SUBARU LEGACY 1999 Complete Factory Service / Repair / Workshop Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 1999 Generation Generation Code: BD/BG/BK (Second Generation) 👋 Introduction Market Position Segment: Compact/Mid-size Sedan and Wagon, known for its standard All-Wheel Drive and practical nature Competitive Analysis Competitors: Toyota Camry, Honda Accord, Ford Taurus, Mazda Millenia, Nissan Altima Key Features All Wheel Drive: Standard Symmetrical All-Wheel Drive (AWD) was a defining feature, offering superior traction in adverse conditions. Reliability: Generally regarded as a reliable vehicle, especially with proper maintenance. Practicality: Offered in both sedan and versatile wagon body styles, appealing to those needing cargo space. Engine Options: Provided two reliable boxer engine options with distinct power characteristics. 📋 Manual Details Coverage Areas Primary Coverage: North America (likely, based on typical sales) Engine Coverage: 2.2L EJ22E, 2.5L EJ25D SOHC Transmission Coverage: 4-speed Automatic, 5-speed Manual Page Count Estimated Page Count: 1500-2000+ Manual Type Type: Factory Service Manual / Workshop Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, pistons, crankshaft, camshafts, timing belts, lubrication system, cooling system Engine Performance: Fuel injection, ignition system, emissions control, exhaust system, engine diagnostics and troubleshooting Transmission Manual: Clutch system, transmission assembly, gear shift mechanism, lubrication Transmission Automatic: Torque converter, transmission assembly, valve body, hydraulic controls, shift solenoids, lubrication, diagnostics Drivetrain: All-Wheel Drive (AWD) system, front and rear differentials, drive shafts, CV joints Suspension: Front struts, rear struts, control arms, ball joints, bushings, sway bars Brakes: Front disc brakes, rear disc brakes, ABS system, brake fluid, hydraulic lines, parking brake Steering: Power steering system, steering rack, steering column, tie rods Electrical System: Battery, charging system (alternator), starting system, fuses, relays, wiring diagrams, lighting system Body And Chassis: Body panels, doors, hood, trunk, interior trim, structural components, collision repair guidelines HVAC: Heating, ventilation, and air conditioning system, climate control, refrigerant Diagnostics: On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), troubleshooting flowcharts Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, drive belt inspection/replacement Major Repairs: Engine overhaul, transmission rebuild, suspension component replacement, brake caliper replacement, power steering pump replacement Diagnostics And Troubleshooting: Step-by-step diagnostic procedures for various symptoms, fault code interpretation and resolution Electrical Diagnostics: Using multimeters, interpreting wiring diagrams, troubleshooting electrical faults Component Removal And Installation: Detailed instructions for removing and installing virtually every serviceable component Specification Charts: Torque specifications for all fasteners, clearances, timing settings, electrical component resistance values Technical Depth Depth: Comprehensive (from basic maintenance to complete engine/transmission overhauls and advanced diagnostics) 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable (depending on source scan quality) Print Quality Quality: Variable (depends on the original scanning or digitization process, typically good for factory manuals) Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine 1: 2.2L SOHC 16-valve Boxer-4 (EJ22E) Engine 1 Displacement: 2197 cc (2.2 Liters) Engine 1 Horsepower: 135 hp @ 5600 rpm (approx.) Engine 1 Torque: 140 lb-ft @ 4000 rpm (approx.) Engine 1 Bore X Stroke: 96.0 mm x 75.0 mm Engine 1 Compression Ratio: 9.5:1 Secondary Engine Engine 2: 2.5L SOHC 16-valve Boxer-4 (EJ25D) Engine 2 Displacement: 2457 cc (2.5 Liters) Engine 2 Horsepower: 165 hp @ 5600 rpm (approx.) Engine 2 Torque: 162 lb-ft @ 4000 rpm (approx.) Engine 2 Bore X Stroke: 99.5 mm x 79.0 mm Engine 2 Compression Ratio: 9.5:1 Performance Fuel Type: Unleaded Gasoline Fuel System Injection Type: Electronic Fuel Injection (EFI) - Multi-point Engine Management ECU Type: Engine Control Unit (ECU) - Manufacturer specific, likely Denso or Hitachi 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Transmission Optional Transmission Type Optional: 4-Speed Automatic Transmission (with lock-up torque converter) Features AWD System: Symmetrical All-Wheel Drive (Active AWD for automatic, viscous coupling for manual) Fluid Specs Automatic Transmission Fluid: Subaru ATF HP or equivalent Dexron III/Mercon Manual Transmission Fluid: GL-5 75W-90 Gear Oil (approx. 3.5-4.0 L) Differential Fluid: GL-5 75W-90 Gear Oil (Front and Rear) 📐 Dimensions Exterior Wheelbase: 104.3 inches (2649 mm) Length: 184.6 inches (4690 mm) - Sedan / 187.2 inches (4755 mm) - Wagon Width: 69.1 inches (1755 mm) Height: 55.7 inches (1415 mm) - Sedan / 57.9 inches (1470 mm) - Wagon Weights Curb Weight: 3050-3200 lbs (approx., depending on trim and drivetrain) Cargo Cargo Volume Sedan: 14.1 cu ft (approx.) Cargo Volume Wagon: 35.9 cu ft (rear seats up) / 67.0 cu ft (rear seats folded down) (approx.) Wheels And Tires Wheel Size: 15-inch or 16-inch alloy wheels Tire Sizes: P205/60R15, P205/55R16 (common) Bolt Pattern: 5x100 mm Center Bore: 56.1 mm 🛡️ Safety Features Ratings NHTSA Driver Front Impact: 4-star (1999 model year) NHTSA Passenger Front Impact: 4-star (1999 model year) Active Features ABS: Standard Anti-lock Braking System (ABS) on most trims AWD: Standard Symmetrical All-Wheel Drive system provides enhanced traction and stability...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy

Year:

Generation

Generation Code:

BD/BG/BK (Second Generation)

👋 Introduction

Market Position

Segment:

Compact/Mid-size Sedan and Wagon, known for its standard All-Wheel Drive and practical nature

Competitive Analysis

Competitors:

Toyota Camry, Honda Accord, Ford Taurus, Mazda Millenia, Nissan Altima

Key Features

All Wheel Drive:

Standard Symmetrical All-Wheel Drive (AWD) was a defining feature, offering superior traction in adverse conditions.

Reliability:

Generally regarded as a reliable vehicle, especially with proper maintenance.

Practicality:

Offered in both sedan and versatile wagon body styles, appealing to those needing cargo space.

Engine Options:

Provided two reliable boxer engine options with distinct power characteristics.

📋 Manual Details

Coverage Areas

Primary Coverage:

North America (likely, based on typical sales)

Engine Coverage:

2.2L EJ22E, 2.5L EJ25D SOHC

Transmission Coverage:

4-speed Automatic, 5-speed Manual

Page Count

Estimated Page Count:

1500-2000+

Manual Type

Type:

Factory Service Manual / Workshop Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, pistons, crankshaft, camshafts, timing belts, lubrication system, cooling system

Engine Performance:

Fuel injection, ignition system, emissions control, exhaust system, engine diagnostics and troubleshooting

Transmission Manual:

Clutch system, transmission assembly, gear shift mechanism, lubrication

Transmission Automatic:

Torque converter, transmission assembly, valve body, hydraulic controls, shift solenoids, lubrication, diagnostics

Drivetrain:

All-Wheel Drive (AWD) system, front and rear differentials, drive shafts, CV joints

Suspension:

Front struts, rear struts, control arms, ball joints, bushings, sway bars

Brakes:

Front disc brakes, rear disc brakes, ABS system, brake fluid, hydraulic lines, parking brake

Steering:

Power steering system, steering rack, steering column, tie rods

Electrical System:

Battery, charging system (alternator), starting system, fuses, relays, wiring diagrams, lighting system

Body And Chassis:

Body panels, doors, hood, trunk, interior trim, structural components, collision repair guidelines

HVAC:

Heating, ventilation, and air conditioning system, climate control, refrigerant

Diagnostics:

On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), troubleshooting flowcharts

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, drive belt inspection/replacement

Major Repairs:

Engine overhaul, transmission rebuild, suspension component replacement, brake caliper replacement, power steering pump replacement

Diagnostics And Troubleshooting:

Step-by-step diagnostic procedures for various symptoms, fault code interpretation and resolution

Electrical Diagnostics:

Using multimeters, interpreting wiring diagrams, troubleshooting electrical faults

Component Removal And Installation:

Detailed instructions for removing and installing virtually every serviceable component

Specification Charts:

Torque specifications for all fasteners, clearances, timing settings, electrical component resistance values

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine/transmission overhauls and advanced diagnostics)

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable (depending on source scan quality)

Print Quality

Quality:

Variable (depends on the original scanning or digitization process, typically good for factory manuals)

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine 1:

2.2L SOHC 16-valve Boxer-4 (EJ22E)

Engine 1 Displacement:

2197 cc (2.2 Liters)

Engine 1 Horsepower:

135 hp @ 5600 rpm (approx.)

Engine 1 Torque:

140 lb-ft @ 4000 rpm (approx.)

Engine 1 Bore X Stroke:

96.0 mm x 75.0 mm

Engine 1 Compression Ratio:

9.5:1

Secondary Engine

Engine 2:

2.5L SOHC 16-valve Boxer-4 (EJ25D)

Engine 2 Displacement:

2457 cc (2.5 Liters)

Engine 2 Horsepower:

165 hp @ 5600 rpm (approx.)

Engine 2 Torque:

162 lb-ft @ 4000 rpm (approx.)

Engine 2 Bore X Stroke:

99.5 mm x 79.0 mm

Engine 2 Compression Ratio:

9.5:1

Performance

Fuel Type:

Unleaded Gasoline

Fuel System

Injection Type:

Electronic Fuel Injection (EFI) - Multi-point

Engine Management

ECU Type:

Engine Control Unit (ECU) - Manufacturer specific, likely Denso or Hitachi

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual Transmission

Optional

Transmission Type Optional:

4-Speed Automatic Transmission (with lock-up torque converter)

Features

AWD System:

Symmetrical All-Wheel Drive (Active AWD for automatic, viscous coupling for manual)

Fluid Specs

Automatic Transmission Fluid:

Subaru ATF HP or equivalent Dexron III/Mercon

Manual Transmission Fluid:

GL-5 75W-90 Gear Oil (approx. 3.5-4.0 L)

Differential Fluid:

GL-5 75W-90 Gear Oil (Front and Rear)

📐 Dimensions

Exterior

Wheelbase:

104.3 inches (2649 mm)

Length:

184.6 inches (4690 mm) - Sedan / 187.2 inches (4755 mm) - Wagon

Width:

69.1 inches (1755 mm)

Height:

55.7 inches (1415 mm) - Sedan / 57.9 inches (1470 mm) - Wagon

Weights

Curb Weight:

3050-3200 lbs (approx., depending on trim and drivetrain)

Cargo

Cargo Volume Sedan:

14.1 cu ft (approx.)

Cargo Volume Wagon:

35.9 cu ft (rear seats up) / 67.0 cu ft (rear seats folded down) (approx.)

Wheels And Tires

Wheel Size:

15-inch or 16-inch alloy wheels

Tire Sizes:

P205/60R15, P205/55R16 (common)

Bolt Pattern:

5x100 mm

Center Bore:

56.1 mm

🛡️ Safety Features

Ratings

NHTSA Driver Front Impact:

4-star (1999 model year)

NHTSA Passenger Front Impact:

4-star (1999 model year)

Active Features

Standard Anti-lock Braking System (ABS) on most trims

Standard Symmetrical All-Wheel Drive system provides enhanced traction and stability

Passive Features

Airbags:

Driver and front passenger airbags standard

Seatbelts:

Three-point front and rear seatbelts

Child Seat Anchors:

Rear seat ISOFIX/LATCH anchors not standard for this era, typically relied on seatbelt systems

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette player with optional CD player. Basic speaker configurations.

Climate Control:

Manual climate control system with rotary knobs for temperature, fan speed, and air direction.

Driver Assistance

Cruise Control:

Factory cruise control system standard on many trims.

Instrument Cluster:

Analog gauges for speedometer, tachometer, fuel, and temperature. Warning lights for system status.

Connectivity

Connectivity Features:

Limited by era; primarily focused on radio and basic vehicle operation. No modern infotainment or smartphone integration.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 3 months (severe use) / 7,500 miles or 6 months (normal use) - Consult manual for specifics

Engine Oil Type:

SAE 5W-30 or 10W-30 (depending on ambient temperature, check manual)

Engine Oil Capacity:

4.2 US quarts (4.0 L) with filter (EJ22E) / 4.5 US quarts (4.3 L) with filter (EJ25D)

Timing Belt Replacement:

Recommended every 60,000 miles or 4 years (critical for EJ series engines to prevent catastrophic failure)

Spark Plug Replacement:

Every 30,000-60,000 miles (depending on plug type, typically copper or platinum)

Coolant Replacement:

Every 30,000 miles or 2 years (using Subaru Super Coolant or equivalent).

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4

Power Steering Fluid:

Subaru Power Steering Fluid or Dexron II/III ATF

Known Issues

Head Gaskets:

While not as prevalent as in later EJ engines, potential for head gasket leaks on the EJ25D, especially with high mileage or overheating.

Timing Belt Tensioner:

Tensioner failure can lead to premature timing belt wear or failure. Replacement with the belt is highly recommended.

Cv Joint Boots:

Front CV joint boots can be susceptible to tearing, leading to grease loss and eventual joint failure.

Radiator And Hoses:

Original radiator and hoses may degrade over time, leading to leaks and potential overheating.

Automatic Transmission Cooling:

Ensure the transmission cooler is functioning correctly, as overheating can lead to premature failure, especially in heavy-duty use.

📚 Vehicle History

Brand Heritage

Subaru Heritage:

Subaru Corporation (formerly Fuji Heavy Industries) has a history dating back to aviation, leading to their distinctive horizontally opposed (boxer) engines and focus on AWD technology.

Model Evolution

Legacy Introduction:

The Subaru Legacy was introduced globally in 1989 as a replacement for the Subaru Leone. It was designed to compete in the growing mid-size car market.

Second Generation Launch:

The second generation (BD/BG/BK) was launched in 1993 (Japan) and 1995 (North America), featuring a more modern design and increased size.

1999 Facelift:

The 1999 model year represents a mid-cycle refresh for the second generation, receiving updated styling cues, improved interiors, and potentially minor mechanical revisions.

Production

Manufacturing Location:

Primary manufacturing typically in Gunma, Japan.

🏆 Awards & Recognition

Recognitions

General Reputation:

Subaru Legacy models of this era are often praised for their AWD capabilities, reliability, and practical nature, especially in regions with challenging weather conditions.

Ratings

Consumer Reports Rating History:

Varied depending on specific model year and engine. Generally good reliability scores for the EJ22 engine, with some concerns for the EJ25D and its head gasket durability.