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Subaru Justy 1990 Factory Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Subaru Model: Justy Year: 1990 Chassis Codes: KA1, KA2, KA5, KA6, KA7, KA8 (depending on engine and drivetrain) Codes Engine Codes: EF10, EF12 (and potential variations) 👋 Introduction Market Position Market Position: The Subaru Justy was a compact and economical subcompact car, often available with Subaru's signature Symmetrical All-Wheel Drive system, positioning it as a practical and capable option in its segment. Competitive Analysis Competitors: Competed against vehicles like the Suzuki Swift/Cultus, Daihatsu Charade, Hyundai Excel, and early models of the Ford Festiva. Key Features Key Features Highlight: Compact size, fuel efficiency, availability of 4WD, reliable mechanicals, and a straightforward design. Manual Value Proposition Value Proposition: Provides comprehensive, factory-authorized repair and maintenance information, enabling owners to perform tasks themselves, saving money on labor costs and ensuring proper vehicle upkeep. 📋 Manual Details Coverage Areas Coverage Scope: All models, all engine types for the specified year. Page Count Estimated Page Count: Approximately 700-1000+ pages (typical for a comprehensive factory service manual) Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical (assembly, disassembly, inspection, repair), lubrication system, cooling system, fuel system (carburetor, fuel injection), ignition system, emission control systems. Drivetrain Systems: Clutch, manual transmission, automatic transmission (if applicable), driveshafts, axles, differentials, four-wheel-drive system (if applicable). Suspension Steering: Front suspension, rear suspension, steering gear, power steering system (if applicable), wheel alignment specifications. Braking Systems: Front brakes (disc/drum), rear brakes (disc/drum), parking brake, hydraulic system, ABS (if applicable). Electrical Systems: Battery, charging system (alternator), starting system, lighting system, instrument cluster, ignition switch, power windows/locks (if equipped), wiper/washer system, audio system, fuse box diagrams, wiring diagrams. Body Chassis: Body construction, doors, hood, trunk lid, bumpers, interior trim, glass, exterior trim, chassis components. HVAC System: Heating system, ventilation, air conditioning system (if equipped). Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspections and adjustments, tire rotation and pressure checks. Repair Procedures: Step-by-step instructions for engine overhaul, transmission repair, brake caliper replacement, suspension component replacement, electrical component troubleshooting and repair, body panel repair. Diagnostics Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting charts, component testing procedures. Wiring Diagrams: Comprehensive wiring diagrams for all electrical systems, including color coding and connector pinouts. Technical Depth Technical Depth: Extensive, covering everything from basic routine maintenance to complete engine and transmission rebuilds, including detailed specifications and tolerances. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding Type: Digital download (no physical binding) Paper Type Paper Type: Digital (PDF - printable) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 3-cylinder, 4-stroke, naturally aspirated gasoline engine. Displacement: 1.0L (997cc) and 1.2L (1189cc) - EF10 and EF12 respectively. Performance Horsepower 1.0L: Approx. 55-60 PS (40-44 kW) at 6,000 RPM (depending on market and tune) Torque 1.0L: Approx. 80-85 Nm (59-63 lb-ft) at 3,500 RPM (depending on market and tune) Horsepower 1.2L: Approx. 65-70 PS (48-51 kW) at 6,000 RPM (depending on market and tune) Torque 1.2L: Approx. 95-100 Nm (70-74 lb-ft) at 3,500 RPM (depending on market and tune) Fuel System Fuel Delivery: Carburetor (single or dual barrel) for most 1.0L and some 1.2L models; Fuel Injection (MPI) on later or higher-trim 1.2L models. Engine Management Ignition System: Distributor-based ignition system, typically with electronic ignition control (points may be present on very early models but unlikely for 1990). 🔧 Transmission Standard Standard Transmission: 5-speed manual transmission. Optional Optional Transmission: 3-speed automatic transmission (ECVT - Electronic Continuously Variable Transmission) on some models, particularly those with 4WD. Features Drivetrain Options: Front-Wheel Drive (FWD) and Symmetrical All-Wheel Drive (AWD). Fluid Specifications Manual Transmission Fluid: Hypoid gear oil, API GL-4, SAE 75W-90 or 80W-90 (refer to specific vehicle's owner's manual or this manual for exact specification). Automatic Transmission Fluid: Subaru's proprietary ATF or equivalent specified in the manual for the ECVT system. 📐 Dimensions Exterior Length: Approx. 3,565 mm (140.4 in) for 3-door hatchback; Approx. 3,620 mm (142.5 in) for 5-door hatchback. Width: Approx. 1,565 mm (61.6 in). Height: Approx. 1,390 mm (54.7 in) for 3-door; Approx. 1,405 mm (55.3 in) for 5-door. Weights Curb Weight: Approx. 750-850 kg (1650-1875 lbs) depending on configuration (engine, drivetrain, body style). 🛡️ Safety Features Ratings Safety Ratings Era: Safety standards were less stringent in 1990; specific crash test ratings from modern agencies are unlikely to be available. Focus on passive safety features of the era. Active Features Active Safety Features: Front disc brakes, rear drum brakes (or disc on some higher trims), optional ABS on some AWD models, effective handling due to compact wheelbase and suspension tuning. Passive Features Passive Safety Features: Seat belts (front and rear), reinforced body structure for its class, safety steering column. 💡 Technology...
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Subaru Justy 1990 Factory Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Justy
Year:
1990
Chassis Codes:
KA1, KA2, KA5, KA6, KA7, KA8 (depending on engine and drivetrain)
Codes
Engine Codes:
EF10, EF12 (and potential variations)
👋 Introduction
Market Position
Market Position:
The Subaru Justy was a compact and economical subcompact car, often available with Subaru's signature Symmetrical All-Wheel Drive system, positioning it as a practical and capable option in its segment.
Competitive Analysis
Competitors:
Competed against vehicles like the Suzuki Swift/Cultus, Daihatsu Charade, Hyundai Excel, and early models of the Ford Festiva.
Key Features
Key Features Highlight:
Compact size, fuel efficiency, availability of 4WD, reliable mechanicals, and a straightforward design.
Manual Value Proposition
Value Proposition:
Provides comprehensive, factory-authorized repair and maintenance information, enabling owners to perform tasks themselves, saving money on labor costs and ensuring proper vehicle upkeep.
📋 Manual Details
Coverage Areas
Coverage Scope:
All models, all engine types for the specified year.
Page Count
Estimated Page Count:
Approximately 700-1000+ pages (typical for a comprehensive factory service manual)
Manual Type
Manual Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical (assembly, disassembly, inspection, repair), lubrication system, cooling system, fuel system (carburetor, fuel injection), ignition system, emission control systems.
Drivetrain Systems:
Clutch, manual transmission, automatic transmission (if applicable), driveshafts, axles, differentials, four-wheel-drive system (if applicable).
Suspension Steering:
Front suspension, rear suspension, steering gear, power steering system (if applicable), wheel alignment specifications.
Braking Systems:
Front brakes (disc/drum), rear brakes (disc/drum), parking brake, hydraulic system, ABS (if applicable).
Electrical Systems:
Battery, charging system (alternator), starting system, lighting system, instrument cluster, ignition switch, power windows/locks (if equipped), wiper/washer system, audio system, fuse box diagrams, wiring diagrams.
Body Chassis:
Body construction, doors, hood, trunk lid, bumpers, interior trim, glass, exterior trim, chassis components.
HVAC System:
Heating system, ventilation, air conditioning system (if equipped).
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspections and adjustments, tire rotation and pressure checks.
Repair Procedures:
Step-by-step instructions for engine overhaul, transmission repair, brake caliper replacement, suspension component replacement, electrical component troubleshooting and repair, body panel repair.
Diagnostics Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting charts, component testing procedures.
Wiring Diagrams:
Comprehensive wiring diagrams for all electrical systems, including color coding and connector pinouts.
Technical Depth
Technical Depth:
Extensive, covering everything from basic routine maintenance to complete engine and transmission rebuilds, including detailed specifications and tolerances.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding Type:
Digital download (no physical binding)
Paper Type
Paper Type:
Digital (PDF - printable)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 3-cylinder, 4-stroke, naturally aspirated gasoline engine.
Displacement:
1.0L (997cc) and 1.2L (1189cc) - EF10 and EF12 respectively.
Performance
Horsepower 1.0L:
Approx. 55-60 PS (40-44 kW) at 6,000 RPM (depending on market and tune)
Torque 1.0L:
Approx. 80-85 Nm (59-63 lb-ft) at 3,500 RPM (depending on market and tune)
Horsepower 1.2L:
Approx. 65-70 PS (48-51 kW) at 6,000 RPM (depending on market and tune)
Torque 1.2L:
Approx. 95-100 Nm (70-74 lb-ft) at 3,500 RPM (depending on market and tune)
Fuel System
Fuel Delivery:
Carburetor (single or dual barrel) for most 1.0L and some 1.2L models; Fuel Injection (MPI) on later or higher-trim 1.2L models.
Engine Management
Ignition System:
Distributor-based ignition system, typically with electronic ignition control (points may be present on very early models but unlikely for 1990).
🔧 Transmission
Standard
Standard Transmission:
5-speed manual transmission.
Optional
Optional Transmission:
3-speed automatic transmission (ECVT - Electronic Continuously Variable Transmission) on some models, particularly those with 4WD.
Features
Drivetrain Options:
Front-Wheel Drive (FWD) and Symmetrical All-Wheel Drive (AWD).
Fluid Specifications
Manual Transmission Fluid:
Hypoid gear oil, API GL-4, SAE 75W-90 or 80W-90 (refer to specific vehicle's owner's manual or this manual for exact specification).
Automatic Transmission Fluid:
Subaru's proprietary ATF or equivalent specified in the manual for the ECVT system.
📐 Dimensions
Exterior
Length:
Approx. 3,565 mm (140.4 in) for 3-door hatchback; Approx. 3,620 mm (142.5 in) for 5-door hatchback.
Width:
Approx. 1,565 mm (61.6 in).
Height:
Approx. 1,390 mm (54.7 in) for 3-door; Approx. 1,405 mm (55.3 in) for 5-door.
Weights
Curb Weight:
Approx. 750-850 kg (1650-1875 lbs) depending on configuration (engine, drivetrain, body style).
🛡️ Safety Features
Ratings
Safety Ratings Era:
Safety standards were less stringent in 1990; specific crash test ratings from modern agencies are unlikely to be available. Focus on passive safety features of the era.
Active Features
Active Safety Features:
Front disc brakes, rear drum brakes (or disc on some higher trims), optional ABS on some AWD models, effective handling due to compact wheelbase and suspension tuning.
Passive Features
Passive Safety Features:
Seat belts (front and rear), reinforced body structure for its class, safety steering column.
💡 Technology Features
Infotainment
Infotainment Features:
Basic AM/FM radio with cassette player, potentially with two speakers. Analog gauges for speedometer, tachometer (if equipped), fuel, and temperature.
Driver Assistance
Driver Assistance Features:
Limited to mechanical systems. ABS was an optional, advanced feature for its time on some models.
Connectivity
Connectivity Features:
No modern connectivity features like Bluetooth or USB. Analog radio antenna is the primary external interface.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first (typical recommendation for this era).
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on driving conditions.
Spark Plug Replacement:
Every 30,000-60,000 miles, depending on plug type (copper vs. platinum).
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 10W-30 or 10W-40 is commonly recommended. Check manual for specific viscosity based on temperature. Capacity approx. 3.0-3.5 liters.
Coolant Type:
Ethylene glycol based coolant, typically a green or orange color (refer to manual for specific formulation). A 50/50 mix with distilled water is standard. Capacity approx. 4.5-5.0 liters.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Power Steering Fluid:
ATF Dexron II or equivalent if equipped with power steering.
Known Issues
Common Issues Engine:
Carburetor tuning issues, worn timing belts (critical replacement interval), potential for oil leaks from gaskets and seals, valve seat wear in higher mileage engines.
Common Issues Drivetrain:
Clutch wear, noisy wheel bearings (especially on AWD models), potential for leaks from transmission seals, worn CV joints.
Common Issues Electrical:
Corroded grounds, worn starter motors, alternator bearing noise, intermittent dashboard lights, aging wiring harnesses.
Common Issues Chassis:
Rust and corrosion on the underbody, suspension bushings wear, exhaust system deterioration.
📚 Vehicle History
Brand Heritage
Brand Heritage Connection:
Subaru is known for its horizontally opposed ('boxer') engines and All-Wheel Drive systems. While the Justy primarily used inline engines, its AWD system shared Subaru's focus on traction and capability.
Model Evolution
Model Evolution Context:
The Justy (known as the Suzuki Cultus and Geo Metro in other markets) was developed in conjunction with Suzuki. The 1990 model represents a later iteration of the second generation, often with styling updates and improved powertrains.
Production
Production Location:
Primarily manufactured in Japan by Suzuki, and then sold under the Subaru and Geo brands in various international markets.
🏆 Awards & Recognition
Recognitions
Recognitions And Ratings:
The Justy was generally praised for its fuel economy and the unique capability of AWD in a small car. Its design was functional and utilitarian, appealing to budget-conscious buyers.
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