Subaru Sambar KS4 Truck Engine Rebuild

This video shows my journey to rebuild the 4-cylinder engine in my 1990 Subaru Sambar. I hope it can be useful to other KEI truck owners out there!
0:00 Intro
1:26 Engine Removal
8:01 Engine Transmission Seperation
10:03 Top End Disassembly
13:00 Cylinder Inspection
16:02 Botton End Disassembly & Inspection
22:00 Engine Bore Measurement
29:12 Engine Block Cleaned, Hone, & Painted
32:29 Engine Reassembly Parts
38:00 Piston Ring Gap Check & Assembly
45:00 Crankshaft install
55:02 Piston/Connection Rod Assembly & Install
57:50 Cylinder Head Assembly & Install
1:07:00 Oil & Water Pump Install
1:11:38 Timing Belt Install
1:13:05 Valve Cover Install
1:14:30 Oil Pan Install
1:16:48 Exhaust Manifold Install
1:17:45 Oil Pump Sensor & Filter Install
1:19:02 Coolant System Part Assembly
1:20:28 Transmission Install
1:23:29 Engine Install
1:29:40 Carburetor Install
1:32:33 Final Assembly
1:36:07 Startup
NOTE - This video is meant to be informational only.

[@user-en8lt1nv2z]

The ultimate rubix cube. I would never be able to get this back together LOL - Awesome!!

[@Ronnach16]

Thanks a lot for bringing us along on the rebuild. Camera positions, framing and detail were excellent and it will be a big help if ever I have to pull apart the engine in my '95. Not an easy task having to think about the rebuild alongside video recording. Nice work!

[@carbonauto]

Thanks! Happy to answer any questions as well!

[@joeygarrido1917]

HOW CAN I GET 1995 subaru sambar cam shaf original

[@carbonauto]

@@joeygarrido1917 Maybe try ttps://yokohamamotors.net

[@SuperCooperville]

Wow, thanks for bringing us along on the rebuild

[@glmwpg]

Such good detail, pointers, and i noticed some best practices regardless of the engine/vehicle working on. Appreciate this video!

[@carbonauto]

@@glmwpg thank you!

[@vladghelu516]

Maaaan! What a detailed video 🌟

[@seanmanness1351]

So I watched your video, skipped most of the time lapse parts, this isn't my first engine, and thought it was pretty well done. I'm assembling my engine today and when I opened the rings I realized that they were a different profile and had no dot. I assumed the printing would go upward but assuming isn't my favorite way to build an engine! Lol. Your clarification helped! Thanks!

[@carbonauto]

Ring orientation is important. When I was in high school auto shop. We got a free F150 V8 engine from a local dealership that was burning oil. It was brand new. They couldnt figure out what was wrong. My class took it apart and found the rings were put in upside down from the factory.

[@awdawdawdawd222]

incredible video, the rebuild looks and sounds beautiful. obsessed with these trucks! subbed

[@carbonauto]

Much appreciated!

[@DeneMcDonald]

Nice, can't wait to see more.

[@jamesamber6009]

I love the little trucks' simplicity and durability !!!

[@drain_001]

Very comprehensive video, I have a 1992 Sambar myself so if I do any hardcore engine work I'm definitely rewatching this. Thanks!

[@carbonauto]

Thanks!

[@CJBuxMom]

Very well done video!

[@jefferywise1906]

Pretty good so far, I’m watching is sections. Now if that god awful noise was cut to 1db during the fast forward parts so only a bat 🦇 could hear it, then it would be a lot more pleasant to watch. 😊

[@carbonauto]

I will reduce the music for the next video.

[@Carnold_YT]

Great work!

[@PentagonPirate]

Hell, yeah this is rad.

[@carbonauto]

Greatest world rally racer in history?

[@andrewspinney]

Nice work! TY!

[@jamesamber6009]

Handy man!

[@jamesmason7124]

Nicely done bro. For your information, the older Subaru's had blue valve covers and air cleaner, kinda of a baby blue

[@carbonauto]

Thanks! Stayed tuned, I got alot of content coming with a new build.

[@TheRyanpeel]

Great videos, mate. Inspired me to try my first ever engine rebuild. I have a 90 sambar also. I'm a clean freak. How do you clean up those parts like valves and springs and all that without damaging them. I want to clean my carb all up too. Any tips?

[@jimzorzi417]

can you show the box removal ? or the which fasteners are affected? and how about the seal to the cab area?

[@tedd1091]

Outstanding video. Anychance you can let us know your source of rebuild parts, overhaul manual and cost for the job. Also, what was the mileage before you stared. Thanks

[@Chonchonilolhi]

my subaru power steering having some problem, when long distance driven wheel is hard and steering message shown on dashboad and engine off and on its fine but after few minutes again it happens why

[@bbillingsfilms7200]

Great informational video, thanks! Where did you get the rebuild kit (gaskets, bearings)? I have a 93 and it's got a loud rattle and I'm considering rebuild vs replacement cost.

[@carbonauto]

I got the kit from G&R imports. They are out of Missouri and usually have a lot of common parts in stock. Rebuilding it was really cost-effective. I'm sure a replacement from Japan is great, but at like $3k+ that just didn't make sense. I didn't pay much for the truck! Let me know if you have any questions.

[@bennyhill3642]

I dont have one. But im still Grateful for you making this vid.. I wondered where did you get your manual for that engine? Tjanks again😇😁

[@carbonauto]

Thanks! I think I got my manual from Amazon.

[@ajenomorris4797]

Do you have the video if you making the carburetor

[@BDT1029]

Hello, I just purchased a mid 90's Sanburn, it comes with no info, where would I look to determine the year, model, and engine model? I see you were using what looked like a service manual, I was wondering where I could find one once I know all my info on what have? That was a great video you made

[@carbonauto]

There is lots of manual floating around on amazon and ebay for these. Be aware though that they don't always have the accurate info. Check the FB group facebook.com/groups/sambarsquad You can drop your trucks vin number in there and someone can help decode it for ya.

[@harleyrice7770]

I’m in total awe of your patients and memory. I wish you had told us the mileage and age of that motor. It would appear you’re frequently reading the Bible as I don’t know of any rebuilding manuals for this motor, unless you’re fluent in Japanese. I’d probably do the same.

[@carbonauto]

Thank you! The truck is a 1990 and it probably had close to 120k miles on it but could be hard to say. There is manuals for these trucks and motors. I have a KS4 Manual for sale. Let me know if I can help you find a manual.

[@Nanashi_MYOB]

The blue fits on a Subaru.

[@jamesamber6009]

Subaru Sambar is a lot more practical than F150

[@mannydelrio1]

Looks awesome , hey I noticed that you are in TX , did you get it plated , if so how , I am thinking of getting one in Austin.

[@carbonauto]

Yes, it's fully registered. It's pretty simple. Texas is friendly to Kei Trucks. When you go in to the DMV just say it's a small pickup. Don't give to much info.

[@mongohighboy5739]

Where did you get your rebuild kit from? Great informative video, good work.

[@carbonauto]

I got mine from G&R imports.

[@retsbeWxelA]

What triggered you to rebuild the engine? Was there a problem that drove this need? Did you notice any performance differences before and after a rebuild?

[@carbonauto]

Yes, the piston rings were bad. I was able to determine this using a compression gauge. Power is definitely better now. I ported and polished the head which may have helped a bit.

[@ajenomorris4797]

Thank you mine is always flooding I don't know how to fix it

[@carbonauto]

How did you determine it was flooding? Depending upon your model. There is a fuel solenoid that will shut off fuel to the bowl. Make sure this is working. The wires are common to short burning through. If that looks good I would rebuild the carb and look at the bowl float for proper height.

[@ednovak6060]

Great video, what charges should we expect from machine shop?

[@carbonauto]

Pretty cheap. Cylinder hone was $35. You could hone it yourself but since I needed the cleaning on the block. Just made sense to have them do it. The soda blasting and hot tank for the block, head, and some misc pieces was $250.

[@hesham1319]

I wounder how you do air pleading. Sambar is really pain in ass for air pleading

[@noahkraft6453]

I was curious how many mikes did it have before you did the rebuild on it.

[@carbonauto]

The truck had about 150k but i think the engine had less from a previous rebuild. Not completely sure.

[@NM-ql9er]

What was the approximate cost for the machining work for the engine. You did an awesome job too. Loved those final colors

[@carbonauto]

It was $500. I had them soda blast some additional parts though. If you just wanted the block hot tanked and honed. Shouldn't be more than $200.

[@NM-ql9er]

@@carbonauto wow. Not bad. Thanks for the additional info

[@kennethrobertson1201]

Very interesting but the music is very distracting

[@littlefreak3000]

Where did you get your sambar mechanic manual?

[@carbonauto]

I think from Amazon. I will sell ya mine

[@Chonchonilolhi]

what is used of second fan nearby petrol tank area was stored

[@carbonauto]

Would need a picture to see what you mean. There is a fan on the radiator to keep the engine.

[@Chonchonilolhi]

@@carbonauto how can i send picture .. do u give me ur whats app or other way to communicate u

[@ronstorey6012]

What I'd like to see is one of you owners consider putting a 1600 cc VW an transaxle in one of these mini trucks. How about that?

[@carbonauto]

Lots of guys drop K-motors into these because of the little mods needed to make it work. But you lose 4WD by doing so.

[@ronstorey6012]

@@carbonauto didn't know that but you guys are the experts

[@bobpineo6376]

Great video, but man, that music during time lapses is WAY TOO LOUD....

[@lolsalot1000]

extremely cheap? where did you get your rebuild kit?

[@carbonauto]

$500 from G&R imports

[@Pigpenned]

I know this motor uses belts but reminded me of building CB750's. Trouble is I was stupid. I took advantage of workshops I had access to then suddenly I had no workshop and had to start again. Love the effort & care you put into it but that transmission with the same paint- I think you should have done it but it's up to you. BTW the video music sounds like someone saying "F**k Freddo" lol. A Romahome demountable would be cool on it bt the Hi-Jets have the 1300 motor. kzbin.info/www/bejne/porYoYZ-jKp9rqM

[@manjulafd]

i need wiring diagram

[@carbonauto]

What year and model Sambar do you have?

[@T_Hawk86]

How long did this take you to complete?

[@carbonauto]

Probably 8 hours all in

[@T_Hawk86]

@@carbonauto Was it tempting just to bore it and get some bigger pistons, try to get a little extra performance out of it?

[@carbonauto]

@@T_Hawk86 I didn’t think the cost of the bore and pistons would be worth it. I did port and polish the head though.

[@T_Hawk86]

@@carbonauto Great job on the engine! Appreciate the video.

[@Chonchonilolhi]

my trunk getting stuck when driving long distance why?

[@carbonauto]

What do you mean by stuck? The engine dies? Need more info to help you trouble shoot.

[@Chonchonilolhi]

@@carbonauto being able to stop engine

[@carbonauto]

@@Chonchonilolhi so you turn the key to the off position but the engine keeps running?

[@Chonchonilolhi]

@@carbonauto are u sure? Ok will try it

[@henryblackburn831]

oil filter should be hand tight

[@moonspoonx2]

might have been sea foamed or water spray cleaned just gess.

[@stephencrowther524]

Great video,but ‘orrible ,too loud,muzak !

[@GtoJohn]

Couldn't watch because of the horrible music

[@MrStratbat]

when that music kicked in I couldn't leave fast enough...Not in the mood for music interested in an engine build..Damn

[@jamesjohnson8661]

That's the problem with Sambars; most of them need the engine rebuilt