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Subaru Justy 1991 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Subaru Model: Justy Year: 1991 Codes Chassis Code: KA5 Engine Codes: EK23 👋 Introduction Market Position Market Segment: Subcompact car, economy car Competitive Analysis Competitors: Suzuki Swift, Daihatsu Charade, Honda Civic (early generations), Toyota Starlet, Ford Festiva, Hyundai Excel Key Features Value Proposition: Affordable, fuel-efficient, and compact urban transportation, often featuring a distinctive styling and Subaru's known durability (though with some unique quirks). Manual Advantage: Provides comprehensive factory-level repair and maintenance information, enabling DIY enthusiasts and independent mechanics to service and repair the vehicle effectively, saving on dealership costs. 📋 Manual Details Coverage Areas Primary Regions Covered: Global (based on factory specifications for 1991 model) Page Count Estimated Pages: Hundreds (as stated in product description) Manual Type Type: Factory Service Repair Workshop Manual Language Language: English (implied by product description and common for service manuals) Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, tune-up, fuel system, ignition system, lubrication system, cooling system, emission control systems Transmission: Manual transmission (operation, overhaul, adjustment), Automatic transmission (if applicable to the 1991 model and this specific manual's scope, typically covers operation, diagnosis) Drivetrain: Front-wheel drive (FWD) system, all-wheel drive (4WD/AWD) system (if applicable), driveshafts, differentials, axles Suspension: Front suspension (McPherson struts, control arms, etc.), Rear suspension (dependent or independent, depending on configuration), shock absorbers, springs, bushings, alignment specifications Steering: Steering gear, steering column, power steering system (if equipped), tie rods, ball joints, steering linkage Brakes: Front and rear brake systems (disc/drum configuration), master cylinder, brake booster, hydraulic lines, parking brake system, ABS components (if applicable) Electrical: Battery, charging system (alternator, regulator), starting system (starter motor), lighting system, ignition system, instrument cluster, wiring diagrams, fuses, relays, body electrical components, electronic control units (ECUs) if present HVAC: Heating, ventilation, and air conditioning (HVAC) system components, refrigerant system, controls, blower motor, ducting Body: Body panels, doors, windows, interior trim, exterior trim, bumpers, glass replacement, body repair procedures, corrosion prevention Chassis: Frame, subframes, body mounting, exhaust system, fuel tank and lines Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, fluid checks), tune-ups, inspections, lubrication points Troubleshooting: Diagnostic procedures for all major systems, common problems and solutions, symptom-based troubleshooting guides Repair: Detailed step-by-step repair instructions for all major components and systems, including disassembly, inspection, repair, and reassembly Replacement: Component replacement procedures for parts such as engine components, transmission parts, suspension parts, brake components, electrical parts, body panels Adjustment: Adjustments for engine timing, carburetor (if applicable), brakes, clutch, door latches, suspension alignment Installation: Installation procedures for new or replacement parts, including proper torque specifications and alignment Torque Specifications: Comprehensive torque specifications for all fasteners and critical components Technical Depth Depth: Comprehensive: Covers everything from basic maintenance and adjustments to complete engine and transmission overhauls, electrical diagnostics, and bodywork Diagrams And Photos: Detailed photos and exploded diagrams for all procedures, aiding in visualization and accuracy Diagnostic Codes: Includes diagnostic information, though specific OBD-I/OBD-II code coverage may be limited for this era, focusing more on symptom-based troubleshooting 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable PDF (standard for modern digital manuals) Print Quality Printability: Printable (single pages or entire manual) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Licensing Usage License: Lifetime usage on multiple devices, no expiry or renewal fees Compatibility Operating Systems: Windows and MAC compatible ⚙️ Engine Specifications Primary Engine Engine Type: Inline 3-cylinder, 4-stroke, naturally aspirated gasoline engine Displacement: 1.0 Liter (993 cc) Bore X Stroke: 70.0 mm x 86.0 mm (estimated) Compression Ratio: 9.5:1 (estimated) Valvetrain: SOHC (Single Overhead Camshaft), 12 valves (3 valves per cylinder) Performance Horsepower: Approx. 55-60 PS (40-44 kW) at 6000 RPM (engine code EK23) Torque: Approx. 78-83 Nm (57-61 lb-ft) at 3500 RPM (engine code EK23) Fuel System Fuel Delivery: Carburetor (single downdraft) for most markets, potentially fuel injection for some variants or later models/regions Fuel Type: Unleaded Gasoline (Octane rating appropriate for the era, likely 87 AKI or 91 RON) Engine Management Ignition System: Electronic Ignition (Distributor with coil) Cooling System Cooling Type: Liquid-cooled Lubrication System Oil Capacity: Approx. 3.0 - 3.5 Liters (with filter change) - specific value to be confirmed in manual Engine Mounts Type: Hydraulic or rubber mounts to isolate vibration 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 3-speed Automatic Transmission (CVT not typically associated with this generation Justy) Features Drive Layout: Front-Wheel Drive (FWD) or Full-Time 4-Wheel Drive (4WD) with lockable center differential (depending on model variant) Fluid Type Manual Transmission Fluid: API GL-4 SAE 75W-90 or SAE 80W-90 Gear Oil (specifics in manual) Automatic Transmission Fluid: Dexron-II or equivalent (specifics in manual) 📐 Dimensions Exterior Length: Approx. 3,500 - 3,600 mm (exact value varies by body style) Width: Approx. 1,500 - 1,550 mm Height: Approx. 1,400 - 1,450 mm Wheelbase Wheelbase: Approx. 2,300 mm Weights...
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Subaru Justy 1991 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Justy
Year:
1991
Codes
Chassis Code:
KA5
Engine Codes:
EK23
👋 Introduction
Market Position
Market Segment:
Subcompact car, economy car
Competitive Analysis
Competitors:
Suzuki Swift, Daihatsu Charade, Honda Civic (early generations), Toyota Starlet, Ford Festiva, Hyundai Excel
Key Features
Value Proposition:
Affordable, fuel-efficient, and compact urban transportation, often featuring a distinctive styling and Subaru's known durability (though with some unique quirks).
Manual Advantage:
Provides comprehensive factory-level repair and maintenance information, enabling DIY enthusiasts and independent mechanics to service and repair the vehicle effectively, saving on dealership costs.
📋 Manual Details
Coverage Areas
Primary Regions Covered:
Global (based on factory specifications for 1991 model)
Page Count
Estimated Pages:
Hundreds (as stated in product description)
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English (implied by product description and common for service manuals)
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, tune-up, fuel system, ignition system, lubrication system, cooling system, emission control systems
Transmission:
Manual transmission (operation, overhaul, adjustment), Automatic transmission (if applicable to the 1991 model and this specific manual's scope, typically covers operation, diagnosis)
Drivetrain:
Front-wheel drive (FWD) system, all-wheel drive (4WD/AWD) system (if applicable), driveshafts, differentials, axles
Suspension:
Front suspension (McPherson struts, control arms, etc.), Rear suspension (dependent or independent, depending on configuration), shock absorbers, springs, bushings, alignment specifications
Steering:
Steering gear, steering column, power steering system (if equipped), tie rods, ball joints, steering linkage
Brakes:
Front and rear brake systems (disc/drum configuration), master cylinder, brake booster, hydraulic lines, parking brake system, ABS components (if applicable)
Electrical:
Battery, charging system (alternator, regulator), starting system (starter motor), lighting system, ignition system, instrument cluster, wiring diagrams, fuses, relays, body electrical components, electronic control units (ECUs) if present
HVAC:
Heating, ventilation, and air conditioning (HVAC) system components, refrigerant system, controls, blower motor, ducting
Body:
Body panels, doors, windows, interior trim, exterior trim, bumpers, glass replacement, body repair procedures, corrosion prevention
Chassis:
Frame, subframes, body mounting, exhaust system, fuel tank and lines
Procedures Included
Maintenance:
Scheduled maintenance (oil changes, filter replacements, fluid checks), tune-ups, inspections, lubrication points
Troubleshooting:
Diagnostic procedures for all major systems, common problems and solutions, symptom-based troubleshooting guides
Repair:
Detailed step-by-step repair instructions for all major components and systems, including disassembly, inspection, repair, and reassembly
Replacement:
Component replacement procedures for parts such as engine components, transmission parts, suspension parts, brake components, electrical parts, body panels
Adjustment:
Adjustments for engine timing, carburetor (if applicable), brakes, clutch, door latches, suspension alignment
Installation:
Installation procedures for new or replacement parts, including proper torque specifications and alignment
Torque Specifications:
Comprehensive torque specifications for all fasteners and critical components
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance and adjustments to complete engine and transmission overhauls, electrical diagnostics, and bodywork
Diagrams And Photos:
Detailed photos and exploded diagrams for all procedures, aiding in visualization and accuracy
Diagnostic Codes:
Includes diagnostic information, though specific OBD-I/OBD-II code coverage may be limited for this era, focusing more on symptom-based troubleshooting
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely text-searchable PDF (standard for modern digital manuals)
Print Quality
Printability:
Printable (single pages or entire manual)
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Licensing
Usage License:
Lifetime usage on multiple devices, no expiry or renewal fees
Compatibility
Operating Systems:
Windows and MAC compatible
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 3-cylinder, 4-stroke, naturally aspirated gasoline engine
Displacement:
1.0 Liter (993 cc)
Bore X Stroke:
70.0 mm x 86.0 mm (estimated)
Compression Ratio:
9.5:1 (estimated)
Valvetrain:
SOHC (Single Overhead Camshaft), 12 valves (3 valves per cylinder)
Performance
Horsepower:
Approx. 55-60 PS (40-44 kW) at 6000 RPM (engine code EK23)
Torque:
Approx. 78-83 Nm (57-61 lb-ft) at 3500 RPM (engine code EK23)
Fuel System
Fuel Delivery:
Carburetor (single downdraft) for most markets, potentially fuel injection for some variants or later models/regions
Fuel Type:
Unleaded Gasoline (Octane rating appropriate for the era, likely 87 AKI or 91 RON)
Engine Management
Ignition System:
Electronic Ignition (Distributor with coil)
Cooling System
Cooling Type:
Liquid-cooled
Lubrication System
Oil Capacity:
Approx. 3.0 - 3.5 Liters (with filter change) - specific value to be confirmed in manual
Engine Mounts
Type:
Hydraulic or rubber mounts to isolate vibration
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
3-speed Automatic Transmission (CVT not typically associated with this generation Justy)
Features
Drive Layout:
Front-Wheel Drive (FWD) or Full-Time 4-Wheel Drive (4WD) with lockable center differential (depending on model variant)
Fluid Type
Manual Transmission Fluid:
API GL-4 SAE 75W-90 or SAE 80W-90 Gear Oil (specifics in manual)
Automatic Transmission Fluid:
Dexron-II or equivalent (specifics in manual)
📐 Dimensions
Exterior
Length:
Approx. 3,500 - 3,600 mm (exact value varies by body style)
Width:
Approx. 1,500 - 1,550 mm
Height:
Approx. 1,400 - 1,450 mm
Wheelbase
Wheelbase:
Approx. 2,300 mm
Weights
Curb Weight:
Approx. 750 - 850 kg (depending on FWD/4WD and equipment)
Cargo
Cargo Volume:
Limited, typical for a subcompact hatchback
🛡️ Safety Features
Ratings
Crash Test Results:
Limited data available for this era and specific model, but generally considered basic safety for its class and time.
Active Features
Braking System:
Front ventilated discs, rear drums (standard). Some models may have rear discs. Anti-lock Braking System (ABS) was rare or unavailable on early 1990s subcompacts.
Passive Features
Seatbelts:
Standard front and rear seatbelts. May feature pretensioners depending on market and trim.
Airbags:
Driver airbag was an option or not available on all models for this year.
Body Structure:
Designed with crumple zones and a reinforced safety cage, typical for vehicles of the late 1980s/early 1990s.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player (optional CD player might exist on higher trims).
Driver Assistance
ABS:
Limited availability or optional on some models.
Connectivity
Connectivity Features:
None beyond basic audio connectivity.
Instrumentation
Dashboard Features:
Analog gauges for speedometer, tachometer (optional), fuel level, engine temperature. Warning lights for oil pressure, charging system, etc.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, whichever comes first.
Air Filter Replacement:
Every 15,000 - 20,000 miles (24,000 - 32,000 km) or annually.
Spark Plug Replacement:
Every 30,000 - 40,000 miles (48,000 - 64,000 km), depending on plug type.
Coolant Flush:
Every 24,000 - 30,000 miles (38,000 - 48,000 km) or 2-3 years.
Fluid Specifications
Engine Oil Spec:
API SG or SH, SAE 10W-30 or 10W-40 (check manual for exact viscosity and specification based on climate).
Coolant Type:
Ethylene Glycol based coolant, mixed 50/50 with distilled water. Check manual for specific Subaru coolant recommendations.
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for exact specification).
Known Issues
Common Wear Items:
Clutch wear (manual transmission), CV joints, wheel bearings, exhaust system corrosion, aging rubber hoses and mounts.
Engine Quirks:
Small 3-cylinder engines can be prone to vibration; proper engine mount maintenance is crucial. Carburetor adjustment may be needed over time.
Rust Prone Areas:
Wheel arches, rocker panels, underbody, especially in regions with road salt.
📚 Vehicle History
Brand Heritage
Subaru Philosophy:
Subaru is known for its boxer engines, Symmetrical All-Wheel Drive, and focus on reliability and durability, often appealing to a niche market.
Model Evolution
Justy Generations:
The 1991 model belongs to the second generation (1987-1994), which saw styling updates and the introduction of a more capable 4WD system. It was also sold under different names in various markets (e.g., Suzuki Swift/Cultus platform).
Production
Manufacturing Location:
Primarily Japan (by Suzuki for Subaru)
Production Years:
First generation: 1984–1994 (global). Second generation (KA5 chassis): 1987–1994.
🏆 Awards & Recognition
Recognitions
General Reputation:
While the Justy itself didn't win major awards, it represented Subaru's entry into the highly competitive subcompact segment, offering an alternative to established players with a focus on efficiency and a unique driving experience, particularly in 4WD variants.
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