Subaru 360 Custom Rear-Engined City Car Manuals

Manuals and User Guides for Subaru 360 Custom Rear-Engined City Car. We have 1 Subaru 360 Custom Rear-Engined City Car manual available for free PDF download: Service Manual

Subaru 360 Custom Service Manual (247 pages)

360 Series Engine Section Service manual

Brand: Subaru | Category: Automobile | Size: 39 MB

Contents
4
Engine Performance Curve
7
Main Specifications
8
Mounting and Dismounting Engine
11
Mounting and Dismounting the Engine
13
Supporting the Car Body
13
Removing the Battery Grounding Band
13
Dismounting the Engine
14
Removing the Engine Room under Cover
14
Draining Gear Oil
14
Shifting the Position of the Diagonal Member
14
Removing the Clutch Gear
15
Removing the Oil Tank Pipe
15
Protector (When Removing the Clutch Housing)
15
Removing the Rear Axle
16
Removing the Engine Hood
16
Removing the Choke Cable and Accelerator Cable
18
Removing the Fuel Pipe and Fuel Cock Pipe
18
Removing the Wiring Harnes (Rear) and Battery Cable
19
Removing the Boot (Duct)
19
Removing the Gear Change Rod
20
Removing the Heater Duct
20
Disconnecting the Back-Up Light Switch Wires
20
Supporting the Engine
21
Removing the Engine Mounting Bracket
21
Removing the Cross Member
21
Removing Ancillary Parts
22
Removing the Muffler
22
Removing the Clutch Lever and Bracket (Clutch Cable Support)
23
Removing the Cross Member (Engine Rear Support)
23
Removing the Lower Duct
23
Mounting the Engine
24
Removing the Engine Mounting Bracket and Cushion Rubber
24
Mounting and Dismounting the Engine for Truck & Van
26
Removing the Trap Door and Grounding Band
26
Removing the Hose (Battery)
26
Disconnecting the Back-Up Light Switch Wire
27
Removing the Wiring Harness (Rear) and Battery Cable
28
Removing the Air Intake Hose and Boot (Duct)
30
Engine and Transmission
37
Engine Power Unit
39
Construction of Engine
40
Crankshaft
40
Crankcase
40
Cylinder and Cylinder Head
40
Piston
41
Connecting Rod
41
Intake and Exhaust Manifolds
41
Cooling System
42
Carburetor and Intake System
42
Clutch
43
Transmission
43
Differential
43
Ancillary Parts
44
Ignition System
44
Starter Motor
45
Generator
45
Engine Maintenance
46
Clutch View
46
Engine Disassembly
47
Removing the Generator
48
Removing the Clutch Cable
48
Removing the Starter
49
Removing the Clutch Housing Cover
49
Removing the Clutch Assembly
50
Disassembly of Clutch Assembly
50
Removing the Clutch Housing
51
Checking and Adjusting Parts
52
Adjusting the Heihgt of the Release Lever
52
Transmission Torque of Clutch
52
Checking the Clutch Disc
53
Load of Clutch Spring
53
Wear of the Clutch Disc and Spline of the Primary Reduction Pinion
54
Clearance between the Clutch Cover and Primary Reduction Pinion
54
Engine Assembly
55
Assembling the Clutch Assembly
55
Refitting the Clutch Housing
56
Refitting the Clutch Assembly
56
Refitting Clutch Housing Cover
57
Refitting Starter
57
Refitting Generator
58
Refitting Protector
58
Refitting the Clutch Cable
59
Attaching the Engine Room under Cover
59
Cylinder Head, Cylinder and Piston Disassembly
60
Cylinder Head, Cylinder and Piston - Checking and Adjustments
64
Cylinder Head, Cylinder and Piston Assembly
66
Engine Maintenance Procedures
71
Engine Cleaning
72
Engine Proper Cross-Section Drawing
74
Engine Disassembly Procedures
75
Checking and Adjusting of Engine Parts
84
Measuring and Correcting Cylinder Wear
84
Boring and Honing of the Cylinder
85
Minimum Clearance between the Cylinder and Piston
86
Fitting of the Piston and Piston Pin
86
Checking the Crankshaft Assembly
87
Engine Assembly Procedures
88
Wear of the Distributor Drive Gear and Distributor Pinion
88
Checking the Fan
88
Engine Running-In Operation
94
Transmisson Diagram
96
Regarding the Synchromesh Gear System
97
Synchromesh Gear System Disassembly
99
Transmission Parts Checking and Adjustment
109
Wear of the Synchronizer Ring
109
Wear of the Insert (Synchronizer Hub)
109
Deformation and Wear of the Snap Ring (Transmission Synchronizer)
110
Meshing of the Synchronizer Sleeve and Synchronizer Hub
110
Wear of the Main Shaft Spline
110
Wear of Gears
110
Wear of Bushing
111
Wear of the Ball Bearings and Needle Bearing
111
Transmission Assembly
112
Gear Shifting Force
112
Differential Diagram
123
Differential Disassembly
124
Differential Parts Checking and Adjusting
126
Wear of the Differential Side Gear and Differential Pinion
126
Clearance between the Differential Side Gear and Block
126
Clearance between the Universal Joint Cross and Side Gear
127
Wear of the Universal Joint Needle Bearing
127
Differential Assembly
128
Clearance in the Rear Axle Direction of the Differential Assembly
128
Wear of the Final Reduction Gear and Pinion
128
Wear of the Ball Bearing
128
Checking and Adjusting Engine
131
Checking Compression Pressure
131
Checking Spark Plugs
131
Adjusting Ignition Timing
132
Replacing Air Cleaner Element
134
Cleaning the Carburetor (Without Removing)
135
Checking the Battery
136
Checking and Changing Gear Oil
137
Adjusting Engine Idling Speed
137
Engine Ancillary Parts
139
Carburetor Construction and Function
141
Main Fuel System
142
Low Speed System
142
Starting System
142
Carburetor Setting
144
Carburetor Handling Precautions
144
Precausions in Disassembly and Assembly
145
Troubles and Remedies
146
Fuel Pump Performance and Specifications
148
Fuel Pump Test Standard
148
Fuel Pump Construction and Function
149
Fuel Pump Disassembly and Assembly
149
Fuel Pump Check after Assembly
150
Oil Pump Description
151
Reciprocating and Rotating Movement of the Plunger
152
Rotating Movement of the Plunger and Valve Action
152
Duty of Differential Plunger
153
Pumping Action
153
Delivery Controlling Function
156
Oil Pump Maintenance
157
Check Valve
157
Draining Air from Oil Pipes
157
Adjusting the Oil Pump Control Cable
158
Checking and Correcting the Oil Pump
160
When Oil Consumption Is Either too High or too Low
161
When the Accelerator Pedal Becomes Suddenly Light or Heavy
162
Checking of the Oil Pump at 50,000 Km (30,000 Miles)
162
Replacing the Oil Pump
164
Measuring Method of the Oil Pump Delivety Efficiency
165
Electrical Equipment
171
Electrial Equipment Specifications
173
Starter Motor View and Specifications
173
Starter Motor Test Standard
174
Starter Motor Construction and Function
175
Starter Function
176
Starter Parts Function and Construction
178
Over-Running Clutch
178
Magnetic Switch
179
Threaded Spline
179
Armature Brake
179
Starter Motor Lubrication
180
Starter Motor Troubles and Repairs
180
Worn Bearing Bush
181
Poor Engaging between the Pinion and Gear
181
Starting Motor Electrical Failures
182
Starting Motor Disassembly and Assembly
184
Starter Motor Testing
187
No-Load Test
187
Testing the Action of a Magnetic Switch
187
Precautions in Starter Handling
188
Return Test
188
Measuring Actuation Voltage
188
Generator (DC) View, Performance and Specifications
191
Generator Exploded View
192
Generator Testing
193
Output Test (Generator)
194
Motoring Test (Generator)
194
Generator Ttoubles and Repairs
195
Cause and Remedy for Poor Generation
195
Brush Wear
197
Regulator Performance and Specificaions
200
Regulator Construction
201
Regulator Adjustment
202
Remedies for Abnormalities of the Regulator
206
Distributor Performance and Specifications
207
Distributor Construction
208
Reverse Rotation Prevention (Distributor)
209
Precaution in Distributor Handling
210
Point Gap Adjustment
211
Checking the Condenser
211
Checking the Cap Rotor Head
211
Precautions in Handling the Governor Advancer
211
Distributor Troubles and Remedies
214
The Engine Does Not Start
214
The Engine Turns but the Running Condition Is Not Good
215
Ignition Coil Construction and Performance
217
Ignition Coil Handling
218
Spark Plug
219
Tightening Torque Table
223
Special Tools
227
Separate Lubrication System (Subarumatic)
241
Special Characteristics of Subarumatic Two-Stroke Engine
243
Subarumatic Oil
244

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Subaru 360 Custom Service Manual (247 pages)

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