles, often with a focus on AWD technology and practical design.
Model Evolution
Justy Introduction:
The Subaru Justy (also known as the Subaru J10 in some markets) was introduced in the mid-1980s as Subaru's entry into the subcompact car segment, competing with vehicles like the Honda Civic and Toyota Starlet.
Second Generation:
The 1990 model year represents the second generation of the Justy (KJ), which saw styling updates and potential mechanical refinements over the first generation.
Production
Manufacturing Location:
Primarily manufactured in Japan by Subaru (Fuji Heavy Industries).
🏆 Awards & Recognition
Recognitions
Market Reception:
The Justy was generally well-received for its affordability, fuel efficiency, and surprisingly capable AWD system (when equipped), particularly in markets where small, economical cars were in demand.
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