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Subaru 360 Custom, Service Manual

The Subaru 360 Custom Service Manual is a comprehensive and essential resource for all owners. This user manual provides detailed instructions and maintenance tips to ensure the smooth operation of your Subaru 360. Download this valuable manual for free from our manualshive.com, the ultimate destination for automotive manuals.

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Summary of Contents for 360 Custom

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Page 3: ... and Subaru 360 Truck Please utilize this manual fully to ensure complete maintenance work for satisfying our customers by keeping their vehicles in the best condition For information on the body please refer to the Service Manual Body Section When it is necessary to replace parts during maintenance be sure to use genuine Subaru parts 1969 FUJI HEAVY INDUSTRIES LTD ...

Page 4: ...IONS AND PERFORMANCE 1 CHAPTER 2 MOUNTING AND DISMOUNTING ENGINE 2 CHAPTER 3 ENGINE AND TRANSMISSION 3 CHAPTER 4 ENGINE ANCILLARY PARTS 4 CHAPTER 5 ELECTRICAL EQUIPMENT 5 CHAPTER 6 TIGHTENING TORQUE 6 CHAPTER 7 SPECIAL TOOL 7 SUPPLEMENT ...

Page 5: ...CHAPTER 1 MAIN SPECIFICATIONS AND PERFORMANCE 1 1 ENGINEPERFORMANCECURVE 1 1 1 2 MAIN SPECIFICATIONS 1 2 ...

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Page 7: ...1 1 ENGINE PERFORMANCE CURVE 30 1W 8 lb ft 2500 3 M H 1 3500 4WO 4500 5WO 5500 6WorPm ENGINE SPEED ...

Page 8: ...aximum torque 3 5 kg m 25 3 lb ft Minimum fuel consumption at 300 gr hp h at 5200 rpm full load Dimensions weight dry Length x width x height 634 x 618 x 476 mm 25 0 x 24 3 x 18 7 in Weight SEDAN 78 3 kg 172 3 lb CUSTOM TRUCK VAN 78 8 kg 173 4 lb Piston type Single action cylinder piston Piston material High silicon aluminum alloy cast Number of piston rings 3 pressure rings Valve timing Intake po...

Page 9: ...ENERATOR Type Generating method Voltage and capacity STARTER M O T O R Type Voltage and output HITACHI 51504 1100 NIPPON DENS0 29100 136 HITACHI D 203 Automatic c e n t r i f u g a l NIPPON TOKUSHU T O G Y O NGK B7H 14 mm 0 7 mm 0 0276 i n HITACHI Solex Type HAB28 1 Side d r a f t O i l w e t type paper f i l t e r 1 2 5 e 6 6 U S gal 5 5 Imp g a l 2 0 e 5 3 U S g a l 4 4 Imp g a l 3 0 l 8 0 US ga...

Page 10: ...on gear Type Helical gear Reduction r a t i o 1 605 Transmission 5 P e 4 forward 1 reverse synchromesh on 2nd 3rd 6 4th OT Gear r a t i o 4th OT 0 806 3rd 1 000 2nd 1 601 1st 3 130 Reverse 4 248 Final reduction gear Type Helical gear Reduction r a t i o Sedan 3 667 Custom 3 667 Truck 4 188 Van 3 882 Amount of gear o i l 1 6 l 3 4 U S pt 2 8 Imp pt DIFFERENTIAL Differential case Separate type Diffe...

Page 11: ...BARU 360 SEDAN CUSTOM 2 1 PREPARATION 2 1 DISMOUNTING THE ENGINE 2 2 REMOVING ANCILLARY PARTS 2 10 MOUNTING THE ENGINE 2 12 MOUNTING AND DISMOUNTING THE ENGINE FOR THE SAMBAR TRUCK VAN 2 14 PREPARATION 2 14 DISMOUNTING THE ENGINE 2 14 RWOVING ANCILLARY PARTS 2 21 4 MOUNTING THE ENGINE 2 23 ...

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Page 13: ...ground B REMOVING THE TRAP DOOR a SEDAN Remove t h e 4 mm screws and detach t h e t r a p doors on t h e r e a r bulkhead b C U S T O M Remove the 8 mm screws and detach the t r a p door on t h e r e a r s h e l f C REMOVING THE BATTERY G R O U N D ING BAND a Remove t h e 6 mm b o l t t o detach t h e b a t t e r y grounding band b Bend the grounding band s o t h a t i t w i l l not touch t h e ca...

Page 14: ...lug clutch housing and 22 mm plug transmission case and drain the gear o i l FTING T H E POSITION OF T H E G O N A L MEMBER ove the 10 mm b o l t which f i x e s diagonal member t o the cross member loosen the 10 mm b o l t on the other side and s h i f t t h e position of the diagonal member toward the inside s o t h a t it w i l l not be i n the way when t h e engine is t o be remved ...

Page 15: ... t h e cable out from the clutch lever t h e p i n clutch lever sometimes drops Be c a r e f u l not t o l o s e i t REMOVING THE O I L TANK P I P E Loosen the screw of the o i l pump s i d e c l i p and p u l l out t h e pipe from the o i l pump PROTECTOR WREN REMOVING THE C L MHOUSING Remove the three 8 mm nuts and detach t h e protector and spacer ...

Page 16: ... c k wire SPECIAL TOOL b Remove t h e rear a x l e b o l t s u s i n g t h e s p e c i a l t o o l 921220000 921220000 c P u l l t h e wheels outward and disconnect t h e coupling of t h e a x l e l F T I REMOVING THE ENGINE HOOD CUSTOM only Remove t h e f o u r 5 mm screws of t h e engine hood hinge and detach t h e engine hood ...

Page 17: ...the right and two on the l e f t and remove the rear bumper from the body K REMOVING THE REAR SKIRT a SEDAN Remove the three 6 mm nuts and the two 6 mm bolts to detach the rear skirt CUSTOM Remove the three 5 mm screws and four 6 mm bolts to remove the rear skirt ...

Page 18: ...ble from t h e t h r o t t l e lever Loosen t h e 6 mm nut and detach the cable from t h e bracket M REMOVING THE FUEL PIPE AND FUEL C O C K PIPE a SEDAN 1 Detach the f u e l pipe and f u e l cock pipe from the c l i p s 2 Remove t h e f u e l pipe from t h e carburetor f l o a t chamber 3 P u l l out t h e f u e l cock pipe from the intake manif old b C U S T O M 1 Detach t h e f u e l pipe from ...

Page 19: ...wire t h i n c Remove sb o l t of the c l i p and detach the b a t t e r y cable with the c l i p from t h e cowl d Remove t h e black yellow wire of the wiring harness from t h e terminal S of the s t a r t e r switch e P u l l out t h e high tension cord from the i g n i t i o n c o i l and loosen the primary terminal nut of the d i s t r i b u t o r t o remove the primary l i n e 0 REMOVING T H...

Page 20: ...r change rod from the gear shifter shaft REMOVING IHE HEATER DUCT Loosen the clip exhaust manifold side and disconne the heater duct from the exhaust manifold R DISCONNECTING THE BACK UP LIQIT SWITCH WIRES Disconnect the back up light switch wires from the wiring harness ...

Page 21: ...a r support a Remove t h e l e f t and r i g h t 8 rnm b o l t s of t h e cross member NOTE The b o l t is a through b o l t from t h e o u t s i d e of the c a r body In t h i s c a s e do n o t p u l l o u t the b o l t Leave t h e b o l t i n t h e h o l e s o t h a t i t can be pulled out a t any time b u t keep the nut removed T h i s is s a f e r b Now cautiously push i n two 1 0 mm b o l t ...

Page 22: ...e i t i s not always neces sary t o remove a l l the ancillary p a r t s i n t h i s manner D o not remove them unless they are i n the way of disassembly o r repair work A REMOVING THE MUFFLER a Remove the two 8 mm nuts and two 8 mm b o l t s of the clamp muffler pipe connecting and separate the clamp i n t o two pieces b The muffler w i l l come off when t h e four 8 mm nuts and I f o u r 8 m m ...

Page 23: ...se 6 mm nuts one secures t h e clutch housing with t h e studs of t h e engine case C REMOVING THE CROSS MEMBER Engine r e a r support a Remove the grouding band engine from t h e cross member b Remove the two 12 mm b o l t s of t h e engine mounting bracket Then t h e cross member w i l l be removed together with t h e bracket and cushion rubber D REMOVING THE LOWER D U C T Remove the three 6 mm ...

Page 24: ...with the rear axle bolts be sure t o lock the b o l t s with a lock wire 3 0 3 3 kg m 21 7 23 8 lb ft 2 Supplying gear o i l Remove the 22 mm plug from the gear o i l hole on the trans mission cover I1 and f i l l the case with approximately 1 6e 3 4 US pt 2 8 Imp pt of gear o i l 3 Adjusting i d l i n g speed a F i r s t make sure t h a t t h e carburetor choke valve and t h r o t t l e valve act...

Page 25: ...ng the clutch cable Adjust the clutch cable with the wing nut Refer t o item h on page 3 21 5 Checking the gear s h i f t Check gear shifting gently at low speed 6 Make sure there i s no absormality i n any part ...

Page 26: ... each 8 m m b o l t s t o detach the t r a p doors on t h e r e a r shelf and r e a r bulkhead b Remove t h e 6 mm b o l t of the battery grounding band Bend t h e grounding band so t h a t i t does not contact t h e car body B RFMOVING T H E HOSE BATTERY Loosen t h e 4 mm screw of t h e duct s i d e c l i p and remove t h e hose from the duct REMOVING T H E HEATER D U C T Loosen t h e c l i p exh...

Page 27: ...ect the back up light switch wires from the wiring harness DRAINING GEAR OIL Remove the 14 mm plug clutch housing and 22 mm plug transmission case and drain the gear oil F REMOVING THE REAR BUMPER Remove the two 8 mm screws and detach the rear bumper I ...

Page 28: ...ra tor A terminal White red wire F terminal White wire E terminal Black wire Remove the 8 uan nut of the starter switch terminal and remove the battery cable thick black wire and white black wire thin c Remove the 6 mm bolt of the clip and detach the battery cable with the clip from the cowl d Remove the black yellow wire of the wiring harness from the terminal S of the starter switch e Pull out t...

Page 29: ...he 6 mm nut and detach the choke cable from the bracket Remove the 5 mm nut t o remove the accelerator cable from the t h r o t t l e lever Then loosen the 6 mm nut and detach the accelerator cable from the bracket J R E M O V I N G THE ENGINE GROUNDING BAND Remove the 8 mm bolt and detach the grounding band from the cross member ...

Page 30: ...the d SHIFTING THE POSITION O F THE DIAGONAL M E M B E R Remove t h e 8 mm b o l t which tighten t h e diagonal member t o the cross member loosen the 8 mn bolt on t h e other s i d e and s h i f t the position of the diagonal member toward the i n s i d e so t h a t it w i l l not be i n the way when t h e engine is t o be removed 1 N REMOVING THE UNDER C O V E R Remove the s i x 6 m b o l t s t ...

Page 31: ...REMOVING THE OIL T A N K PIPE Loosen the screw of t h e o i l pump s i d e c l i p and p u l l out t h e pipe from t h e o i l pump REMOVING T H E R E A R A X L E F i r s t remove the c l i p of the axle boot and p u l l out t h e boot Then cut off the lock wire SPECIAL T O O L Remove the r e a r axle b o l t s with the s p e c i a l t o o l 921220000 921220000 c P u l l t h e wheels outward and d...

Page 32: ...he engine with a stand box or garage jack REMOVING T H E ENGINE MOUNTING BRACKET ENGINE FRONT Remove the two 10 mm nuts of t h e engine mounting bracket U REMOVING THE CROSS M E M B E R a Remove the l e f t and r i g h t 8 mm nuts of the cross member b Then cautiously p u l l out two each l e f t and r i g h t 8 m b o l t s of t h e cross member and remove the engine from t h e chassis ...

Page 33: ... muffler pipe connecting and separate t h e clamp i n t o two pieces b Remove the muffler by removing the four 8 mm b o l t s A r i n g muffler pipe connect ing is inserted between t h e muffler pipe and exhaust manifold B RENOVING THE CLUTCH LEVER AND BRACKET CLUTCH CABLE SUPPORT a Remove one 6 mm b o l t and p u l l out the lever Remove one 4 mm woodruff key and then remove t h e r e t u r n spr...

Page 34: ...ecure the cushion rubber t o t h e r i g h t and l e f t mounting brackets Then remove the four 8 mm nuts and detach the cushion rubber and both brackets E REMOVING T H E CROSS MEMBER AND BRACKET ENGINE REAR SUPPORT Remove the two 12 mm b o l t s of the engine mounting bracket Then t h e cross member w i l l be removed together with the cushion rubber and bracket Also detach the s t a y by removin...

Page 35: ...s t a l l i n g t h e r e a r a x l e A f t e r t i g h t e n i n g t h e r e a r a x l e with t h e r e a r a x l e b o l t s be s u r e t o l o c k t h e b o l t s with a l o c k wire 2 Supplying g e a r o i l TIGHTENING TORQUE Remove t h e 22 mm plug from t h e gear o i l h o l e on t h e transmission cover I1 and f i l l t h e c a s e w i t h approximately 1 6 3 4 US p t 2 8 1mp pt of gear o i...

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