Subaru Brumby 1989 Duty Coupe Utility Manuals

Manuals and User Guides for Subaru Brumby 1989 Duty Coupe Utility. We have 1 Subaru Brumby 1989 Duty Coupe Utility manual available for free PDF download: Service & Repair Manual

Subaru Brumby 1989 Service & Repair Manual (358 pages)

2WD-4WD

Brand: Subaru | Category: Automobile | Size: 31 MB

Contents
2
Introduction
4
Tools and Equipment
5
Basic Tool Kit
5
Tool Selection and Care
6
Miscellaneous Equipment and Stores
6
Safety Tools
7
Lubrication and Maintenance
8
Specifications
8
How to Grease and Oil Change
8
Service Schedule
11
Lubrication Chart
16
Maintenance Chart
17
Wheels and Tyres
18
How to Change a Road Wheel
18
Tyre Wear Trouble Shooting
20
Care and Maintenance
21
Engine Tune-Up
22
Tune-Up Specifications
22
Tune-Up Operations
22
To Adjust Drive Belts
22
To Service Air Cleaner
23
To Check and Renew Fuel Filter
23
To Service Contact Breaker Points
24
To Service High Tension Leads
25
To Service Spark Plugs
25
To Adjust Valve Clearances
27
To Test Compression
28
To Adjust Dwell Angle and Ignition Timing
28
To Adjust Idle Speed and Mixture
29
Roadside Troubleshooting
30
To Check Ignition and Electrical Systems
30
To Check Fuel System
32
To Check Mechanical System
33
Cooling System Specifications
35
Coolant Leakage - External
35
Coolant Leakage - Internal
35
Engine Overheating
35
Coolant Circulation Faulty
36
Cooling System Description
36
Radiator
37
To Check Coolant Level
37
To Drain and Refill
37
To Remove Radiator
38
To Flush and Clean Radiator
38
To Install Radiator
39
To Test Fan Motor on Vehicle
39
To Remove and Install Fan Motor
39
To Remove and Install Thermoswitch
39
To Remove and Install Water Pump
41
To Renew Water Pump Drive Belt
42
Heater Unit Assembly
42
To Remove and Install 1985-1987 Sedan and Station Wagon Models
42
To Remove and Install 1979-1984 and Utility Models
43
To Remove and Install Heater Blower Motor
44
Heater Controls
44
Fuel System Specifications
46
Fuel System Troubleshooting
46
Engine will Not Start
46
Engine Stalls at Idle Speed
47
Flat Spot on Acceleration
47
Engine Misfires or Cuts out at High Speed
47
Excessive Fuel Consumption
48
To Remove and Install Air Cleaner
48
Carburetor
49
To Remove and Install Carburetor
50
To Service Carburetor
51
To Dismantle Carburetor
51
To Service Carburetor Top Cover
52
To Service Carburetor Main Body
53
To Service Throttle Body
55
To Assemble Throttle Body
55
To Adjust Float Level
56
To Adjust Throttle Interlock
56
To Adjust Fast Idle Speed
57
To Adjust Choke Unloader Clearance, Automatic Choke Models
57
To Check Automatic Choke Operation
57
To Renew Automatic Choke Cover
57
Electromagnetic Plunger Fuel Pump
58
To Test Pump
58
To Remove and Install Test Pump
59
Electromagnetic Diaphragm Fuel Pump
59
Electromagnetic Diaphragm Fuel Pump to Remove and Install
60
Fuel Filter
61
To Remove and Install Fuel Tank
61
To Remove and Install Throttle Cable
62
To Adjust Throttle Cable
62
Clutch Specifications
63
Clutch Shudder
63
Clutch Slipping
63
Clutch Grab
63
Insufficient Clutch Release
64
Clutch Noise
64
To Remove Clutch Unit
65
To Check and Inspect Clutch Unit
65
To Install Clutch Unit
65
Clutch Release Mechanism
66
To Remove Clutch Release Mechanism
66
To Install Clutch Release Mechanism
67
To Remove and Install Clutch Pedal
67
To Remove and Install Clutch Cable
67
Clutch Adjustments
68
To Check and Adjust Clutch Pedal Free Play
68
To Check and Adjust Hill Holder Cable
68
Manual Transaxle Specifications
69
Transaxle Gear Clash on Changing down
71
Transaxle Slipping out of Gear
71
Transaxle Noise in Neutral
71
Transaxle Noise (Forward Gears Engaged, Vehicle Moving)
72
Difficult High to Low, or Low to High Range Change
72
Difficult to Engage Four Wheel Drive
72
Gear Selected but no Front Wheel Drive
72
Front Wheel Noise(Apparent)
73
Propeller Shaft Vibration
73
Excessive Propeller Shaft Backlash
73
Illustrated View of Four Wheel Drive Dual Ratio Mainshaft and Components
74
Manual Transaxle Description
74
Illustrated View of Four Wheel Drive Single Ratio Mainshaft and Components
74
Illustrated View of Two Wheel Drive, Drive Pinion Shaft and Components
75
Illustrated View of Four Wheel Drive, Drive Pinion Shaft and Components
75
Illustrated View of Four Wheel Drive Rear Drive Pinion Shaft and Components
76
Transaxle Assembly
77
To Remove Transaxle
77
To Install Transaxle
80
To Renew Rear Case Oil Seal - Two Wheel Drive
82
To Renew Rear Extension Oil Seal - Four Wheel Drive
82
To Remove and Install Transaxle Controls
83
To Adjust Four Wheel Drive Dual Ratio High/Low Linkage
89
To Adjust Four Wheel Drive Single Ratio Cable
90
To Remove and Dismantle Axle Shafts
90
To Check and Inspect Axle Shafts
91
To Assemble and Install Axle Shafts
91
To Remove and Install Propeller Shaft
92
To Renew Universal Joints
92
To Remove and Install Centre Bearing Assembly
93
Automatic Transaxle Specifications
94
Automatic Transaxle Troubleshooting
94
Transmission Fluid
95
To Check and Top up Transmission Fluid
95
To Drain and Refill Transmission Fluid
96
To Adjust Brake Band
96
To Remove and Install Kickdown Solenoid
97
To Remove and Install Vacuum Modulator
97
To Remove and Install Four Wheel Drive Transfer Solenoid
97
To Remove and Install Automatic Four Wheel Drive Switch
98
Neutral Safety Switch
98
To Remove and Dismantle Selector Lever and Linkage
99
To Assemble and Install Selector Lever and Linkage
100
Rear Axle Specifications
104
Rear Axle Troubleshooting
104
Rear Axle Description
106
To Remove Axle Shafts
107
To Dismantle and Assemble Axle Shafts
107
To Install Axle Shafts
107
Differential Assembly
107
To Renew Differential Drive Shaft Oil Seal
109
To Renew Differential Drive Pinion Oil Seal
109
To Renew and Install Differential Rear Cover
109
To Renew Rear Crossmember Bushes
110
To Renew Differential Mounting Bracket Bush
110
Steering Troubleshooting
112
Faults, Causes and Remedies
112
Conventional Steering
114
Conventional Steering Specifications
114
Steering Gear Assembly
114
To Remove Steering Gear
114
To Dismantle Steering Gear
115
To Clean and Inspect Steering Gear
115
To Assemble Steering Gear
115
To Install Steering Gear
116
To Remove and Install Non-Adjustable Steering Column
116
To Dismantle and Assemble Non-Adjustable Steering Column
117
Tilt Adjustable Steering Column
118
To Remove and Install Steering Column
118
To Dismantle and Assemble Steering Column
118
To Remove and Install Intermediate Shaft
120
Power Steering
121
Power Steering Specifications
121
Preliminary Inspection Ans Testing of Power Steering
121
Pump Drive Belt
121
To Check Fluid Level/Fluid Leaks
122
To Check Turning Effort
122
Pump Drive Belt Tension
122
To Purge the Power Steering System of Air
122
To Flush the Power Steering System
123
To Remove and Install Power Steering Pump
123
To Dismantle Power Steering Pump
123
Tp Inspect Power Steering Pump
124
To Assemble Power Steering Pump
124
To Remove and Install Power Steering Gear
125
Steering Column
126
Intermediate Shaft
126
Front Suspension
127
Front Suspension Specifications
127
Front Suspension Troubleshooting
127
Torque Wrench Settings
127
To Remove and Dismantle Front Hub
129
To Clean and Inspect Front Hub
129
To Assemble and Install Front Hub
130
To Remove Suspension Unit
130
To Dismantle and Assemble Front Hub
131
To Install Front Hub
131
To Remove and Install Ball Joint
132
To Remove and Install Suspension Control Arm
132
To Remove and Install Radius Rod
132
To Remove and Install Stabiliser Bar
133
Steering Angles and Ground Clearance
133
Wheel Alignment
133
To Check and Adjust Ground Clearance
134
To Check and Adjust Toe In/Out
135
Rear Suspension Troubleshooting
136
Torsion Bar Rear Suspension
137
To Remove and Install Torsion Bar and Trailing Link
137
Torsion Bar Rear Suspension Specifications
137
To Remove Shock Absorber
138
To Test and Bleed Shock Absorber
138
To Install Shock Absorber
139
To Remove and Install Trailing Arm
139
Rear Hub
139
Gas Pressured Shock Absorbers
139
Coil Spring Rear Suspension Specifications
140
To Remove and Install Trailing Link
140
To Remove Coil Spring Rear Suspension Unit
141
To Dismantle, Inspect and Assemble Coil Spring Rear Suspension Unit
141
To Install Coil Spring Rear Suspension Unit
142
To Remove and Install Rear Hub
142
To Check and Inspect Rear Hub
143
To Assemble and Install Rear Hub
143
Brakes Specifications
145
Brakes Troubleshooting
145
To Remove and Install Master Cylinder
148
To Dismantle Master Cylinder
149
To Assemble Master Cylinder
149
To Clean and Inspect Master Cylinder
149
Front Disc Brake Assembly
150
To Remove and Install Brake Pads
150
To Overhaul Caliper
151
To Remove and Install Brake Disc
153
To Adjust Rear Brakes
154
Rear Drum Brake Assembly
154
To Remove and Dismantle Rear Drum Brake
154
To Assemble and Install Rear Drum Brake
155
To Check Operation of Brake Servo Unit
156
To Test One Way Check Valve
156
To Remove and Install Servo Unit
157
To Adjust Handbrake
157
To Remove and Install Handbrake Cables
157
To Remove and Install Proportioning Valve
159
To Adjust Hill Holder Valve(HHV)
159
To Remove and Install Hill Holder Valve
159
To Bleed Hydraulic System
160
Electrical System Specifications
161
Battery and Charging System Troubleshooting
161
Battery and Starting System Troubleshooting
163
Lighting System Troubleshooting
163
Turn Signal Lamp Troubleshooting
164
Ignition System Troubleshooting
164
Test Equipment and some Applications
165
Battery Maintenance
166
To Remove and Install Battery
167
To Clean Battery Case
167
Alternator
167
To Test Battery
167
To Test Alternator on Vehicle
168
To Remove and Install Alternator
168
To Dismantle Alternator
168
To Clean Alternator Parts
169
To Check and Test Alternator Component Parts
169
To Assemble Alternator
170
External Voltage Regulator
170
Starter Motor
171
Starter Motor Test on Vehicle
171
To Remove and Install Starter Motor
172
To Dismantle Starter Motor
172
To Check and Inspect Starter Motor
173
To Assemble Starter Motor
174
Breaker Point Distributor
174
To Remove and Install Breaker Point Distributor
175
To Dismantle Breaker Point Distributor
175
To Clean and Inspect Distributor
176
To Assemble Distributor
176
Electronic Distributor Description
177
To Remove and Install Electronic Distributor
177
To Dismantle Electronic Distributor Description
178
To Check and Inspect Electronic Distributor Description
179
To Assemble Electronic Distributor Description
180
Switches and Controls
181
Ignition Switch
181
Combination Switch
181
Headlamp Switch
181
Wiper/Washer Switch
182
Heater Fan Switch
182
Rear Demister Switch
182
Rear Wiper/Washer Switch
182
Stop Lamp Switch
183
Reverse Lamp Switch - Manual Transaxle Models
183
Handbrake Warning Lamp Switch
183
Courtesy Lamp Door Switch
183
Courtesy Lamp Tailgate Switch
184
To Remove and Install Steering Wheel and Horn Control
184
To Remove and Install 1979-1984 Instrument Cluster and All Utility Models
184
To Remove and Install 1985-1987 Sedan Instrument Cluster and Station Wagon Models
185
To Remove and Install Speedometer Cable
186
To Remove and Install 1979-1984 Heater Blower Motor
186
To Remove and Install 1985-1987 Sedan Heater Blower Motor and Station Wagon Models
186
Lamp Units
187
Park Lamp - Twin Headlamp Models
187
Combination Lamp - Single Headlamp Models
187
Front Turn Signal Lamp - Bumper Mounted
190
Rear Combination Lamp
190
Front Turn Signal Repeater Lamp - Fender Mounted
190
Number Plate Lamp
191
Courtesy Lamp
192
Windscreen Wipers
193
To Renew Wiper Blades
193
To Remove and Install Wiper Arms
193
To Remove and Install Wiper Motor
193
To Renew Wiper Blade
194
To Remove and Install Wiper Arm
194
To Check and Renew Fuse
195
To Check and Renew Fusible Link
195
How to Wire up a Trailer
196
Wiring Diagram for 1979-1981 Models
198
Wiring Diagram for 1982 Models
200
Wiring Diagram for 1983-1984 and Late Utility Models
202
Wiring Diagram for 1985-1986 Sedan and Station Wagon Models
204
Wiring Diagram for 1987 Models
206
Wiring Diagram for Auto 4WD System 1983-1986 Models
208
Wiring Diagram for Power Windows 1983-1984 Models
209
Wiring Diagram for Power Windows and Door Locks 1985-1986 Models
210
Fuse Box Wiring Diagram for 1979-1981 Models
211
Fuse Box Wiring Diagram for 1982 Models
211
Fuse Box Wiring Diagram for 1983 Models
212
Fuse Box Wiring Diagram for 1984 Models
212
Fuse Box Wiring Diagram for 1985 Models
212
Fuse Box Wiring Diagram for 1986 Models
213
Fuse Box Wiring Diagram for 1987 Models
213
Emission Control
214
Positive Crankcase Ventilation (PCV) System
214
To Service the PCV System
214
To Check Operation of PCV System
214
Evaporative Control System
215
To Test Two Way Evaporative Control System Valve
215
To Test Charcoal Canister
215
To Test Two Port Thermal Vacuum Valve
216
To Test Three Port Thermal Vacuum Valve
216
To Test Fuel Bowl Ventilation System
216
Air Preheat System
219
To Check Air Preheat System Operation
219
Exhaust Gas Recirculation (EGR) System
220
To Test EGR Valve
221
To Test Speed Switch Solenoid Valve
222
Coasting By-Pass System
222
To Check Coasting By-Pass System Operation
222
Air Injection System
223
Reed Valve
223
Catalytic Converter System
224
Body Components
225
Windscreen and Rear Glass
225
Front Doors
225
Interior Handles and Trim Panels
225
Door Glass
226
Window Regulator
226
To Adjust Door Glass
227
Remote Control and Door Lock
227
Exterior Door Handle and Lock Cylinder
227
Lock Striker
228
Exterior Mirror
228
To Remove and Install Engine Bonnet
231
To Remove and Install Luggage Compartment Lid - Sedan and Coupe
232
To Remove and Install Lid Lock and Lock Cylinder
233
To Remove and Install Tailgate - Station Wagon
233
To Remove and Install Lock, Lock Cylinder and Outer Handle
234
To Remove and Install Tailgate - Utility
235
To Remove and Install Tailgate Locks
235
To Remove and Install Radiator Grille
236
To Remove and Install Centre Console
236
Vehicle Cleaning
236
Cleaning the Exterior
236
General Cleaning of Vinyl Upholstery and Trim
237
To Remove Stubborn Stains on Vinyl Upholstery and Trim
237
Cleaning Cloth Trim
238
Body Repairs Introduction
239
Body Repairs Safety
239
Body Repairs Tools
239
Body Repairs Equipment
241
Body Repairs Materials
242
Rust Repairs
244
How to Repair Rust Damage Using Plastic Body Fillers
244
To Repair Rust Damage
244
How to Repair Rust Holes Using a Fill-In-One Type Product
245
How to Repair Rust Holes Using Soldered Metal Patch
246
Panel Damage
247
Working Metal
247
How to Use Slide Hammer
247
Hand Bumping
248
Planishing
248
Hot Shrinking
249
Panel Replacement
250
How to Use Plastic Body Fillers
251
Fundamentals of Spray Painting
252
Selecting an Air Compressor
252
Pressure Regulator/Filter
252
Air Hoses
252
Spray Guns
253
How to Use a Spray Gun
253
Painting with Aerosols
254
Brush Touching
255
Types of Paint
255
Removing Exterior Trim
256
Washing the Vehicle
256
Paint Stripping
256
Spray Painting
258
Masking
258
To Prepare the Surface for the Primer/Surfacer
258
To Apply the Primer/Surfacer
258
To Apply the Color Coats
259
Fluid Leaking from Needle Gland Packing
260
Fluid Leaking from Front of Gun
260
Air Leaking from Front of Gun
260
Intermittent Spray
260
Paint Difficulties - Causes and Cures
261
Blushing
262
Chalking of Lacquers
262
Compounding too Early
262
Crazing, Cracking or Checking
262
Orange Peel
263
Overspray - Dry Spray
263
Pinholing
263
Shrinking and Splitting of Primer/Surfacer
265
Wrinkling
265
Finishing off Painting
265
Hand Compounding
265
Machine Compounding
266
Conversion Tables
267
Engine: Contents
269
Specifications and Service Data
270
Entire Engine Specifications
270
Lubrication System Specifications
271
Engine Oil Flow Diagram
272
Engine Oil Cooling System
272
Engine Cooling System Specifications
274
Coolant
275
Coolant Flow Diagram
275
Automatic Transmission Fluid Cooling System
276
Engine Service Data
277
Crankcase Component Parts
282
Cylinder Heads Parts
283
Flywheel Housing and Fittings Parts
284
Crankshaft and Related Parts
285
Valve System Parts
286
Valve Rocker Parts
287
Emission Control Equipment Parts
288
Intake Manifold Parts
293
Oil Pan, Oil Filler Duct and Fittings
297
Oil Pump Parts
298
Engine Cooling System Parts
299
Water Pump and Relative Fittings Parts
300
Exhaust System Parts
302
Turbocharger Parts
304
On-Car Services
305
Ignition Timing
305
Engine Compression
305
Intake Manifold Vacuum
306
Hot Air Control System
307
Engine Idle Speed and Idle Mixture
308
Engine Idle Speed and Idle Mixture Troubleshooting
309
Hydraulic Valve Lifter
311
Engine Radiator
311
Engine Exhaust System
312
Oxygen(O2) Sensor
313
Removal and Installation of Crank Pulley
314
Turbocharger System Inspection
314
Dismounting and Remounting
315
Engine Inspection and Test
321
Non-TURBO Vehicle Engine Removal
322
TURBO Vehicle Engine Removal
323
Engine Disassembly
325
Intake Manifold Assembly
325
Valve Rocker Assembly
325
Cylinder Head/Crankshaft
325
Engine Inspection and Adjustment
326
Engine Assembly
342
Engine Installation
349

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Subaru Brumby 1989 Service & Repair Manual (358 pages)

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