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Subaru Justy 1991 Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Justy Year: 1991 Codes Chassis Code: KA5 👋 Introduction Market Position Segment: Subcompact Hatchback Target Audience: Budget-conscious consumers, first-time car buyers, urban commuters. Competitive Analysis Key Competitors: Suzuki Swift, Daihatsu Charade, Honda Civic (earlier generations), Toyota Starlet. Key Features Distinguishing Features: Compact size, fuel efficiency, available All-Wheel Drive (Symmetrical AWD) in certain markets/trims, affordable pricing. 📋 Manual Details Coverage Areas Geographic Coverage: Global (technical information relevant to North American, European, and Asian markets) Page Count Estimated Page Count: Varies based on digital compression, likely 500-1500 pages (typical for comprehensive service manuals) Manual Type Type: Service and Repair Manual Language Language: English Format Delivery Format: Digital Download (PDF, ZIP, RAR, or EXE) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine construction, cylinder head, block, pistons, crankshaft, camshafts, timing, lubrication system, cooling system, fuel system (carburetor/injection), exhaust system. Engine Management: Ignition system, emissions control system, sensor diagnostics, ECU (Electronic Control Unit) operation. Transmission: Manual transmission (clutch, gearbox, driveline), Automatic transmission (if applicable to specific trims), transfer case (for 4WD models). Drivetrain: Front-wheel drive (FWD) and All-wheel drive (AWD) systems, differentials, CV joints, driveshafts. Suspension: Front suspension (struts, control arms), rear suspension (independent/semi-independent), shock absorbers, springs, bushings. Steering: Steering system components, steering column, power steering (if equipped), wheel alignment specifications. Brakes: Front and rear brake systems (disc/drum), master cylinder, brake lines, calipers, wheel cylinders, parking brake. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting system, fuses, relays, wiring diagrams, instrument cluster. Body And Chassis: Body panels, doors, windows, seats, interior trim, chassis structure, corrosion protection. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system components and service. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt adjustments. Troubleshooting: Diagnostic procedures for common faults, symptom-based troubleshooting guides, fault code interpretation (if applicable). Repair: Step-by-step instructions for disassembly, repair, and reassembly of all major vehicle components and systems. Diagnostics: System diagnostics, electrical troubleshooting with wiring diagrams, fuel system testing, emissions testing. Rebuilding: Detailed procedures for engine, transmission, and other component rebuilding. Technical Depth Depth: Comprehensive (covers basic maintenance to complete engine and transmission rebuilds, including detailed electrical diagnostics). 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable if originally produced as such, or OCR'd. Print Quality Printability: Printable on any standard printer. Illustration Quality: Illustrated with clear, step-by-step diagrams and exploded views. Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code And Type: EK23 (3-cylinder, SOHC, 12-valve) Displacement: 993 cc (0.99 Liters) Bore X Stroke: 72.0 mm x 81.6 mm Compression Ratio: 9.5:1 Performance Horsepower: Approx. 50-55 PS (37-41 kW) at 5,500 rpm (market dependent) Torque: Approx. 76-80 Nm (56-59 lb-ft) at 3,500 rpm (market dependent) Fuel System Fuel Delivery: Carburetor (single barrel) or Electronic Fuel Injection (EFI) depending on market and trim. Fuel Type: Unleaded Gasoline Engine Management Ignition System: Distributor-based electronic ignition. 🔧 Transmission Standard Type: 5-Speed Manual Optional Type: 3-Speed Automatic (less common) Features Drivetrain Options: Front-Wheel Drive (FWD) or Full-Time 4-Wheel Drive (4WD) with viscous coupling center differential. 📐 Dimensions Exterior Length: Approx. 3,570 mm (140.6 in) Width: Approx. 1,595 mm (62.8 in) Height: Approx. 1,370 mm (53.9 in) (FWD), 1,390 mm (54.7 in) (4WD) Wheelbase: Approx. 2,270 mm (89.4 in) Weights Curb Weight: Approx. 730 kg (1,609 lbs) for FWD manual, higher for 4WD/automatic. 🛡️ Safety Features Ratings Crash Test Performance: Limited specific official ratings available for this model year and market segment in many regions. Generally basic safety features for the era. Active Features Active Safety: Disc front brakes, Drum rear brakes. Passive Features Passive Safety: Seat belts, reinforced safety cell structure. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with cassette player. Aftermarket upgrades are common. Driver Assistance Driver Aid: Minimal driver assistance features for the era. Focus on basic functionality. Connectivity Connectivity: No integrated connectivity features like Bluetooth or USB. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 km (3,000 miles) or 6 months, whichever comes first. Air Filter Replacement: Every 15,000 km (9,000 miles) or 12 months. Spark Plug Replacement: Every 30,000 km (18,000 miles). Fluid Specifications Engine Oil Type: API SF or SG, SAE 10W-30 or 10W-40 (check manual for specific climate recommendations). Engine Oil Capacity: Approx. 3.0 - 3.5 Liters (3.2 - 3.7 US Quarts) with filter change. Coolant Type: Ethylene glycol-based antifreeze (50/50 mix with distilled water). Transmission Fluid Type Manual: API GL-4 SAE 75W-90 Gear Oil. Transmission Fluid Capacity Manual: Approx. 2.0 - 2.2 Liters (2.1 - 2.3 US Quarts). Transmission Fluid Type Automatic: Dexron II or equivalent. Brake Fluid Type: DOT 3 or DOT 4. Known Issues Common Faults: Carburetor issues (clogging, adjustment), ignition system component wear (distributor cap, rotor, coil), exhaust system corrosion,...
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Subaru Justy 1991 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Justy
Year:
1991
Codes
Chassis Code:
KA5
👋 Introduction
Market Position
Segment:
Subcompact Hatchback
Target Audience:
Budget-conscious consumers, first-time car buyers, urban commuters.
Competitive Analysis
Key Competitors:
Suzuki Swift, Daihatsu Charade, Honda Civic (earlier generations), Toyota Starlet.
Key Features
Distinguishing Features:
Compact size, fuel efficiency, available All-Wheel Drive (Symmetrical AWD) in certain markets/trims, affordable pricing.
📋 Manual Details
Coverage Areas
Geographic Coverage:
Global (technical information relevant to North American, European, and Asian markets)
Page Count
Estimated Page Count:
Varies based on digital compression, likely 500-1500 pages (typical for comprehensive service manuals)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Delivery Format:
Digital Download (PDF, ZIP, RAR, or EXE)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine construction, cylinder head, block, pistons, crankshaft, camshafts, timing, lubrication system, cooling system, fuel system (carburetor/injection), exhaust system.
Engine Management:
Ignition system, emissions control system, sensor diagnostics, ECU (Electronic Control Unit) operation.
Transmission:
Manual transmission (clutch, gearbox, driveline), Automatic transmission (if applicable to specific trims), transfer case (for 4WD models).
Drivetrain:
Front-wheel drive (FWD) and All-wheel drive (AWD) systems, differentials, CV joints, driveshafts.
Suspension:
Front suspension (struts, control arms), rear suspension (independent/semi-independent), shock absorbers, springs, bushings.
Steering:
Steering system components, steering column, power steering (if equipped), wheel alignment specifications.
Brakes:
Front and rear brake systems (disc/drum), master cylinder, brake lines, calipers, wheel cylinders, parking brake.
Electrical System:
Battery, charging system (alternator), starting system (starter motor), lighting system, fuses, relays, wiring diagrams, instrument cluster.
Body And Chassis:
Body panels, doors, windows, seats, interior trim, chassis structure, corrosion protection.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system components and service.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt adjustments.
Troubleshooting:
Diagnostic procedures for common faults, symptom-based troubleshooting guides, fault code interpretation (if applicable).
Repair:
Step-by-step instructions for disassembly, repair, and reassembly of all major vehicle components and systems.
Diagnostics:
System diagnostics, electrical troubleshooting with wiring diagrams, fuel system testing, emissions testing.
Rebuilding:
Detailed procedures for engine, transmission, and other component rebuilding.
Technical Depth
Depth:
Comprehensive (covers basic maintenance to complete engine and transmission rebuilds, including detailed electrical diagnostics).
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable if originally produced as such, or OCR'd.
Print Quality
Printability:
Printable on any standard printer.
Illustration Quality:
Illustrated with clear, step-by-step diagrams and exploded views.
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper Type:
Not Applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
EK23 (3-cylinder, SOHC, 12-valve)
Displacement:
993 cc (0.99 Liters)
Bore X Stroke:
72.0 mm x 81.6 mm
Compression Ratio:
9.5:1
Performance
Horsepower:
Approx. 50-55 PS (37-41 kW) at 5,500 rpm (market dependent)
Torque:
Approx. 76-80 Nm (56-59 lb-ft) at 3,500 rpm (market dependent)
Fuel System
Fuel Delivery:
Carburetor (single barrel) or Electronic Fuel Injection (EFI) depending on market and trim.
Fuel Type:
Unleaded Gasoline
Engine Management
Ignition System:
Distributor-based electronic ignition.
🔧 Transmission
Standard
Type:
5-Speed Manual
Optional
Type:
3-Speed Automatic (less common)
Features
Drivetrain Options:
Front-Wheel Drive (FWD) or Full-Time 4-Wheel Drive (4WD) with viscous coupling center differential.
📐 Dimensions
Exterior
Length:
Approx. 3,570 mm (140.6 in)
Width:
Approx. 1,595 mm (62.8 in)
Height:
Approx. 1,370 mm (53.9 in) (FWD), 1,390 mm (54.7 in) (4WD)
Wheelbase:
Approx. 2,270 mm (89.4 in)
Weights
Curb Weight:
Approx. 730 kg (1,609 lbs) for FWD manual, higher for 4WD/automatic.
🛡️ Safety Features
Ratings
Crash Test Performance:
Limited specific official ratings available for this model year and market segment in many regions. Generally basic safety features for the era.
Active Features
Active Safety:
Disc front brakes, Drum rear brakes.
Passive Features
Passive Safety:
Seat belts, reinforced safety cell structure.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player. Aftermarket upgrades are common.
Driver Assistance
Driver Aid:
Minimal driver assistance features for the era. Focus on basic functionality.
Connectivity
Connectivity:
No integrated connectivity features like Bluetooth or USB.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km (3,000 miles) or 6 months, whichever comes first.
Air Filter Replacement:
Every 15,000 km (9,000 miles) or 12 months.
Spark Plug Replacement:
Every 30,000 km (18,000 miles).
Fluid Specifications
Engine Oil Type:
API SF or SG, SAE 10W-30 or 10W-40 (check manual for specific climate recommendations).
Engine Oil Capacity:
Approx. 3.0 - 3.5 Liters (3.2 - 3.7 US Quarts) with filter change.
Coolant Type:
Ethylene glycol-based antifreeze (50/50 mix with distilled water).
Transmission Fluid Type Manual:
API GL-4 SAE 75W-90 Gear Oil.
Transmission Fluid Capacity Manual:
Approx. 2.0 - 2.2 Liters (2.1 - 2.3 US Quarts).
Transmission Fluid Type Automatic:
Dexron II or equivalent.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Common Faults:
Carburetor issues (clogging, adjustment), ignition system component wear (distributor cap, rotor, coil), exhaust system corrosion, suspension wear (bushings, ball joints), water pump leaks, radiator issues.
📚 Vehicle History
Brand Heritage
Subaru Legacy:
Subaru is known for its Symmetrical All-Wheel Drive system and horizontally opposed 'Boxer' engines, though the Justy utilized a different configuration.
Model Evolution
Justy Generations:
The 1991 model belongs to the second generation of the Subaru Justy, which was a rebadged Suzuki Cultus (Swift) in many markets, built in Japan by Suzuki.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Awards And Ratings:
While specific awards for the 1991 Justy are not widely documented, it was recognized for its affordability and practicality within the subcompact segment.
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