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Subaru Legacy 2004-2005 Repair Service Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Product Name: Subaru Legacy 2004-2005 Repair Service Manual Product Type: Repair Service Manual Generation Generation Code: BP/BL Generation Years: 2004-2009 Codes Chassis Code: BP (Wagon), BL (Sedan) 👋 Introduction Market Position Vehicle Class: Mid-size Sedan and Wagon Competitive Segment: Direct competitor to vehicles like Toyota Camry, Honda Accord, Mazda6, Nissan Altima. Subaru Niche: Known for standard Symmetrical All-Wheel Drive, Boxer engines, and a reputation for reliability and safety. Competitive Analysis Differentiation: Standard AWD provided a significant advantage in traction and all-weather capability compared to most competitors in its class. Engine Offerings: Offered a range of Boxer engines, including naturally aspirated and turbocharged variants, appealing to performance-oriented buyers. Key Features Standard AWD: Symmetrical All-Wheel Drive was a hallmark feature of the Legacy, enhancing grip and stability. Boxer Engine Layout: Low center of gravity from horizontally opposed 'Boxer' engines contributed to better handling dynamics. Safety Focus: Subaru's commitment to safety, often receiving high marks in crash tests. Available Performance Variants: The GT and GT Limited trims offered turbocharged power and sport-tuned suspension for enthusiast appeal. 📋 Manual Details Coverage Areas Model Years Covered: 2004, 2005 Engine Variants Covered: 2.5L Naturally Aspirated (EJ253), 2.5L Turbocharged (EJ255 - GT models), 3.0L H6 Naturally Aspirated (EZ30D) Transmission Types Covered: 5-speed Manual, 4-speed Automatic, 5-speed Automatic (5EAT) Trim Levels Covered: All available trim levels including 2.5i, GT, GT Limited, Outback (if applicable to the generation covered by manual) Page Count Estimated Page Count: 1500-2500+ (typical for comprehensive service manuals) Manual Type Manual Type: Factory Service Manual (FSM) Target Audience: Professional Technicians, Experienced DIYers Language Language: English Format Format: PDF Download Searchable Text: Yes (assumed for PDF service manuals) Printable: Yes (assumed for PDF service manuals) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, assembly, overhaul, and component testing for EJ253, EJ255, EZ30D engines. Includes timing belt replacement, valve adjustments, piston ring installation, cylinder head reconditioning. Engine Electrical: Ignition system, fuel injection system (EFI), sensors (MAF, MAP, O2, Crank/Cam), ignition coils, starter motor, alternator, battery, wiring diagrams. Transmission Manual: Disassembly, assembly, inspection, and repair of 5-speed manual transmission. Includes clutch operation, gear synchros, shift forks, output shaft, bearings. Transmission Automatic: Troubleshooting, repair, and overhaul of 4-speed and 5EAT automatic transmissions. Includes valve body diagnostics, torque converter, transmission control module (TCM) operation, fluid types and capacities. Drivetrain: All-Wheel Drive (AWD) system, front and rear differentials, driveshafts, CV joints, wheel bearings, propeller shaft. Suspension: Front and rear suspension components, struts, shocks, coil springs, control arms, ball joints, bushings, anti-roll bars, alignment specifications. Steering: Power steering system (hydraulic), steering rack, tie rods, steering column, steering angle sensor, alignment procedures. Brakes: Front and rear disc brake systems, ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), brake fluid specifications, bleeding procedures, rotor and pad replacement, caliper repair. Electrical System Body: Lighting system (headlights, taillights, interior), power windows, power locks, mirrors, wipers, horn, central locking, keyless entry, immobilizer system. HVAC: Heating, Ventilation, and Air Conditioning system. Includes refrigerant types, charging procedures, blower motor, evaporator, condenser, compressor, cabin air filter replacement. Body Exterior: Body panel removal and installation (fenders, bumpers, doors, hood, trunk), glass replacement, seals, exterior trim. Body Interior: Dashboard removal, seat removal and installation, interior trim panels, headliner, carpeting, airbag system safety precautions. Safety Systems: Airbag system (SRS), seatbelt pre-tensioners, pre-collision systems (if equipped), safety sensor locations and testing. Diagnostics: OBD-II (On-Board Diagnostics II) system, diagnostic trouble codes (DTCs), diagnostic scan tool usage, live data interpretation, component testing procedures. Procedures Included Routine Maintenance: Oil and filter change, air filter replacement, cabin air filter replacement, spark plug replacement, fluid checks and top-offs. Major Maintenance: Timing belt replacement (EJ engines), coolant flush and replacement, brake fluid flush, transmission fluid change, differential fluid change. Troubleshooting: Systematic diagnostic procedures for common and uncommon issues across all vehicle systems, symptom-based troubleshooting guides. Repair And Overhaul: Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation. Component Testing: Electrical component testing using multimeters, resistance checks, voltage checks, continuity tests. Calibration And Adjustment: Wheel alignment procedures, idle speed adjustment (if applicable), headlight aim adjustment. Technical Depth Depth Of Coverage: Comprehensive, detailed, and thorough. Covers everything from basic maintenance to complete engine and transmission rebuilds. Diagnostic Capability: Advanced diagnostic procedures for electrical and mechanical systems, including interpretation of sensor data and fault codes. Rebuild Instructions: Detailed instructions for rebuilding major components like engines, transmissions, and differentials. Specification Accuracy: Highly accurate torque specifications, clearances, fluid capacities, and electrical resistance values. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Image Resolution: High-resolution images, diagrams, and schematics suitable for clear viewing and printing. Binding Type Binding Method: N/A (Digital Download - printable pages) Paper Type Recommended Paper Type: N/A (Digital Download - printable pages) ⚙️ Engine Specifications Primary Engine Engine Code Base: EJ253 Engine Type Base: 2.5L...
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Subaru Legacy 2004-2005 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy
Product Name:
Subaru Legacy 2004-2005 Repair Service Manual
Product Type:
Repair Service Manual
Generation
Generation Code:
BP/BL
Generation Years:
2004-2009
Codes
Chassis Code:
BP (Wagon), BL (Sedan)
👋 Introduction
Market Position
Vehicle Class:
Mid-size Sedan and Wagon
Competitive Segment:
Direct competitor to vehicles like Toyota Camry, Honda Accord, Mazda6, Nissan Altima.
Subaru Niche:
Known for standard Symmetrical All-Wheel Drive, Boxer engines, and a reputation for reliability and safety.
Competitive Analysis
Differentiation:
Standard AWD provided a significant advantage in traction and all-weather capability compared to most competitors in its class.
Engine Offerings:
Offered a range of Boxer engines, including naturally aspirated and turbocharged variants, appealing to performance-oriented buyers.
Key Features
Standard AWD:
Symmetrical All-Wheel Drive was a hallmark feature of the Legacy, enhancing grip and stability.
Boxer Engine Layout:
Low center of gravity from horizontally opposed 'Boxer' engines contributed to better handling dynamics.
Safety Focus:
Subaru's commitment to safety, often receiving high marks in crash tests.
Available Performance Variants:
The GT and GT Limited trims offered turbocharged power and sport-tuned suspension for enthusiast appeal.
📋 Manual Details
Coverage Areas
Model Years Covered:
2004, 2005
Engine Variants Covered:
2.5L Naturally Aspirated (EJ253), 2.5L Turbocharged (EJ255 - GT models), 3.0L H6 Naturally Aspirated (EZ30D)
Transmission Types Covered:
5-speed Manual, 4-speed Automatic, 5-speed Automatic (5EAT)
Trim Levels Covered:
All available trim levels including 2.5i, GT, GT Limited, Outback (if applicable to the generation covered by manual)
Page Count
Estimated Page Count:
1500-2500+ (typical for comprehensive service manuals)
Manual Type
Manual Type:
Factory Service Manual (FSM)
Target Audience:
Professional Technicians, Experienced DIYers
Language
Language:
English
Format
Format:
PDF Download
Searchable Text:
Yes (assumed for PDF service manuals)
Printable:
Yes (assumed for PDF service manuals)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed disassembly, assembly, overhaul, and component testing for EJ253, EJ255, EZ30D engines. Includes timing belt replacement, valve adjustments, piston ring installation, cylinder head reconditioning.
Engine Electrical:
Ignition system, fuel injection system (EFI), sensors (MAF, MAP, O2, Crank/Cam), ignition coils, starter motor, alternator, battery, wiring diagrams.
Transmission Manual:
Disassembly, assembly, inspection, and repair of 5-speed manual transmission. Includes clutch operation, gear synchros, shift forks, output shaft, bearings.
Transmission Automatic:
Troubleshooting, repair, and overhaul of 4-speed and 5EAT automatic transmissions. Includes valve body diagnostics, torque converter, transmission control module (TCM) operation, fluid types and capacities.
Drivetrain:
All-Wheel Drive (AWD) system, front and rear differentials, driveshafts, CV joints, wheel bearings, propeller shaft.
Suspension:
Front and rear suspension components, struts, shocks, coil springs, control arms, ball joints, bushings, anti-roll bars, alignment specifications.
Steering:
Power steering system (hydraulic), steering rack, tie rods, steering column, steering angle sensor, alignment procedures.
Brakes:
Front and rear disc brake systems, ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), brake fluid specifications, bleeding procedures, rotor and pad replacement, caliper repair.
Electrical System Body:
Lighting system (headlights, taillights, interior), power windows, power locks, mirrors, wipers, horn, central locking, keyless entry, immobilizer system.
HVAC:
Heating, Ventilation, and Air Conditioning system. Includes refrigerant types, charging procedures, blower motor, evaporator, condenser, compressor, cabin air filter replacement.
Body Exterior:
Body panel removal and installation (fenders, bumpers, doors, hood, trunk), glass replacement, seals, exterior trim.
Body Interior:
Dashboard removal, seat removal and installation, interior trim panels, headliner, carpeting, airbag system safety precautions.
Safety Systems:
Airbag system (SRS), seatbelt pre-tensioners, pre-collision systems (if equipped), safety sensor locations and testing.
Diagnostics:
OBD-II (On-Board Diagnostics II) system, diagnostic trouble codes (DTCs), diagnostic scan tool usage, live data interpretation, component testing procedures.
Procedures Included
Routine Maintenance:
Oil and filter change, air filter replacement, cabin air filter replacement, spark plug replacement, fluid checks and top-offs.
Major Maintenance:
Timing belt replacement (EJ engines), coolant flush and replacement, brake fluid flush, transmission fluid change, differential fluid change.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues across all vehicle systems, symptom-based troubleshooting guides.
Repair And Overhaul:
Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation.
Component Testing:
Electrical component testing using multimeters, resistance checks, voltage checks, continuity tests.
Calibration And Adjustment:
Wheel alignment procedures, idle speed adjustment (if applicable), headlight aim adjustment.
Technical Depth
Depth Of Coverage:
Comprehensive, detailed, and thorough. Covers everything from basic maintenance to complete engine and transmission rebuilds.
Diagnostic Capability:
Advanced diagnostic procedures for electrical and mechanical systems, including interpretation of sensor data and fault codes.
Rebuild Instructions:
Detailed instructions for rebuilding major components like engines, transmissions, and differentials.
Specification Accuracy:
Highly accurate torque specifications, clearances, fluid capacities, and electrical resistance values.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Print Quality
Image Resolution:
High-resolution images, diagrams, and schematics suitable for clear viewing and printing.
Binding Type
Binding Method:
N/A (Digital Download - printable pages)
Paper Type
Recommended Paper Type:
N/A (Digital Download - printable pages)
⚙️ Engine Specifications
Primary Engine
Engine Code Base:
EJ253
Engine Type Base:
2.5L SOHC Naturally Aspirated Boxer-4
Displacement Base:
2457 cc
Bore X Stroke Base:
99.5 mm x 79.0 mm
Compression Ratio Base:
9.7:1
Horsepower Base:
165 hp @ 5600 rpm
Torque Base:
166 lb-ft @ 4000 rpm
Performance Engine
Engine Code Gt:
EJ255
Engine Type Gt:
2.5L DOHC Turbocharged Boxer-4
Displacement Gt:
2457 cc
Compression Ratio Gt:
8.4:1
Horsepower Gt:
250 hp @ 6000 rpm
Torque Gt:
250 lb-ft @ 3600 rpm
H6 Engine
Engine Code H6:
EZ30D
Engine Type H6:
3.0L DOHC Naturally Aspirated Boxer-6
Displacement H6:
2999 cc
Compression Ratio H6:
10.7:1
Horsepower H6:
245 hp @ 6600 rpm
Torque H6:
217 lb-ft @ 4200 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane recommended, 91+ for GT models for optimal performance)
Fuel Tank Capacity:
65 Liters (17.2 Gallons)
Engine Management
ECU:
Engine Control Unit (ECU) with various sensors for closed-loop operation.
Turbocharger Specs:
IHI VF40 (GT models), Wastegate-controlled, intercooled.
🔧 Transmission
Standard
Standard Transmission Type:
5-Speed Manual Transmission
Optional
Optional Transmission Type 1:
4-Speed Automatic Transmission
Optional Transmission Type 2:
5-Speed 'Sportshift' Automatic Transmission (5EAT)
Features
AWD System Integration:
All transmissions are paired with Subaru's Symmetrical All-Wheel Drive system.
Manual Gear Ratios:
Specific gear ratios for each gear are detailed in the manual (e.g., 1st: 3.454, 2nd: 1.842, 3rd: 1.370, 4th: 1.060, 5th: 0.788, Reverse: 3.333).
Automatic Transmission Modes:
5EAT models feature a sequential manual shift mode ('Sportshift').
Fluid Specs
Manual Transmission Fluid:
API GL-5 SAE 75W-90 Hypoid Gear Oil.
Automatic Transmission Fluid:
Subaru ATF-HP (High Performance) or equivalent DEXRON III compatible fluid. Capacity approx. 6.5-7.5 quarts for change with filter.
Center Differential Fluid:
Subaru Differential Fluid-5 (or GL-5 equivalent).
Rear Differential Fluid:
Subaru Differential Fluid-5 (or GL-5 equivalent).
📐 Dimensions
Exterior
Sedan Length:
Approx. 4760 mm (187.4 in)
Wagon Length:
Approx. 4755 mm (187.2 in)
Width:
Approx. 1770 mm (69.7 in)
Height:
Approx. 1430 mm (56.3 in) (Sedan), Approx. 1470 mm (57.9 in) (Wagon)
Wheelbase:
Approx. 2670 mm (105.1 in)
Ground Clearance:
Approx. 150 mm (5.9 in)
Interior
Passenger Volume:
Approx. 97.4 cu ft (Sedan), Approx. 101.4 cu ft (Wagon)
Cargo
Trunk Volume Sedan:
Approx. 14.7 cu ft
Cargo Volume Wagon:
Approx. 30.0 cu ft (behind rear seats), Approx. 67.6 cu ft (with rear seats folded)
Weights
Curb Weight Base:
Approx. 1490 kg (3285 lbs)
Curb Weight Gt Sedan:
Approx. 1580 kg (3483 lbs)
Gross Vehicle Weight Rating:
Typically around 1950-2050 kg (4300-4500 lbs)
Towing Capacity:
Not officially specified or recommended by Subaru for most trims.
Wheel Bolt Pattern:
5x100 mm
Wheel Size Standard:
16 or 17 inches
Wheel Size Gt:
17 or 18 inches
Tire Size Example:
205/55R16 (base), 215/45R17 (GT)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver:
5 Stars (2004-2006 models)
NHTSA Frontal Passenger:
5 Stars (2004-2006 models)
NHTSA Side Driver:
5 Stars (2004-2006 models)
NHTSA Side Passenger:
5 Stars (2004-2006 models)
NHTSA Side Rear Occupant:
5 Stars (2004-2006 models)
IIHS Moderate Overlap Frontal:
Good (2005 models)
IIHS Side Impact:
Good (2005 models)
Active Features
ABS:
Standard Anti-lock Braking System
Ebd:
Standard Electronic Brake-force Distribution
Traction Control:
Available (often standard on higher trims or with certain transmissions)
Stability Control:
Available (Vehicle Dynamics Control - VDC)
Passive Features
Airbags:
Front dual-stage airbags, front side-impact airbags, front and rear side-curtain airbags (availability varies by trim).
Seatbelts:
3-point height-adjustable front seatbelts with pretensioners and load limiters, 3-point rear seatbelts.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for CHildren) system.
Rollover Protection:
Reinforced chassis structure designed to resist roof crush.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with CD player. Premium audio systems with subwoofer and amplifier were available on higher trims. SiriusXM satellite radio integration.
Navigation:
Optional factory GPS navigation system available on select models and trims.
Climate Control:
Manual climate control standard, optional automatic climate control with dual-zone capability on higher trims.
Driver Assistance
Cruise Control:
Standard cruise control.
Remote Keyless Entry:
Available on most trims.
Security System:
Factory alarm system and immobilizer.
Tire Pressure Monitoring:
Optional on some models.
Connectivity
Auxiliary Input:
Optional auxiliary audio input jack (often on premium audio systems).
Bluetooth:
Not a standard feature on most models from this era. Aftermarket solutions common.
Usb Port:
Not standard. Usually added via aftermarket integration for infotainment systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 6 months, or 7,500 miles (12,000 km) / 12 months with synthetic oil, under normal driving conditions. Severe conditions may require more frequent changes.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months, or more often in dusty conditions.
Cabin Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Spark Plug Replacement:
Every 60,000 miles (96,000 km) for platinum/iridium plugs (e.g., NGK).
Timing Belt Replacement:
Every 105,000 miles (168,000 km) or 7 years for EJ engines (critical preventative maintenance item).
Coolant Replacement:
Every 30,000 miles (48,000 km) or 24 months for the initial service, then every 60,000 miles (96,000 km) or 48 months thereafter.
Brake Fluid Replacement:
Every 30,000 miles (48,000 km) or 24 months.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 Synthetic (preferred) or 5W-30 Conventional. Check owner's manual for exact specification.
Engine Oil Capacity:
4.5 US Quarts (4.3 Liters) with filter for 2.5L, 5.0 US Quarts (4.7 Liters) with filter for 3.0L H6.
Coolant Type:
Subaru Super Coolant (Blue) or equivalent silicate-free, long-life coolant. Never use green conventional coolant.
Power Steering Fluid:
Subaru Power Steering Fluid or Dexron III ATF.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Head Gaskets:
While not as prevalent as in earlier generations, some EJ25 engines can still experience head gasket issues, especially if overheated. The manual will detail inspection and replacement procedures.
Oil Leaks:
Common areas for oil leaks include valve cover gaskets and crankshaft seals. The manual covers seal replacement.
Evaporative Emissions System:
Issues with the EVAP system, such as a faulty purge valve or charcoal canister, can trigger check engine lights. The manual details EVAP system diagnostics.
Automatic Transmission Issues:
Some 5EAT transmissions have been known to develop issues with torque converters or valve bodies. Proper maintenance and fluid changes are crucial. The manual provides diagnostic guidance.
Wheel Bearing Wear:
Premature wear of wheel bearings can occur, especially with aggressive driving or in areas with road salt. The manual details bearing replacement.
Ac System Leaks:
O-rings and seals in the AC system can degrade over time, leading to refrigerant leaks. The manual outlines AC system servicing.
Clutch Wear:
Standard wear item for manual transmission vehicles. The manual provides clutch replacement procedures and specifications.
Brake Component Wear:
Rotors and pads are wear items, with replacement intervals depending on driving style. The manual covers brake system inspection and replacement.
Cv Axle Boots:
Torn CV axle boots can lead to joint failure. The manual details CV axle replacement.
📚 Vehicle History
Brand Heritage
Subaru Origin:
Founded in 1953, originally Fuji Heavy Industries. Known for its automotive division specializing in horizontally opposed 'Boxer' engines and Symmetrical All-Wheel Drive.
Legacy Brand Introduction:
The Subaru Legacy was introduced in 1989 as a replacement for the Subaru Leone.
Model Evolution
Generation Introduction:
The fourth generation (BP/BL) Legacy was introduced for the 2005 model year, with the 2004 model year being the final year of the third generation (BD/BG/BK).
Design Philosophy Gen4:
Featured a more aerodynamic and refined exterior design compared to its predecessor. Increased wheelbase and track width improved handling and interior space.
Engine Updates Gen4:
Introduction of the 3.0L EZ30D H6 engine for premium trims and continued use of updated EJ25 variants.
Production
Manufacturing Location:
Ota City, Gunma Prefecture, Japan
Production Period:
2003-2009 (for the BP/BL generation)
Sales Performance:
Competed effectively in the mid-size segment, with AWD appeal driving sales, especially in regions with challenging weather.
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick:
The 2005 Subaru Legacy received an 'Excellent' rating in frontal offset crash tests by the IIHS, often earning 'Top Safety Pick' status.
NHTSA Ratings:
Consistently achieved 5-star ratings from the National Highway Traffic Safety Administration (NHTSA) for frontal and side-impact crashworthiness.
Consumer Reports Reliability:
Consumer Reports often rated Subaru models, including the Legacy, favorably for reliability and owner satisfaction, though specific model year ratings can vary.
Motor Trend Car Of The Year Nominee:
While not winning, the Legacy generation was often a contender or praised in reviews by automotive publications for its AWD and performance variants.
Klюд Safety Award:
Subaru's commitment to safety is often recognized by various organizations, including the Insurance Institute for Highway Safety (IIHS).
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