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Subaru Legacy EJ22 1991-1994 Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Generation: First Generation (BD/BG/BK) Market Segment: Mid-size Sedan/Wagon Codes Chassis Codes: BD (Sedan), BG (Wagon) 👋 Introduction Market Position Positioning: The Subaru Legacy EJ22 1991-1994 Service Repair Manual is a critical resource for owners and independent repair shops seeking in-depth technical information for this generation of Subaru's mid-size offering. It bridges the gap for owners who want to perform their own maintenance or diagnostics on a vehicle known for its all-wheel-drive capability and flat-four engine character. Competitive Analysis Competition: Competed against vehicles like the Toyota Camry, Honda Accord, Nissan Maxima, and Mitsubishi Galant. The Legacy distinguished itself with standard AWD across most trims and its unique boxer engine. Key Features Vehicle Strengths: Standard Symmetrical All-Wheel Drive (AWD), reliable EJ22 engine, comfortable ride, practical wagon variant available. Manual Value Value Proposition: Provides the essential factory-level data required for accurate maintenance, diagnosis, and repair, enabling owners to extend the lifespan and maintain the performance of their Subaru Legacy. 📋 Manual Details Coverage Areas Vehicle Years: 1991, 1992, 1993, 1994 Engine Coverage: EJ22 (2.2L SOHC) Page Count Estimated Page Count: 1500-2000 Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (EJ22), Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System Drivetrain: Automatic Transmission (4EAT), Manual Transmission (5-speed), All-Wheel Drive (AWD) System, Differentials Chassis: Suspension (Front Struts, Rear Multi-link), Steering System, Braking System (Front Disc/Rear Disc or Drum) Electrical: Wiring Diagrams, Battery, Charging System, Starting System, Lighting, Fuses, Relays, ECUs (Engine Control Unit) Body: Exterior Body Panels, Interior Trim, Doors, Windows, Seating, HVAC System Procedures Included Maintenance: Oil Changes, Filter Replacements, Fluid Checks and Replenishment, Belt Inspections and Replacements, Spark Plug Replacement, Tune-ups Repair: Engine Rebuilds, Transmission Overhauls, Suspension Component Replacement, Brake System Repairs, Electrical Component Diagnosis and Replacement, Body Panel Repair Diagnostics: Troubleshooting Guides, DTC (Diagnostic Trouble Code) Interpretation, Symptom-based Diagnosis Technical Depth Depth: Comprehensive diagnostic procedures, detailed disassembly and reassembly instructions, torque specifications, component testing methods, wiring diagrams 📊 Manual Specifications File Format Quality: High-resolution scans, searchable text where available Print Quality Printability: Printable pages for workshop use Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code: EJ22 Engine Type: Naturally Aspirated Boxer (Horizontally Opposed) Four-Cylinder Displacement: 2.2 Liters (2212 cc) Bore X Stroke: 96.0 mm x 75.0 mm Compression Ratio: 9.5:1 Valve Train: SOHC (Single Overhead Camshaft), 2 Valves Per Cylinder Performance Horsepower: 130 hp @ 5600 rpm (approx.) Torque: 137 lb-ft @ 4400 rpm (approx.) Fuel System Induction: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Cooling System Coolant Type: Subaru Super Coolant (or equivalent ethylene glycol based, 50/50 mix with distilled water) Lubrication System Oil Capacity With Filter: 4.7 US Quarts (4.5 Liters) Recommended Oil Viscosity: 10W-30 (API SG or higher) Ignition System Spark Plugs: NGK PFR6G (or equivalent - specific part numbers may vary, consult manual) 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transmission Optional Transmission Type: 4-Speed Automatic Transmission with Electronic Control (4EAT) Features AWD Engagement: Full-time Symmetrical All-Wheel Drive Fluid Specifications Auto Atf Type: Subaru ATF (Dexron II or III compatible - verify specific model year) Fluid Specifications Manual Mtf Type: GL-5 Gear Oil (75W-90 recommended) 📐 Dimensions Exterior Sedan Length: 4590 mm (180.7 in) Width: 1700 mm (66.9 in) Height: 1400 mm (55.1 in) Exterior Wagon Length: 4620 mm (181.9 in) Width: 1700 mm (66.9 in) Height: 1450 mm (57.1 in) Wheelbase Wheelbase: 2625 mm (103.3 in) Weights Curb Weight Approx: 1350-1450 kg (2976-3197 lbs) Gross Vehicle Weight Rating: Varies by model/trim, consult manual Towing Capacity: Not officially rated for significant towing in most markets, consult owner's manual/local regulations 🛡️ Safety Features Ratings NHTSA Ratings: Limited data available for this era; expect average for its time. Consult specific recall databases. Active Features ABS: Optional on some trims/years, standard on higher trims Passive Features Airbags: Driver-side airbag standard; passenger airbag optional/introduced later in the generation Seat Belts: Front 3-point height-adjustable, Rear 3-point retractable 💡 Technology Features Infotainment Audio System: Factory AM/FM/Cassette or CD player, typically with 4 speakers. Optional premium sound systems may exist. Climate Control: Manual or automatic climate control depending on trim level. Covers HVAC system operation and repair. Driver Assistance Cruise Control: Standard on most models, electronic cruise control system. Connectivity Connectivity Features: Limited to basic analog systems of the era. No integrated Bluetooth or USB found. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 miles (6,000 km) or 3 months, whichever comes first (severe conditions may require more frequent changes). Engine Air Filter Replacement: Every 15,000 miles (24,000 km) or 12 months. Cabin Air Filter Replacement: Not equipped with a cabin air filter in these years. Spark Plug Replacement: Every 30,000 miles (48,000 km) for standard...
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Subaru Legacy EJ22 1991-1994 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy
Generation:
First Generation (BD/BG/BK)
Market Segment:
Mid-size Sedan/Wagon
Codes
Chassis Codes:
BD (Sedan), BG (Wagon)
👋 Introduction
Market Position
Positioning:
The Subaru Legacy EJ22 1991-1994 Service Repair Manual is a critical resource for owners and independent repair shops seeking in-depth technical information for this generation of Subaru's mid-size offering. It bridges the gap for owners who want to perform their own maintenance or diagnostics on a vehicle known for its all-wheel-drive capability and flat-four engine character.
Competitive Analysis
Competition:
Competed against vehicles like the Toyota Camry, Honda Accord, Nissan Maxima, and Mitsubishi Galant. The Legacy distinguished itself with standard AWD across most trims and its unique boxer engine.
Key Features
Vehicle Strengths:
Standard Symmetrical All-Wheel Drive (AWD), reliable EJ22 engine, comfortable ride, practical wagon variant available.
Manual Value
Value Proposition:
Provides the essential factory-level data required for accurate maintenance, diagnosis, and repair, enabling owners to extend the lifespan and maintain the performance of their Subaru Legacy.
📋 Manual Details
Coverage Areas
Vehicle Years:
1991, 1992, 1993, 1994
Engine Coverage:
EJ22 (2.2L SOHC)
Page Count
Estimated Page Count:
1500-2000
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (EJ22), Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System
Drivetrain:
Automatic Transmission (4EAT), Manual Transmission (5-speed), All-Wheel Drive (AWD) System, Differentials
Chassis:
Suspension (Front Struts, Rear Multi-link), Steering System, Braking System (Front Disc/Rear Disc or Drum)
Electrical:
Wiring Diagrams, Battery, Charging System, Starting System, Lighting, Fuses, Relays, ECUs (Engine Control Unit)
Body:
Exterior Body Panels, Interior Trim, Doors, Windows, Seating, HVAC System
Procedures Included
Maintenance:
Oil Changes, Filter Replacements, Fluid Checks and Replenishment, Belt Inspections and Replacements, Spark Plug Replacement, Tune-ups
Repair:
Engine Rebuilds, Transmission Overhauls, Suspension Component Replacement, Brake System Repairs, Electrical Component Diagnosis and Replacement, Body Panel Repair
Diagnostics:
Troubleshooting Guides, DTC (Diagnostic Trouble Code) Interpretation, Symptom-based Diagnosis
Technical Depth
Depth:
Comprehensive diagnostic procedures, detailed disassembly and reassembly instructions, torque specifications, component testing methods, wiring diagrams
📊 Manual Specifications
File Format
Quality:
High-resolution scans, searchable text where available
Print Quality
Printability:
Printable pages for workshop use
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code:
EJ22
Engine Type:
Naturally Aspirated Boxer (Horizontally Opposed) Four-Cylinder
Displacement:
2.2 Liters (2212 cc)
Bore X Stroke:
96.0 mm x 75.0 mm
Compression Ratio:
9.5:1
Valve Train:
SOHC (Single Overhead Camshaft), 2 Valves Per Cylinder
Performance
Horsepower:
130 hp @ 5600 rpm (approx.)
Torque:
137 lb-ft @ 4400 rpm (approx.)
Fuel System
Induction:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Cooling System
Coolant Type:
Subaru Super Coolant (or equivalent ethylene glycol based, 50/50 mix with distilled water)
Lubrication System
Oil Capacity With Filter:
4.7 US Quarts (4.5 Liters)
Recommended Oil Viscosity:
10W-30 (API SG or higher)
Ignition System
Spark Plugs:
NGK PFR6G (or equivalent - specific part numbers may vary, consult manual)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Transmission
Optional
Transmission Type:
4-Speed Automatic Transmission with Electronic Control (4EAT)
Features
AWD Engagement:
Full-time Symmetrical All-Wheel Drive
Fluid Specifications Auto
Atf Type:
Subaru ATF (Dexron II or III compatible - verify specific model year)
Fluid Specifications Manual
Mtf Type:
GL-5 Gear Oil (75W-90 recommended)
📐 Dimensions
Exterior Sedan
Length:
4590 mm (180.7 in)
Width:
1700 mm (66.9 in)
Height:
1400 mm (55.1 in)
Exterior Wagon
Length:
4620 mm (181.9 in)
Width:
1700 mm (66.9 in)
Height:
1450 mm (57.1 in)
Wheelbase
Wheelbase:
2625 mm (103.3 in)
Weights
Curb Weight Approx:
1350-1450 kg (2976-3197 lbs)
Gross Vehicle Weight Rating:
Varies by model/trim, consult manual
Towing Capacity:
Not officially rated for significant towing in most markets, consult owner's manual/local regulations
🛡️ Safety Features
Ratings
NHTSA Ratings:
Limited data available for this era; expect average for its time. Consult specific recall databases.
Active Features
ABS:
Optional on some trims/years, standard on higher trims
Passive Features
Airbags:
Driver-side airbag standard; passenger airbag optional/introduced later in the generation
Seat Belts:
Front 3-point height-adjustable, Rear 3-point retractable
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette or CD player, typically with 4 speakers. Optional premium sound systems may exist.
Climate Control:
Manual or automatic climate control depending on trim level. Covers HVAC system operation and repair.
Driver Assistance
Cruise Control:
Standard on most models, electronic cruise control system.
Connectivity
Connectivity Features:
Limited to basic analog systems of the era. No integrated Bluetooth or USB found.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 3 months, whichever comes first (severe conditions may require more frequent changes).
Engine Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Cabin Air Filter Replacement:
Not equipped with a cabin air filter in these years.
Spark Plug Replacement:
Every 30,000 miles (48,000 km) for standard plugs, 60,000 miles (96,000 km) for platinum plugs (if equipped).
Transmission Fluid Change Auto:
Every 30,000 miles (48,000 km) or 24 months.
Timing Belt Replacement:
Crucial: Every 60,000 miles (96,000 km) or 5 years. Failure can cause catastrophic engine damage (interference engine).
Fluid Specifications
Brake Fluid Type:
DOT 3 (or DOT 4 if specified for newer models, but DOT 3 is typical for this era)
Power Steering Fluid:
Subaru Genuine Power Steering Fluid (or equivalent ATF Dexron II/III compatible)
Known Issues
Head Gaskets:
While the EJ22 is generally robust, internal coolant leaks due to head gasket failure can occur over time. The manual will detail inspection and replacement procedures.
Suspension Wear:
Bushings and struts can wear over time, particularly in vehicles driven in harsh climates or on rough roads. The manual covers diagnosis and replacement.
Automatic Transmission Issues:
The 4EAT can experience solenoid failures or torque converter issues if not properly maintained. The manual provides diagnostic steps.
Rust Corrosion:
As with many vehicles of this era, rust and corrosion, particularly in areas with road salt, can affect body panels, suspension components, and exhaust systems. The manual may offer some repair guidance.
📚 Vehicle History
Brand Heritage
Heritage:
Subaru, known for its boxer engines and Symmetrical All-Wheel Drive systems, has a history rooted in aerospace engineering, which influenced its automotive designs.
Model Evolution
Legacy Introduction:
The first-generation Subaru Legacy was introduced in 1989 as a replacement for the Subaru Leone. It marked a significant step up in refinement, size, and performance for Subaru.
First Gen Facelift:
Minor styling updates and feature enhancements occurred throughout the first generation, with the 1991-1994 models representing the initial production run.
Production
Manufacturing Plant:
Subaru of Gunma Plant, Japan
Production Years:
1990-1994 (First Generation)
🏆 Awards & Recognition
Recognitions
Automotive Journalism:
While specific awards for the 1991-1994 models are less documented than later generations, the Legacy platform was generally well-regarded for its handling, AWD capabilities, and value.
AWD System Reputation:
Subaru's Symmetrical AWD system consistently earned praise for its effectiveness in various weather conditions, contributing to the Legacy's strong reputation for all-weather capability.
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