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1991 Subaru Justy Service Repair Manual 91

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$133.00
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🏷️ Basic Information Identification Make: Subaru Model: Justy Year: 1991 Market Segment: Subcompact Hatchback 👋 Introduction Market Position Market Segment Positioning: Affordable, practical subcompact offering for budget-conscious consumers Competitive Analysis Key Competitors: Nissan Sentra, Honda Civic, Toyota Corolla, Ford Festiva, Mazda 323 Key Features Value Proposition: Economical transportation with surprisingly capable 4WD options for its class. Manual Advantage: Empowers owners to maintain and repair their vehicle, saving money and extending lifespan. 📋 Manual Details Coverage Areas Coverage Scope: All Models Page Count Estimated Pages: Over 1000 Manual Type Type: Service and Repair Manual Language Language: English Format Digital Format: PDF (split into over 80 sections) Viewing Software: Adobe Acrobat Reader Compatibility: Mac and Windows 📖 Manual Coverage Systems Covered Engine: Full repair and maintenance procedures Transmission: Repair and maintenance for manual and automatic transmissions Brakes: Hydraulic system, ABS (if equipped), component replacement Suspension: Front and rear suspension, alignment specifications Steering: Power steering system, steering gear Electrical: Complete wiring diagrams, component testing, charging system Fuel System: Fuel delivery, injection system diagnostics Cooling System: Radiator, water pump, thermostat, coolant specifications Exhaust System: Component replacement, emissions control HVAC: Air conditioning and heating system service Body: Panel removal/installation, trim, glass replacement Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements Troubleshooting: Diagnostic procedures for common and complex issues Repair: Step-by-step instructions for component repair and replacement Diagnostics: Testing procedures for electrical and mechanical components Assembly Disassembly: Detailed instructions for taking components apart and reassembling them Technical Depth Depth: Comprehensive, from basic maintenance to advanced diagnostics and major component overhauls Target Audience: Professional mechanics, DIY enthusiasts, and novice owners 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable within PDF (depends on OCR quality if scanned) Print Quality Printable Pages: Yes, users can print specific pages as needed Binding Type Digital Binding: N/A (digital format) Paper Type Digital Paper Type: N/A (digital format) ⚙️ Engine Specifications Primary Engine Engine Code: EK23 (typical for this generation) Configuration: Inline 3-cylinder Displacement: 1.0 Liter (993 cc) Bore X Stroke: 72.0 mm x 81.6 mm (typical) Compression Ratio: 9.5:1 (typical) Performance Horsepower: Approx. 55-60 hp @ 6000 rpm (SAE net) Torque: Approx. 58-62 lb-ft @ 3600 rpm (SAE net) Fuel System Induction: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (87 Octane minimum recommended) Engine Features Engine Management: ECU controlled ignition and fuel injection Timing Drive: Timing Belt 🔧 Transmission Standard Transmission Type: 5-Speed Manual Optional Transmission Type: 3-Speed Automatic Features Drivetrain: Front-Wheel Drive (FWD) or All-Wheel Drive (AWD) (selectable on some models) Clutch: Hydraulically actuated dry single-plate clutch (manual) 📐 Dimensions Exterior Length: Approx. 3500-3600 mm Width: Approx. 1500-1550 mm Height: Approx. 1400-1450 mm Wheelbase Wheelbase: Approx. 2300-2350 mm Weights Curb Weight: Approx. 750-850 kg Cargo Cargo Volume: Varies by configuration, typically modest due to subcompact size 🛡️ Safety Features Ratings Crash Test Performance: Limited official crash test data available for this era; generally considered basic safety for its time. Passive Features Seatbelts: Three-point front seatbelts, lap belts in rear (standard) Headrests: Front headrests Body Structure: Crumple zones, reinforced safety cage (standard construction for the period) 💡 Technology Features Infotainment Audio System: Basic AM/FM radio, optional cassette player Driver Assistance ABS: Anti-lock Braking System was an optional feature on some models. AWD: Symmetrical All-Wheel Drive was a key distinguishing feature and option. Connectivity Connectivity Features: No modern connectivity features (e.g., Bluetooth, USB) 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 miles or 6 months (whichever comes first) Engine Oil Filter Replacement: Replace at every oil change Air Filter Replacement: Every 15,000 miles or 12 months Fuel Filter Replacement: Every 30,000 miles Spark Plug Replacement: Every 30,000 miles Timing Belt Replacement: Every 60,000 miles or 4 years (critical item) Fluid Specifications Engine Oil: API SG or higher, SAE 10W-30 recommended (check manual for temperature variations) Engine Oil Capacity: Approx. 3.2 US quarts (3.0 Liters) with filter Coolant: Ethylene Glycol based antifreeze, 50/50 mix with distilled water Transmission Fluid Manual: API GL-4, SAE 75W-90 gear oil Transmission Fluid Automatic: Dexron II or equivalent Brake Fluid: DOT 3 Power Steering Fluid: ATF Dexron II (if equipped with power steering) Known Issues Timing Belt Failure: Risk of catastrophic engine damage if belt breaks; regular replacement is crucial. Carburetor Issues: Pre-EFI models may experience carburetor wear and tuning problems. Rust And Corrosion: Common in older vehicles, especially in areas with road salt. Ignition Switch Problems: Wear and tear on the ignition switch can lead to starting issues. Cv Joint Wear: With age and mileage, CV joints can wear, causing clicking noises during turns. 📚 Vehicle History Brand Heritage Subaru Heritage: Subaru, a division of Fuji Heavy Industries, is known for its horizontally-opposed engines and Symmetrical All-Wheel Drive systems. Model Evolution First Generation Debut: The Subaru Justy (first generation) debuted globally in 1984. Second Generation Transition: The 1991 model year represents...
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1991 Subaru Justy Service Repair Manual 91
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Justy
Year:
1991
Market Segment:
Subcompact Hatchback
👋 Introduction
Market Position
Market Segment Positioning:
Affordable, practical subcompact offering for budget-conscious consumers
Competitive Analysis
Key Competitors:
Nissan Sentra, Honda Civic, Toyota Corolla, Ford Festiva, Mazda 323
Key Features
Value Proposition:
Economical transportation with surprisingly capable 4WD options for its class.
Manual Advantage:
Empowers owners to maintain and repair their vehicle, saving money and extending lifespan.
📋 Manual Details
Coverage Areas
Coverage Scope:
All Models
Page Count
Estimated Pages:
Over 1000
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Digital Format:
PDF (split into over 80 sections)
Viewing Software:
Adobe Acrobat Reader
Compatibility:
Mac and Windows
📖 Manual Coverage
Systems Covered
Engine:
Full repair and maintenance procedures
Transmission:
Repair and maintenance for manual and automatic transmissions
Brakes:
Hydraulic system, ABS (if equipped), component replacement
Suspension:
Front and rear suspension, alignment specifications
Steering:
Power steering system, steering gear
Electrical:
Complete wiring diagrams, component testing, charging system
Fuel System:
Fuel delivery, injection system diagnostics
Cooling System:
Radiator, water pump, thermostat, coolant specifications
Exhaust System:
Component replacement, emissions control
HVAC:
Air conditioning and heating system service
Body:
Panel removal/installation, trim, glass replacement
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements
Troubleshooting:
Diagnostic procedures for common and complex issues
Repair:
Step-by-step instructions for component repair and replacement
Diagnostics:
Testing procedures for electrical and mechanical components
Assembly Disassembly:
Detailed instructions for taking components apart and reassembling them
Technical Depth
Depth:
Comprehensive, from basic maintenance to advanced diagnostics and major component overhauls
Target Audience:
Professional mechanics, DIY enthusiasts, and novice owners
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable within PDF (depends on OCR quality if scanned)
Print Quality
Printable Pages:
Yes, users can print specific pages as needed
Binding Type
Digital Binding:
N/A (digital format)
Paper Type
Digital Paper Type:
N/A (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
EK23 (typical for this generation)
Configuration:
Inline 3-cylinder
Displacement:
1.0 Liter (993 cc)
Bore X Stroke:
72.0 mm x 81.6 mm (typical)
Compression Ratio:
9.5:1 (typical)
Performance
Horsepower:
Approx. 55-60 hp @ 6000 rpm (SAE net)
Torque:
Approx. 58-62 lb-ft @ 3600 rpm (SAE net)
Fuel System
Induction:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 Octane minimum recommended)
Engine Features
Engine Management:
ECU controlled ignition and fuel injection
Timing Drive:
Timing Belt
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual
Optional
Transmission Type:
3-Speed Automatic
Features
Drivetrain:
Front-Wheel Drive (FWD) or All-Wheel Drive (AWD) (selectable on some models)
Clutch:
Hydraulically actuated dry single-plate clutch (manual)
📐 Dimensions
Exterior
Length:
Approx. 3500-3600 mm
Width:
Approx. 1500-1550 mm
Height:
Approx. 1400-1450 mm
Wheelbase
Wheelbase:
Approx. 2300-2350 mm
Weights
Curb Weight:
Approx. 750-850 kg
Cargo
Cargo Volume:
Varies by configuration, typically modest due to subcompact size
🛡️ Safety Features
Ratings
Crash Test Performance:
Limited official crash test data available for this era; generally considered basic safety for its time.
Passive Features
Seatbelts:
Three-point front seatbelts, lap belts in rear (standard)
Headrests:
Front headrests
Body Structure:
Crumple zones, reinforced safety cage (standard construction for the period)
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio, optional cassette player
Driver Assistance
ABS:
Anti-lock Braking System was an optional feature on some models.
AWD:
Symmetrical All-Wheel Drive was a key distinguishing feature and option.
Connectivity
Connectivity Features:
No modern connectivity features (e.g., Bluetooth, USB)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 6 months (whichever comes first)
Engine Oil Filter Replacement:
Replace at every oil change
Air Filter Replacement:
Every 15,000 miles or 12 months
Fuel Filter Replacement:
Every 30,000 miles
Spark Plug Replacement:
Every 30,000 miles
Timing Belt Replacement:
Every 60,000 miles or 4 years (critical item)
Fluid Specifications
Engine Oil:
API SG or higher, SAE 10W-30 recommended (check manual for temperature variations)
Engine Oil Capacity:
Approx. 3.2 US quarts (3.0 Liters) with filter
Coolant:
Ethylene Glycol based antifreeze, 50/50 mix with distilled water
Transmission Fluid Manual:
API GL-4, SAE 75W-90 gear oil
Transmission Fluid Automatic:
Dexron II or equivalent
Brake Fluid:
DOT 3
Power Steering Fluid:
ATF Dexron II (if equipped with power steering)
Known Issues
Timing Belt Failure:
Risk of catastrophic engine damage if belt breaks; regular replacement is crucial.
Carburetor Issues:
Pre-EFI models may experience carburetor wear and tuning problems.
Rust And Corrosion:
Common in older vehicles, especially in areas with road salt.
Ignition Switch Problems:
Wear and tear on the ignition switch can lead to starting issues.
Cv Joint Wear:
With age and mileage, CV joints can wear, causing clicking noises during turns.
📚 Vehicle History
Brand Heritage
Subaru Heritage:
Subaru, a division of Fuji Heavy Industries, is known for its horizontally-opposed engines and Symmetrical All-Wheel Drive systems.
Model Evolution
First Generation Debut:
The Subaru Justy (first generation) debuted globally in 1984.
Second Generation Transition:
The 1991 model year represents the second generation of the Justy, which ran from 1987/1988 to 1994/1995.
Badge Engineering:
In some markets, the second-generation Justy was also sold as the Suzuki Swift or Cultus.
Production
Manufacturing Location:
Primarily manufactured in Japan
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