Subaru 360 Sedan User manual

FOREWORD
This service manual has been prepared as reference for effective
service and maintenance of the engine for Subaru
360 Sedan,
Subaru
360 Custom, Subaru 360 Van 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.

CONTENTS
CHAPTER 1: MAIN SPECIFICATIONS 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

CHAPTER 1 : MAIN SPECIFICATIONS AND
PERFORMANCE
..............................
1-1 ENGINEPERFORMANCECURVE 1-1
1-2 MAIN SPECIFICATIONS ................................... 1-2

1 - 1 ENGINE PERFORMANCE CURVE
30
1
W
8
*
lb-ft
2500 3MH1 3500 4WO 4500 5WO 5500 6WorPm
ENGINE SPEED

1 - 2 MAIN SPECIFICATIONS
ENGINE
Model
Type
EK32
Gasoline engine
Cooling system and cycle Forced air-cooled; 2-cycle
Number of cylinder and 2 cylinders, in line
arrangement
Bore x stroke 61.5
x 60 mm (2.42 x 2.36 in)
Piston displacement 356 cc
Compression ratio 6.7
Compression pressure
9.1 kg/cm2 (129.4 lb/in2)
at 300 rDm
Max. explosion pressure 25.0 kg/cm2 (355.6 lb/in2)
at 1500 rpm
Mean effective pressure 6.2 kg/cm2 (88.2 lb/in2)
at 4500 rpm
Maximum output 25
HP at 5500 rpm
Maximum 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 port:Opening angle 53' before top dead center
Closing angle 53' after top dead center
Exhaust port:Opening angle 68- before bottom dead center
Closing angle 68' after bottom dead center
IGNITION SYSTEM
Firing order 1-2
Ignition timing 13' before top dead center at
2000 rpm

Ignition coil type
Distributor
Type
: Sedan, Custom
Truck, Van
Firing angle advancer
Spark plug
Type
Thread size
Spark gap
FUEL SYSTEM
Carburetor
Type and number
Air flow-direction
Air cleaner type and number
Fuel tank capacity
Sedan
Custom
Truck, Van
LUBRICATION SYSTEM
Lubrication method
Oil pump type
Oil tank capacity
BATTERY
Type and number
Voltage and capacity
Specific gravity
GENERATOR
Type
Generating method
Voltage and capacity
STARTER MOTOR
Type
Voltage and output
HITACHI 51504
- 1100
NIPPON DENS0 29100-136
HITACHI D-203
Automatic centrifugal
NIPPON TOKUSHU TOGYO (NGK)
B7H
14 mm
0.7 mm (0.0276 in)
HITACHI Solex Type HAB28,
1
Side draft
Oil wet type paper filter, 1
25e, 6.6 US gal, 5.5 Imp. gal
20e, 5.3 US gal, 4.4 Imp. gal
30l, 8.0 US gal, 6.5 Imp. gal
Forced lubrication
Plunger pump
2.5e (2.6 US qt, 2.2 Imp qt)
WASA 12N24-3, 1
12 V, 26 AH
1.280 (when fully charged)
NIPPON DENS0 27000
- 116
Constant voltage
12
v, 200 W
HITACHI S108
12
V, 600 W

REGULATOR
Type NIPPON DENS0 26000
- 108
POWER TRANSMISSION
Clutch
5Pe Dry single plate type
Clutch plate(outside dia. 160
x 110 x 3.1 m
x inside dia. x thickness) (6.30 x 4.33 x 0.12 in)
Facing area 212 cm2 (32.86 in2)
Primary reduction gear
Type Helical gear
Reduction ratio 1.605
Transmission
5Pe 4-forward & 1-reverse,
synchromesh on 2nd, 3rd
6 4th(OT)
Gear ratio : 4th (OT) 0.806
3rd 1.000
2nd 1.601
1st 3.130
Reverse 4.248
Final reduction gear
Type Helical gear
Reduction ratio
: Sedan 3.667
Custom 3.667
Truck 4.188
Van 3.882
Amount of gear oil 1.6
l (3.4 US pt., 2.8 Imp. pt.)
DIFFERENTIAL
Differential case Separate type
Differential gear type Bevel gear, 2.
and number

CHAPTER 2 : MOUNTING AND DISMOUNTING
ENGINE
MOUNTING AND DISMOUNTING THE ENGINE
FOR THE SUBARU
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

2- 1 MOUNTING AND DISMOUNTING THE ENGINE FOR THE
SUBARU
360 SEDAN & CUSTOM
1 : PREPARATION
A. SUPPORTING THE CAR BODY
Support the car body by placing
it on a sturdy block; raise
the rear wheels off the ground.
B. REMOVING THE TRAP DOOR
(a) SEDAN
Remove the 4 mm screws and
detach the trap doors on the
rear bulkhead.
(b) CUSTOM
Remove the
8 mm screws and
detach the trap door on the
rear shelf.
C. REMOVING THE BATTERY GROUND-
ING BAND
(a) Remove the 6 mm bolt to
detach the battery grounding
band.
(b) Bend the grounding band so
that
it will not touch the
car body.

2 : DISMOUNTING THE ENGINE
REMOVING THE ENGINE
ROOM
WDER COVER
Remove the four 6 mm bolts
and one 10
m bolt to detach
the under cover.
B. DRAINING GEAR OIL
Remove the 14
mm plug (clutch
housing) and
22 mm plug
(transmission case) and
drain the gear oil.
--'-FTING THE POSITION OF THE
GONAL MEMBER.
.-... ove the 10 mm bolt which
fixes diagonal member to the
cross member; loosen the
10
mm bolt on the other side
and shift the position of
the diagonal member (toward
the inside) so that
it will
not be in the way when the
engine
is to be remved.

REMOVING mE CLUTm CABLE
Loosen the 6 mm bolt of the
clamp to detach the cable
from the bracket and then
remove the wing nut.
[NOTE I
When pulling the cable out
from the clutch lever the
pin (clutch lever) sometimes
drops.
Be careful not to lose
it.
REMOVING THE OIL TANK PIPE.
Loosen the screw of the oil
pump side clip and pull out
the pipe from the oil pump.
PROTECTOR (WREN REMOVING THE
CL~M HOUSING)
Remove the three 8 mm nuts
and detach the protector and
spacer.

G. REMOVING THE REAR AXLE
(a) Fir re the clip of the
axle ~oor:and pull out the
boot. Then cut off the lock
wire,
SPECIAL TOOL
(b) Remove the rear axle bolts
using the special tool
921220000.
921220000
(c) Pull the wheels outward and
disconnect the coupling of
the axle.
l --F = -
T -' -
.-
I. REMOVING THE ENGINE HOOD
- /--
.? (CUSTOM only)
Remove the four
5 mm screws
of the engine hood hinge and
detach the engine hood.

J. REMOVING THE REAR BUMPER
Remove the four 6 mm bolts
(two
on the right and two on
the left) 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.

L. REMOVING THE CHOKE CABLE
AND ACCELERATOR CABLE
Remove the
5 mm nut to re-
move the choke cable from
the choke lever.
Loosen the
6 mm nut and
detach the cable from the
bracket (cable guide).
Remove the
5 mm nut to re-
move the accelerator cable
from the throttle lever.
Loosen the
6 mm nut and
detach the cable from the
bracket.
M.
REMOVING THE FUEL PIPE AND FUEL COCK PIPE
(a)
SEDAN
(1) Detach the fuel pipe and
fuel cock pipe from the
clips.
(2) Remove the fuel pipe from
the carburetor float
chamber.
(3) Pull out the fuel cock
pipe from the intake
manifold.
(b) CUSTOM
(1) Detach the fuel pipe
from the clip.
(2) Remove the fuel pipe from
the fuel pump.

N. REMOVING THE WIRING HARNESS (REAR) AND BATTERY CABLE
(a) Remove the 5 mm nuts and
screw and disconnect the
A,
F and E wires from the
generator.
A terminal : White-red wire
F terminal : White wire
E terminal : Black wire
(b) Remove the 8 mm nut of the
starter switch terminal and
remove the battery cable
(thick black wire) and white-
black wire (thin).
(c) Remove
" ,,.s 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 the high tension cord
from the ignition coil and
loosen the primary terminal
nut of the distributor to
remove the primary line.
0. REMOVING THE BOOT (DUCT)
Remove the air intake boot
from the air cleaner cover.
Remove the duct side band
(boot) and remove the boot
from the duct.

REMOVING TWE GEAR CKANGE ROD
Remove the 8 mm nut and
separate the gear 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.