Subaru Legacy 1999 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 1999 Generation Generation Code: BD/BG/BK Generation Name: Third Generation 👋 Introduction Market Position Segment: Mid-size sedan/wagon Unique Selling Proposition: Symmetrical All-Wheel Drive standard on most models, boxer engine architecture Competitive Analysis Key Competitors: Toyota Camry, Honda Accord, Mazda 626, Nissan Altima Key Features Standard AWD: Subaru's signature Symmetrical All-Wheel Drive system enhances traction and stability Boxer Engine: Horizontally opposed (boxer) engine design contributes to a lower center of gravity Outback Variant: Introduction of the Outback variant, a raised wagon with rugged styling, pioneering the crossover segment 📋 Manual Details Coverage Areas Engine Coverage: All gasoline engine variants Transmission Coverage: All manual and automatic transmission variants Chassis Coverage: All chassis and body styles Electrical Coverage: Complete electrical system diagnostics and repair Trim Level Coverage: All trim levels including L, LS, GT, Outback Page Count Estimated Pages: 800+ Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, diagnosis, repair for all specified engines Fuel System: Fuel delivery, injection, evaporative emissions (EVAP) system Cooling System: Radiator, water pump, thermostat, fan operation, coolant specifications Lubrication System: Oil pump, oil filter, lubrication specifications, oil change intervals Ignition System: Spark plugs, ignition coils, timing, diagnosis Exhaust System: Manifold, catalytic converter, mufflers, oxygen sensors Transmission Manual: Clutch, gearbox assembly, shifting mechanisms, fluid specifications Transmission Automatic: Torque converter, planetary gear sets, valve body, hydraulic circuits, fluid specifications Drivetrain AWD: All-Wheel Drive system operation, center differential, rear differential, drive shafts Suspension Front: MacPherson strut, control arms, sway bar, bushings Suspension Rear: Multi-link, trailing arms, springs, shock absorbers Steering System: Power steering pump, rack and pinion, tie rods, alignment specifications Braking System: Front and rear disc brakes, ABS system, brake fluid specifications, bleeding procedures Wheels Tires: Wheel bolt pattern, tire pressure specifications, wheel bearing replacement Body Exterior: Panel removal, door mechanisms, bumpers, glass, seals Body Interior: Seat removal, dashboard, trim panels, headliner, HVAC controls Climate Control HVAC: A/C system operation, refrigerant, blower motor, actuators, heater core Lighting System: Headlights, taillights, interior lighting, bulb specifications, wiring Wiper Washer System: Wiper motor, linkages, washer pump, fluid reservoir Power Windows Locks: Window regulators, motors, lock actuators, central locking system Audio System: Radio, speakers, antenna wiring ECU Diagnostics: On-Board Diagnostics (OBD-II) system, DTC code interpretation, sensor data Wiring Diagrams: Complete electrical schematics for all systems Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, tune-ups, spark plug replacement Troubleshooting: System-specific diagnostic flowcharts and symptom-based troubleshooting guides Engine Rebuild: Detailed instructions for engine disassembly, cleaning, inspection, and reassembly Transmission Repair: Step-by-step guides for automatic and manual transmission overhaul Brake Repair: Pad and rotor replacement, caliper service, brake line bleeding, ABS component replacement Suspension Component Replacement: Strut, shock absorber, ball joint, control arm, bushing replacement Electrical Component Replacement: Alternator, starter, battery, sensors, relays, actuators replacement Body Panel Repair: Door hinge adjustment, panel alignment, rust repair techniques HVAC System Repair: Component replacement, leak detection, refrigerant charging Timing Belt Replacement: Detailed procedure with critical timing marks and component torque specifications Torque Specifications: Comprehensive list of all critical fastener torque values Technical Depth Depth Level: Comprehensive factory-level repair and diagnostic information Diagnostic Tools Required: Includes specifications for common tools, diagnostic scanners, and specialized Subaru tools 📊 Manual Specifications File Format File Type: PDF Searchability: Fully searchable text content Print Quality Resolution: High-resolution scans suitable for printing Printability: Printable page-by-page or in its entirety Binding Type Binding Style: N/A (Downloadable PDF) Paper Type Paper Quality: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Code 1: EJ22E Engine Description 1: 2.2L SOHC 16-valve horizontally opposed 4-cylinder boxer engine Horsepower 1: 137 hp @ 5600 rpm Torque 1: 145 lb-ft @ 4000 rpm Compression Ratio 1: 9.7:1 Bore X Stroke 1: 96.0 mm x 75.0 mm Fuel Induction 1: Multi-point fuel injection (MPI) Fuel Type 1: Unleaded gasoline Optional Engine Engine Code 2: EJ25D Engine Description 2: 2.5L DOHC 16-valve horizontally opposed 4-cylinder boxer engine Horsepower 2: 165 hp @ 6000 rpm Torque 2: 166 lb-ft @ 4000 rpm Compression Ratio 2: 10.1:1 Bore X Stroke 2: 99.5 mm x 79.0 mm Fuel Induction 2: Multi-point fuel injection (MPI) Fuel Type 2: Unleaded gasoline Fuel System Fuel Tank Capacity: 15.9 US gallons 🔧 Transmission Standard Type Standard: 5-speed manual transmission Optional Type Optional: 4-speed automatic transmission (4EAT) Features AWD System: Symmetrical All-Wheel Drive standard on all models Automatic Transmission Mode: Includes Subaru's Active AWD system for the automatic transmission Fluid Specification Manual Transmission Fluid: Subaru Gear Oil API GL-5, SAE 75W-90 Automatic Transmission Fluid: Subaru ATF HP, Dexron II or III equivalent 📐 Dimensions Exterior Length: 183.0 inches (Sedan), 185.4 inches (Wagon/Outback) Width: 69.1 inches Height: 55.7 inches (Sedan), 59.3 inches (Wagon/Outback) Wheelbase: 104.0 inches Ground Clearance: 5.9 inches (Sedan/Wagon), 7.7 inches (Outback) Weights...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy

Year:

Generation

Generation Code:

BD/BG/BK

Generation Name:

Third Generation

👋 Introduction

Market Position

Segment:

Mid-size sedan/wagon

Unique Selling Proposition:

Symmetrical All-Wheel Drive standard on most models, boxer engine architecture

Competitive Analysis

Key Competitors:

Toyota Camry, Honda Accord, Mazda 626, Nissan Altima

Key Features

Standard AWD:

Subaru's signature Symmetrical All-Wheel Drive system enhances traction and stability

Boxer Engine:

Horizontally opposed (boxer) engine design contributes to a lower center of gravity

Outback Variant:

Introduction of the Outback variant, a raised wagon with rugged styling, pioneering the crossover segment

📋 Manual Details

Coverage Areas

Engine Coverage:

All gasoline engine variants

Transmission Coverage:

All manual and automatic transmission variants

Chassis Coverage:

All chassis and body styles

Electrical Coverage:

Complete electrical system diagnostics and repair

Trim Level Coverage:

All trim levels including L, LS, GT, Outback

Page Count

Estimated Pages:

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, diagnosis, repair for all specified engines

Fuel System:

Fuel delivery, injection, evaporative emissions (EVAP) system

Cooling System:

Radiator, water pump, thermostat, fan operation, coolant specifications

Lubrication System:

Oil pump, oil filter, lubrication specifications, oil change intervals

Ignition System:

Spark plugs, ignition coils, timing, diagnosis

Exhaust System:

Manifold, catalytic converter, mufflers, oxygen sensors

Transmission Manual:

Clutch, gearbox assembly, shifting mechanisms, fluid specifications

Transmission Automatic:

Torque converter, planetary gear sets, valve body, hydraulic circuits, fluid specifications

Drivetrain AWD:

All-Wheel Drive system operation, center differential, rear differential, drive shafts

Suspension Front:

MacPherson strut, control arms, sway bar, bushings

Suspension Rear:

Multi-link, trailing arms, springs, shock absorbers

Steering System:

Power steering pump, rack and pinion, tie rods, alignment specifications

Braking System:

Front and rear disc brakes, ABS system, brake fluid specifications, bleeding procedures

Wheels Tires:

Wheel bolt pattern, tire pressure specifications, wheel bearing replacement

Body Exterior:

Panel removal, door mechanisms, bumpers, glass, seals

Body Interior:

Seat removal, dashboard, trim panels, headliner, HVAC controls

Climate Control HVAC:

A/C system operation, refrigerant, blower motor, actuators, heater core

Lighting System:

Headlights, taillights, interior lighting, bulb specifications, wiring

Wiper Washer System:

Wiper motor, linkages, washer pump, fluid reservoir

Power Windows Locks:

Window regulators, motors, lock actuators, central locking system

Audio System:

Radio, speakers, antenna wiring

ECU Diagnostics:

On-Board Diagnostics (OBD-II) system, DTC code interpretation, sensor data

Wiring Diagrams:

Complete electrical schematics for all systems

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks, tune-ups, spark plug replacement

Troubleshooting:

System-specific diagnostic flowcharts and symptom-based troubleshooting guides

Engine Rebuild:

Detailed instructions for engine disassembly, cleaning, inspection, and reassembly

Transmission Repair:

Step-by-step guides for automatic and manual transmission overhaul

Brake Repair:

Pad and rotor replacement, caliper service, brake line bleeding, ABS component replacement

Suspension Component Replacement:

Strut, shock absorber, ball joint, control arm, bushing replacement

Electrical Component Replacement:

Alternator, starter, battery, sensors, relays, actuators replacement

Body Panel Repair:

Door hinge adjustment, panel alignment, rust repair techniques

HVAC System Repair:

Component replacement, leak detection, refrigerant charging

Timing Belt Replacement:

Detailed procedure with critical timing marks and component torque specifications

Torque Specifications:

Comprehensive list of all critical fastener torque values

Technical Depth

Depth Level:

Comprehensive factory-level repair and diagnostic information

Diagnostic Tools Required:

Includes specifications for common tools, diagnostic scanners, and specialized Subaru tools

📊 Manual Specifications

File Format

File Type:

Searchability:

Fully searchable text content

Print Quality

Resolution:

High-resolution scans suitable for printing

Printability:

Printable page-by-page or in its entirety

Binding Type

Binding Style:

N/A (Downloadable PDF)

Paper Type

Paper Quality:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

EJ22E

Engine Description 1:

2.2L SOHC 16-valve horizontally opposed 4-cylinder boxer engine

Horsepower 1:

137 hp @ 5600 rpm

Torque 1:

145 lb-ft @ 4000 rpm

Compression Ratio 1:

9.7:1

Bore X Stroke 1:

96.0 mm x 75.0 mm

Fuel Induction 1:

Multi-point fuel injection (MPI)

Fuel Type 1:

Unleaded gasoline

Optional Engine

Engine Code 2:

EJ25D

Engine Description 2:

2.5L DOHC 16-valve horizontally opposed 4-cylinder boxer engine

Horsepower 2:

165 hp @ 6000 rpm

Torque 2:

166 lb-ft @ 4000 rpm

Compression Ratio 2:

10.1:1

Bore X Stroke 2:

99.5 mm x 79.0 mm

Fuel Induction 2:

Multi-point fuel injection (MPI)

Fuel Type 2:

Unleaded gasoline

Fuel System

Fuel Tank Capacity:

15.9 US gallons

🔧 Transmission

Standard

Type Standard:

5-speed manual transmission

Optional

Type Optional:

4-speed automatic transmission (4EAT)

Features

AWD System:

Symmetrical All-Wheel Drive standard on all models

Automatic Transmission Mode:

Includes Subaru's Active AWD system for the automatic transmission

Fluid Specification

Manual Transmission Fluid:

Subaru Gear Oil API GL-5, SAE 75W-90

Automatic Transmission Fluid:

Subaru ATF HP, Dexron II or III equivalent

📐 Dimensions

Exterior

Length:

183.0 inches (Sedan), 185.4 inches (Wagon/Outback)

Width:

69.1 inches

Height:

55.7 inches (Sedan), 59.3 inches (Wagon/Outback)

Wheelbase:

104.0 inches

Ground Clearance:

5.9 inches (Sedan/Wagon), 7.7 inches (Outback)

Weights

Curb Weight Approx:

3100-3400 lbs (depending on configuration)

Gross Vehicle Weight Rating:

Not specified, varies by model

Towing Capacity:

2000 lbs (with proper equipment)

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

4/5 stars (for Outback models)

IIHS Crash Test Results:

Acceptable in frontal offset tests for its time

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Available on some models

Passive Features

Airbags:

Driver and passenger front airbags

Seatbelts:

Three-point front and rear seatbelts, driver's seatbelt pretensioner

Child Safety Anchors:

LATCH system not standard, ISOFIX compatible anchors may be present

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM stereo with cassette player and CD player (optional on some trims), 4-speaker or 6-speaker system

Driver Assistance

Standard Anti-lock Braking System (ABS)

Cruise Control:

Standard on most models

Connectivity

OBD Ii:

Compliant with OBD-II diagnostic standards, enabling modern scan tool diagnostics

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 3 months

Engine Oil Filter Replacement:

At every oil change

Air Filter Replacement:

Every 15,000 miles or 12 months

Cabin Air Filter Replacement:

Not equipped on all models, check if applicable

Spark Plug Replacement:

Every 30,000 miles (copper plugs), 60,000 miles (platinum plugs - if equipped)

Timing Belt Replacement:

Every 60,000 miles or 4 years (critical maintenance item for EJ engines)

Transmission Fluid Change Manual:

Every 30,000 miles or 24 months

Transmission Fluid Change Automatic:

Every 30,000 miles or 24 months (severe duty: 15,000 miles)

Coolant Flush:

Every 30,000 miles or 24 months

Fluid Specifications

Engine Oil Type:

API SG or SH, SAE 5W-30 or 10W-30 (check owner's manual for temperature ranges)

Engine Oil Capacity:

4.5 US quarts (4.3 L) with filter for EJ22, 4.7 US quarts (4.4 L) with filter for EJ25

Brake Fluid Type:

DOT 3

Power Steering Fluid:

Subaru Power Steering Fluid or Dexron II/III ATF

Known Issues

Head Gasket Failure:

Common issue on EJ25D (non-turbo DOHC 2.5L) engines, especially if maintenance is neglected. Manual covers diagnosis and replacement.

Automatic Transmission Issues:

Some reports of premature wear or failure, especially if fluid is not changed regularly. Manual provides detailed troubleshooting.

Suspension Wear:

Typical wear items like bushings, ball joints, and struts/shocks over time. Manual details inspection and replacement.

Exhaust Manifold Cracks:

Can occur on EJ series engines due to heat cycles. Manual details inspection.

📚 Vehicle History

Brand Heritage

Subaru Philosophy:

Focus on All-Wheel Drive technology, boxer engines, safety, and practicality

Model Evolution

Legacy Introduction:

First introduced in 1989 as a replacement for the Subaru Leone

Third Generation Introduction:

Launched in 1999, redesign featuring larger dimensions and updated styling

Outback Genesis:

The Outback, initially a trim level of the Legacy wagon, became its own model in 2000 but its roots are firmly in the 1999 Legacy wagon

Production

Manufacturing Locations:

Japan

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

While the 1999 model itself might not have a specific mention, the Legacy lineage has been a frequent recipient of Car and Driver's 10Best awards in various years for its performance and practicality.

Outback Segment Creation:

The Legacy Outback is credited with pioneering the modern crossover SUV segment, blending car-like handling with SUV capabilities.