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Subaru Legacy 2004-2005 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Model Years Covered: 2004, 2005 Codes Chassis Codes: BP (Wagon), BL (Sedan) 👋 Introduction Market Position Vehicle Segment: Mid-size Sedan/Wagon, AWD standard (primarily) Competitive Analysis Key Competitors: Toyota Camry, Honda Accord, Nissan Altima, Ford Fusion, Mazda6 Key Features All Wheel Drive: Standard Symmetrical All-Wheel Drive system across most trims Reliability: Known for overall reliability and durability, especially powertrain Practicality: Offered in both sedan and wagon body styles, providing versatility 📋 Manual Details Coverage Areas Primary Coverage: Full Service Repair and Maintenance Page Count Estimated Page Count: 1500+ Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, diagnosis, repair for all gasoline engines Engine Management: Fuel injection, ignition, emissions control, ECU diagnostics, sensor data Transmission: Automatic and Manual transmission repair, overhaul, diagnosis, fluid specifications Drivetrain: Front and Rear differentials, driveshafts, CV joints, AWD system operation Suspension: Front and Rear suspension components, alignment specifications, shock absorber/strut replacement Steering: Power steering system, steering rack, tie rods, diagnosis and repair Brakes: Brake system components (discs, pads, calipers, lines), ABS, parking brake, fluid specifications Electrical System: Wiring diagrams, starter, alternator, battery, lighting, fuses, relays, diagnosis HVAC: Heating, Ventilation, and Air Conditioning system repair, recharge, diagnosis Body And Interior: Body panel removal/installation, interior trim, seats, doors, glass, seals Safety Systems: Airbag system diagnosis and repair, seatbelt mechanisms Procedures Included Routine Maintenance: Oil change, filter replacement, spark plug replacement, coolant flush, brake fluid flush Troubleshooting: Diagnostic procedures for common and complex issues, DTC interpretation Component Replacement: Detailed step-by-step instructions for replacing major and minor components Rebuilding: Engine and transmission rebuilding procedures with torque specifications Special Tools: Identification and usage of specialized tools required for specific repairs Technical Depth Depth: Comprehensive: from basic scheduled maintenance to complete engine and transmission overhauls, including electrical system diagnostics. 📊 Manual Specifications File Format Searchability: Searchable text for quick access to information Resolution: High-resolution scans for clarity of diagrams and text Print Quality Print Readability: Printable pages suitable for workshop use Binding Type Binding: N/A (Digital) Paper Type Paper Quality: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Code 1: EJ253 (2.5L SOHC) Displacement 1: 2.5 Liters (2457 cc) Configuration 1: Horizontally-opposed (Boxer), 4-cylinder Horsepower 1: 165 hp @ 5600 rpm Torque 1: 166 lb-ft @ 4000 rpm Optional Engine Engine Code 2: EJ255 (2.5L Turbocharged DOHC - GT models) Displacement 2: 2.5 Liters (2457 cc) Configuration 2: Horizontally-opposed (Boxer), 4-cylinder, turbocharged Horsepower 2: 210 hp @ 5600 rpm (GT Manual) / 215 hp @ 5600 rpm (GT Automatic) Torque 2: 236 lb-ft @ 3600 rpm (GT Manual) / 241 lb-ft @ 3600 rpm (GT Automatic) Fuel System Fuel Delivery: Sequential multi-port fuel injection (MPI) Fuel Type: Unleaded gasoline, 87 octane (91 octane recommended for GT models) Engine Management ECU Type: Subaru Select Monitor (SSM) compatible diagnostic system 🔧 Transmission Standard Transmission Type 1: 5-speed Manual Transmission Optional Transmission Type 2: 4-speed Automatic Transmission (with manual mode on GT models) Features AWD Integration: Symmetrical All-Wheel Drive system integrated with both transmission types Fluid Specifications Automatic Fluid: Subaru ATF HP (High Performance) or equivalent Dexron III/Mercon compatible fluid Manual Fluid: Subaru Extra-S Gear Oil GL-5 75W-90 or equivalent 📐 Dimensions Exterior Length Sedan: Approx. 187.4 inches (4760 mm) Width Sedan: Approx. 69.1 inches (1755 mm) Height Sedan: Approx. 57.7 inches (1465 mm) Wheelbase: Approx. 104.1 inches (2645 mm) Length Wagon: Approx. 188.2 inches (4780 mm) Width Wagon: Approx. 69.1 inches (1755 mm) Height Wagon: Approx. 58.1 inches (1475 mm) Weights Curb Weight Range: Approx. 3200 - 3600 lbs (1450 - 1630 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5 Stars NHTSA Front Impact Passenger: 5 Stars NHTSA Side Impact Front Driver: 5 Stars NHTSA Side Impact Front Passenger: 5 Stars NHTSA Side Impact Rear Passenger: 5 Stars IIHS Front Offset: Good IIHS Side Impact: Good Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Available Traction Control System (TCS) Passive Features Airbags: Front airbags, front side-impact airbags, available curtain airbags (sedan) Seatbelts: Three-point seatbelts with pretensioners and load limiters 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD stereo system, with optional premium audio and subwoofer on higher trims. Navigation: Optional factory navigation system available on select trims. Driver Assistance Cruise Control: Standard electronic cruise control. Connectivity Auxiliary Input: Optional auxiliary audio input jack on some models. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 miles or 3.75 months (severe duty) / 7,500 miles or 7.5 months (normal duty) Spark Plug Replacement: Approx. 60,000 miles (standard igniter plugs) / 100,000 miles (iridium plugs) Coolant Replacement: Initial 7 years/70,000 miles, then every 4 years/50,000 miles thereafter Timing Belt: This generation uses a timing *chain*, not a belt, requiring no scheduled replacement but proper lubrication. Fluid...
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Subaru Legacy 2004-2005 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy
Model Years Covered:
2004, 2005
Codes
Chassis Codes:
BP (Wagon), BL (Sedan)
👋 Introduction
Market Position
Vehicle Segment:
Mid-size Sedan/Wagon, AWD standard (primarily)
Competitive Analysis
Key Competitors:
Toyota Camry, Honda Accord, Nissan Altima, Ford Fusion, Mazda6
Key Features
All Wheel Drive:
Standard Symmetrical All-Wheel Drive system across most trims
Reliability:
Known for overall reliability and durability, especially powertrain
Practicality:
Offered in both sedan and wagon body styles, providing versatility
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Service Repair and Maintenance
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine disassembly, assembly, diagnosis, repair for all gasoline engines
Engine Management:
Fuel injection, ignition, emissions control, ECU diagnostics, sensor data
Transmission:
Automatic and Manual transmission repair, overhaul, diagnosis, fluid specifications
Drivetrain:
Front and Rear differentials, driveshafts, CV joints, AWD system operation
Suspension:
Front and Rear suspension components, alignment specifications, shock absorber/strut replacement
Steering:
Power steering system, steering rack, tie rods, diagnosis and repair
Brakes:
Brake system components (discs, pads, calipers, lines), ABS, parking brake, fluid specifications
Electrical System:
Wiring diagrams, starter, alternator, battery, lighting, fuses, relays, diagnosis
HVAC:
Heating, Ventilation, and Air Conditioning system repair, recharge, diagnosis
Body And Interior:
Body panel removal/installation, interior trim, seats, doors, glass, seals
Safety Systems:
Airbag system diagnosis and repair, seatbelt mechanisms
Procedures Included
Routine Maintenance:
Oil change, filter replacement, spark plug replacement, coolant flush, brake fluid flush
Troubleshooting:
Diagnostic procedures for common and complex issues, DTC interpretation
Component Replacement:
Detailed step-by-step instructions for replacing major and minor components
Rebuilding:
Engine and transmission rebuilding procedures with torque specifications
Special Tools:
Identification and usage of specialized tools required for specific repairs
Technical Depth
Depth:
Comprehensive: from basic scheduled maintenance to complete engine and transmission overhauls, including electrical system diagnostics.
📊 Manual Specifications
File Format
Searchability:
Searchable text for quick access to information
Resolution:
High-resolution scans for clarity of diagrams and text
Print Quality
Print Readability:
Printable pages suitable for workshop use
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Quality:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
EJ253 (2.5L SOHC)
Displacement 1:
2.5 Liters (2457 cc)
Configuration 1:
Horizontally-opposed (Boxer), 4-cylinder
Horsepower 1:
165 hp @ 5600 rpm
Torque 1:
166 lb-ft @ 4000 rpm
Optional Engine
Engine Code 2:
EJ255 (2.5L Turbocharged DOHC - GT models)
Displacement 2:
2.5 Liters (2457 cc)
Configuration 2:
Horizontally-opposed (Boxer), 4-cylinder, turbocharged
Horsepower 2:
210 hp @ 5600 rpm (GT Manual) / 215 hp @ 5600 rpm (GT Automatic)
Torque 2:
236 lb-ft @ 3600 rpm (GT Manual) / 241 lb-ft @ 3600 rpm (GT Automatic)
Fuel System
Fuel Delivery:
Sequential multi-port fuel injection (MPI)
Fuel Type:
Unleaded gasoline, 87 octane (91 octane recommended for GT models)
Engine Management
ECU Type:
Subaru Select Monitor (SSM) compatible diagnostic system
🔧 Transmission
Standard
Transmission Type 1:
5-speed Manual Transmission
Optional
Transmission Type 2:
4-speed Automatic Transmission (with manual mode on GT models)
Features
AWD Integration:
Symmetrical All-Wheel Drive system integrated with both transmission types
Fluid Specifications
Automatic Fluid:
Subaru ATF HP (High Performance) or equivalent Dexron III/Mercon compatible fluid
Manual Fluid:
Subaru Extra-S Gear Oil GL-5 75W-90 or equivalent
📐 Dimensions
Exterior
Length Sedan:
Approx. 187.4 inches (4760 mm)
Width Sedan:
Approx. 69.1 inches (1755 mm)
Height Sedan:
Approx. 57.7 inches (1465 mm)
Wheelbase:
Approx. 104.1 inches (2645 mm)
Length Wagon:
Approx. 188.2 inches (4780 mm)
Width Wagon:
Approx. 69.1 inches (1755 mm)
Height Wagon:
Approx. 58.1 inches (1475 mm)
Weights
Curb Weight Range:
Approx. 3200 - 3600 lbs (1450 - 1630 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5 Stars
NHTSA Front Impact Passenger:
5 Stars
NHTSA Side Impact Front Driver:
5 Stars
NHTSA Side Impact Front Passenger:
5 Stars
NHTSA Side Impact Rear Passenger:
5 Stars
IIHS Front Offset:
Good
IIHS Side Impact:
Good
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS)
Passive Features
Airbags:
Front airbags, front side-impact airbags, available curtain airbags (sedan)
Seatbelts:
Three-point seatbelts with pretensioners and load limiters
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD stereo system, with optional premium audio and subwoofer on higher trims.
Navigation:
Optional factory navigation system available on select trims.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Connectivity
Auxiliary Input:
Optional auxiliary audio input jack on some models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 3.75 months (severe duty) / 7,500 miles or 7.5 months (normal duty)
Spark Plug Replacement:
Approx. 60,000 miles (standard igniter plugs) / 100,000 miles (iridium plugs)
Coolant Replacement:
Initial 7 years/70,000 miles, then every 4 years/50,000 miles thereafter
Timing Belt:
This generation uses a timing *chain*, not a belt, requiring no scheduled replacement but proper lubrication.
Fluid Specifications
Engine Oil Type:
SAE 0W-20 or 5W-30 API SG, SH, SJ, SL, SM certified oil (check owner's manual for specific recommendations)
Coolant Type:
Subaru Super Coolant (Blue) or equivalent silicate-free, long-life coolant
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Known Issues
Head Gasket Leaks:
While less common than previous generations, early 2000s Subarus can still be susceptible to head gasket leaks, particularly on the EJ25 engines.
Oil Consumption:
Some EJ25 engines may exhibit increased oil consumption, especially as mileage increases.
Turbo Issues Gt:
Turbocharger failure or wastegate issues can occur on GT models if not properly maintained or subjected to excessive heat.
📚 Vehicle History
Brand Heritage
Subaru History:
Subaru, a division of Subaru Corporation (formerly Fuji Heavy Industries), has a long history in automotive manufacturing, known for its engineering prowess, particularly with its boxer engines and Symmetrical All-Wheel Drive systems.
Model Evolution
Legacy Generation:
This generation represents the third generation of the Subaru Legacy, introduced for the 2000 model year and facelifted for 2004.
Production
Manufacturing Plant:
Gunma, Japan
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick:
The 2004-2005 Subaru Legacy models were recognized with high safety ratings, often achieving IIHS Top Safety Pick status for their performance in crash tests.
Jdpower Dependability:
Subaru as a brand often ranks well in J.D. Power dependability studies for its long-term reliability.
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