Subaru Sambar 1990 thru 2006, repair e-manual

Content

Vehicle identification

• VIN class breakdown
• Engine and transmission decoding
• Engine-transmission combination charts
• Vin and code locations
• Jacking positions
• Tire size and air pressure guide

General maintenance and tune up

• Engine specifications
• Testing equipment
• Battery and coolant
• Oil and filter including supercharger
• Air and fuel filter
• Spark plugs
• V- belts
• Valve adjustment
• Vacuum hose
• Distributor point settings
• Timing
• Idle setting
• CO-HC levels and adjustment
• Engine vacuum and troubleshooting
• Main relay location guide

Suspension

• Front suspension components
• Rear suspension components
• Front and rear alignment
• Camber and caster settings
• Front strut removal and replacement
• Traverse link
• Rear shock absorber remove and replace

Steering

• Specifications and diagram
• Exploded component view (steering column)
• Exploded component view (rack and pinion)
• Steering column removal / disassembly /assemble / install Steering gear box
• Rack and pinion overhaul
• Tie rods

Brake system

• Bleeding brake system (air)
• Parking brake adjustment
• Master cylinder system
• Brake booster
• Disk brake and caliper overhaul
• Rear brake drum system overhaul
• Parking brake cable system
• Complete brake line system

Engine coolant and cooling system

• Coolant system specifications and capacities
• Coolant system components diagram
• Coolant system radiator components diagrams
• Engine room fan system
• Troubleshooting chart
• Coolant line diagrams (chassis mount)
• Water pump
• Engine room fan circuit
• Cooling master control unit and circuit

Air — fuel system — exhaust

• Air intake system (carbureted)
• Air intake system (fuel injected-supercharged)
• Air cleaner and air intake sensor
• Intake manifold (carbureted)
• Complete fuel system specifications
• Carburetor adjustments and breakdown
• Fuel tank
• Fuel system EMPI (fuel injected vehicles)
• Fuel pump-pressure regulator-knock sensot
• Fuel injection-air/water temp sensors-O2 sensor
• Exhaust truck-van

Starter and alternator

• Starter specifications hitachi series-mitsubishi series
• Starter overhaul diagrams
• Alternator specifications- mitsubishi series-denso series
• Alternator diagram

Engine and transmission removal

• Complete engine and transmission removal

Engine overhaul

• Engine disassembly
• Block inspection
• Cylinder inspection
• Piston inspection including oversize pistons
• Block deck-journal and bore sizes
• Piston rings and installation positioning
• Connecting rods
• Crankshaft and journals
• Journal details and clearances
• Crankshaft oil seals
• Block assembly
• Piston installation
• Oil pump
• Cylinder head and timing belt system
• Valve rocker assembly
• Camshaft specifications and clearances
• Camshaft installation and oil seal
• Cylinder head — valve springs- valves
• Valve guides- valve details
• Oil pump overhaul
• Oil pressure switch

Transmission and differential 2WD - 4WD

• Gear shift system
• TM 60 series 2WD clutch housing — main case - side case
• TM 60 series 2WD main shaft-drive pinion- reverse idler shaft TM 60 series 2WD shift and select system
• TM 60 series 2WD differential
• TM 60 series selective 4WD transmission case assembly
• TM 60 series selective 4WD shifter and selector system
• TM 60 series selective 4WD drive pinion-main shaft-reverse idler
• TM 60 4WD differential
• TM 60 4WD diff-lock differential option
• TM 60 4WD diff-lock side cover assembly
• TM 60 selective 4WD transfer extension
• Clutch and pressure plate specifications
• Clutch system diagram
• Clutch cable adjustment
• Release bearing and fork
• Clutch disk — flywheel — pressure plate
• Clutch assembly
• Axel shaft system
• Axel shaft identification and type

Electrical diagrams and schematics

• General harness locations
• Truck full main harness and connection codes
• Connection codes explained (truck-van)
• Van full main harness and connection codes
• Engine and transmission harness and connections
• Engine and transmission harness code breakdown
• Front component (main) harness dash-front lighting
• Front component (main) connector breakdown
• Electrical schematic breakdowns
• Turn signal and hazard
• Stop lamp circuit
• Lighting circuit (headlights-running lights)
• Lighting circuit tail assemblies and illumination lamps
• Engine control and fuel pump circuits
• Charging system
• Engine room and radiator fan (van and special trucks)
• Engine radiator fan (basic vehicle)
• Radio (audio) circuits and cigarette lighter
• Fuel gage and sending unit
• Full time 4WD control circuits
• Selective 4WD control circuits
• Diff-lock control circuits
• EMPi engine control management system part (fuel injection)
• Windshield wiper system front and rear
• Rear defogger circuit

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