1999-2000 Subaru Legacy Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Model Generations Covered: Third Generation (BD/BG/BK) Model Years Covered: 1999, 2000 Chassis Codes Covered: BD (Sedan), BG (Wagon) 👋 Introduction Market Position Segment: Mid-size Sedan and Wagon Target Audience: DIY mechanics, independent repair shops, Subaru enthusiasts Competitive Analysis Key Competitors: Toyota Camry, Honda Accord, Nissan Altima, Mazda 626 Unique Selling Proposition: Symmetrical All-Wheel Drive (standard on most trims), reliable Boxer engines, practical wagon variant Key Features Platform: Subaru's GC/GF/GM platform AWD Standard: Standard Symmetrical All-Wheel Drive across most models, enhancing traction and stability Engine Layout: Horizontally-opposed 'Boxer' engines for a lower center of gravity and smoother operation 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: Digital (PDF) Page Count: Approximately 1500-2000 (estimated, typical for comprehensive workshop manuals of this era) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication, cooling system, fuel delivery, ignition system, emission controls Transmission Manual: Manual transmission (5-speed) overhaul, clutch system, driveshafts, differential Transmission Automatic: Automatic transmission (4-speed) overhaul, torque converter, transmission control system Drivetrain: All-Wheel Drive (AWD) system, front and rear differentials, hub assemblies, axle shafts Suspension: Front suspension (MacPherson struts, control arms, anti-roll bar), rear suspension (Multi-link Beam), shock absorbers, springs, bushings, alignment specifications Steering: Power steering system, steering rack, tie rods, steering column, components Brakes: Front disc brakes, rear disc brakes, ABS (Anti-lock Braking System) components, hydraulic system, parking brake Electrical System: Battery, charging system, starting system, lighting, fuses, relays, wiring diagrams, body control modules, sensors Body Exterior: Body panels, doors, hood, trunk, bumpers, glass, weatherstripping, exterior trim Body Interior: Seating, dashboard, interior trim, HVAC system (Heating, Ventilation, and Air Conditioning), audio system, airbags Emissions Controls: Catalytic converter, exhaust system, EGR (Exhaust Gas Recirculation), evaporative emission control system Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad replacement, tire rotation Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical system diagnostics, engine performance issues Repair: Engine rebuild, transmission repair, suspension component replacement, brake caliper overhaul, electrical component diagnosis and repair, body panel repair Installation: Component installation and removal (e.g., starter motor, alternator, fuel pump, radiators, suspension parts) Specifications: Torque specifications for all fasteners, diagnostic data, electrical component resistance values, fluid capacities Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission overhauls) Diagnostic Capabilities: Detailed diagnostic procedures, wiring diagrams, component testing methods Rebuild Procedures: Complete step-by-step instructions for rebuilding major components like engines and transmissions 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable for quick information retrieval Printability: Printable pages for on-the-go use Print Quality Image Resolution: High-resolution diagrams and illustrations Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code 1: EJ22 (2.2L) Engine Type 1: SOHC Naturally Aspirated Boxer-4 Displacement 1: 2.2 Liters (2212 cc) Bore X Stroke 1: 96.0 mm x 75.0 mm Compression Ratio 1: 9.5:1 Horsepower 1: 135 hp @ 5600 rpm Torque 1: 135 lb-ft @ 4400 rpm Fuel System 1: Multi-point Fuel Injection (MPI) Secondary Engine Engine Code 2: EJ25D (2.5L DOHC) Engine Type 2: DOHC Naturally Aspirated Boxer-4 Displacement 2: 2.5 Liters (2457 cc) Bore X Stroke 2: 99.5 mm x 79.0 mm Compression Ratio 2: 10.0:1 Horsepower 2: 165 hp @ 5600 rpm Torque 2: 162 lb-ft @ 4000 rpm Fuel System 2: Multi-point Fuel Injection (MPI) Tertiary Engine Engine Code 3: EJ251 (2.5L SOHC - some late 2000 models may have this, though EJ25D is more common for this generation) Engine Type 3: SOHC Naturally Aspirated Boxer-4 Displacement 3: 2.5 Liters (2457 cc) Horsepower 3: 165 hp @ 5600 rpm Torque 3: 162 lb-ft @ 4000 rpm Fuel System 3: Multi-point Fuel Injection (MPI) Performance Performance Notes: Engines are known for durability and smooth operation due to Boxer design. EJ25D (DOHC) offers more power, while EJ22 is generally considered more robust. 🔧 Transmission Standard Standard Transmission Type: 5-Speed Manual Transmission Optional Optional Transmission Type: 4-Speed Automatic Transmission with Lock-up Torque Converter Features AWD Integration: Both transmission types are integrated with Subaru's Symmetrical All-Wheel Drive system. Manual Gearing: Close-ratio gearing for responsive performance in manual models. Automatic Control: Electronically controlled automatic transmission with adaptive shift logic. 📐 Dimensions Exterior Sedan Length: Approx. 187.0 inches (4750 mm) Wagon Length: Approx. 187.6 inches (4765 mm) Width: Approx. 68.1 inches (1730 mm) Height Sedan: Approx. 55.1 inches (1400 mm) Height Wagon: Approx. 56.1 inches (1425 mm) Wheelbase: Approx. 104.3 inches (2650 mm) Ground Clearance: Approx. 5.9 inches (150 mm) Weights Curb Weight Min: Approx. 3150 lbs (1430 kg) Curb Weight Max: Approx. 3400 lbs (1540 kg) Towing Capacity: Typically not recommended or rated for towing without specific equipment; consult owner's manual or Subaru for specifics. Cargo Cargo Volume Wagon:...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy

Model Generations Covered:

Third Generation (BD/BG/BK)

Model Years Covered:

1999, 2000

Chassis Codes Covered:

BD (Sedan), BG (Wagon)

👋 Introduction

Market Position

Segment:

Mid-size Sedan and Wagon

Target Audience:

DIY mechanics, independent repair shops, Subaru enthusiasts

Competitive Analysis

Key Competitors:

Toyota Camry, Honda Accord, Nissan Altima, Mazda 626

Unique Selling Proposition:

Symmetrical All-Wheel Drive (standard on most trims), reliable Boxer engines, practical wagon variant

Key Features

Platform:

Subaru's GC/GF/GM platform

AWD Standard:

Standard Symmetrical All-Wheel Drive across most models, enhancing traction and stability

Engine Layout:

Horizontally-opposed 'Boxer' engines for a lower center of gravity and smoother operation

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

Digital (PDF)

Page Count:

Approximately 1500-2000 (estimated, typical for comprehensive workshop manuals of this era)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, overhaul, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication, cooling system, fuel delivery, ignition system, emission controls

Transmission Manual:

Manual transmission (5-speed) overhaul, clutch system, driveshafts, differential

Transmission Automatic:

Automatic transmission (4-speed) overhaul, torque converter, transmission control system

Drivetrain:

All-Wheel Drive (AWD) system, front and rear differentials, hub assemblies, axle shafts

Suspension:

Front suspension (MacPherson struts, control arms, anti-roll bar), rear suspension (Multi-link Beam), shock absorbers, springs, bushings, alignment specifications

Steering:

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

Brakes:

Front disc brakes, rear disc brakes, ABS (Anti-lock Braking System) components, hydraulic system, parking brake

Electrical System:

Battery, charging system, starting system, lighting, fuses, relays, wiring diagrams, body control modules, sensors

Body Exterior:

Body panels, doors, hood, trunk, bumpers, glass, weatherstripping, exterior trim

Body Interior:

Seating, dashboard, interior trim, HVAC system (Heating, Ventilation, and Air Conditioning), audio system, airbags

Emissions Controls:

Catalytic converter, exhaust system, EGR (Exhaust Gas Recirculation), evaporative emission control system

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad replacement, tire rotation

Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical system diagnostics, engine performance issues

Repair:

Engine rebuild, transmission repair, suspension component replacement, brake caliper overhaul, electrical component diagnosis and repair, body panel repair

Installation:

Component installation and removal (e.g., starter motor, alternator, fuel pump, radiators, suspension parts)

Specifications:

Torque specifications for all fasteners, diagnostic data, electrical component resistance values, fluid capacities

Technical Depth

Depth:

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

Diagnostic Capabilities:

Detailed diagnostic procedures, wiring diagrams, component testing methods

Rebuild Procedures:

Complete step-by-step instructions for rebuilding major components like engines and transmissions

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable for quick information retrieval

Printability:

Printable pages for on-the-go use

Print Quality

Image Resolution:

High-resolution diagrams and illustrations

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

EJ22 (2.2L)

Engine Type 1:

SOHC Naturally Aspirated Boxer-4

Displacement 1:

2.2 Liters (2212 cc)

Bore X Stroke 1:

96.0 mm x 75.0 mm

Compression Ratio 1:

9.5:1

Horsepower 1:

135 hp @ 5600 rpm

Torque 1:

135 lb-ft @ 4400 rpm

Fuel System 1:

Multi-point Fuel Injection (MPI)

Secondary Engine

Engine Code 2:

EJ25D (2.5L DOHC)

Engine Type 2:

DOHC Naturally Aspirated Boxer-4

Displacement 2:

2.5 Liters (2457 cc)

Bore X Stroke 2:

99.5 mm x 79.0 mm

Compression Ratio 2:

10.0:1

Horsepower 2:

165 hp @ 5600 rpm

Torque 2:

162 lb-ft @ 4000 rpm

Fuel System 2:

Multi-point Fuel Injection (MPI)

Tertiary Engine

Engine Code 3:

EJ251 (2.5L SOHC - some late 2000 models may have this, though EJ25D is more common for this generation)

Engine Type 3:

SOHC Naturally Aspirated Boxer-4

Displacement 3:

2.5 Liters (2457 cc)

Horsepower 3:

165 hp @ 5600 rpm

Torque 3:

162 lb-ft @ 4000 rpm

Fuel System 3:

Multi-point Fuel Injection (MPI)

Performance

Performance Notes:

Engines are known for durability and smooth operation due to Boxer design. EJ25D (DOHC) offers more power, while EJ22 is generally considered more robust.

🔧 Transmission

Standard

Standard Transmission Type:

5-Speed Manual Transmission

Optional

Optional Transmission Type:

4-Speed Automatic Transmission with Lock-up Torque Converter

Features

AWD Integration:

Both transmission types are integrated with Subaru's Symmetrical All-Wheel Drive system.

Manual Gearing:

Close-ratio gearing for responsive performance in manual models.

Automatic Control:

Electronically controlled automatic transmission with adaptive shift logic.

📐 Dimensions

Exterior

Sedan Length:

Approx. 187.0 inches (4750 mm)

Wagon Length:

Approx. 187.6 inches (4765 mm)

Width:

Approx. 68.1 inches (1730 mm)

Height Sedan:

Approx. 55.1 inches (1400 mm)

Height Wagon:

Approx. 56.1 inches (1425 mm)

Wheelbase:

Approx. 104.3 inches (2650 mm)

Ground Clearance:

Approx. 5.9 inches (150 mm)

Weights

Curb Weight Min:

Approx. 3150 lbs (1430 kg)

Curb Weight Max:

Approx. 3400 lbs (1540 kg)

Towing Capacity:

Typically not recommended or rated for towing without specific equipment; consult owner's manual or Subaru for specifics.

Cargo

Cargo Volume Wagon:

Approx. 33.7 cu ft (seats up)

Cargo Volume Wagon Max:

Approx. 67.0 cu ft (seats down)

🛡️ Safety Features

Ratings

NHTSA Rollover Rating Sedan:

4/5 stars (1999 model year)

NHTSA Rollover Rating Wagon:

4/5 stars (1999 model year)

Active Features

Available Anti-lock Braking System (ABS) on all four wheels.

Standard Symmetrical All-Wheel Drive for enhanced traction and stability in various conditions.

Passive Features

Airbags:

Dual front airbags (driver and passenger).

Seatbelts:

Three-point seatbelts for all seating positions, pretensioners for front seats.

Child Seat Anchors:

Rear LATCH (Lower Anchors and Tethers for Children) or equivalent ISOFIX anchors (availability may vary by market and trim).

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM stereo with CD player or cassette tape. Speaker configurations vary by trim.

Climate Control:

Manual or automatic climate control systems. Manual covers HVAC component diagnosis and repair.

Driver Assistance

Cruise Control:

Standard on most higher trims, electronic cruise control system.

Connectivity

Power Accessories:

Power windows, power door locks, power mirrors available on higher trims.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 - 7,500 miles or 6 months, depending on driving conditions and oil type used (consult manual for specifics).

Air Filter Replacement:

Every 15,000 - 30,000 miles or as needed based on inspection.

Spark Plug Replacement Ej22:

Approx. 60,000 - 100,000 miles (depending on plug type, typically copper or platinum).

Spark Plug Replacement Ej25D:

Approx. 60,000 - 100,000 miles (depending on plug type, typically copper or platinum).

Timing Belt Replacement:

Critical: Every 90,000 - 105,000 miles or 7-10 years. Failure can cause catastrophic engine damage.

Brake Fluid Flush:

Every 2-3 years or as recommended by Subaru.

Fluid Specifications

Engine Oil Type:

API SG/SH/SJ rated, SAE 5W-30 or 10W-30 (refer to manual for specific viscosity based on ambient temperature).

Engine Oil Capacity Ej22:

Approx. 4.5 US quarts (4.3 L) with filter change.

Engine Oil Capacity Ej25D:

Approx. 4.7 US quarts (4.4 L) with filter change.

Coolant Type:

Subaru Super Coolant (blue) or equivalent ethylene glycol-based coolant with corrosion inhibitors.

Transmission Fluid Manual:

API GL-5, SAE 75W-90 gear oil (approx. 2.0-2.2 US quarts).

Transmission Fluid Automatic:

Subaru ATF (Dexron III compatible) or equivalent (approx. 3.0-3.5 US quarts for drain and fill, more for overhaul).

Power Steering Fluid:

ATF Dexron II/III compatible.

Brake Fluid:

DOT 3 or DOT 4.

Known Issues

Head Gaskets Ej25D:

The EJ25D engine (specifically) is prone to head gasket leaks and potential over-heating issues. The manual will detail inspection and replacement procedures.

O2 Sensors:

Oxygen sensors can degrade over time, affecting fuel economy and emissions. Manual covers testing and replacement.

Idler Pulleys Timing Belt:

Idler pulley bearings can fail, leading to timing belt issues. The manual provides critical timing belt system service.

Suspension Bushings:

Wear in suspension bushings can lead to noisy suspension and reduced handling. Manual details inspection and replacement.

📚 Vehicle History

Brand Heritage

Manufacturer:

Subaru Corporation (formerly Fuji Heavy Industries)

Heritage Focus:

Specializes in horizontally-opposed engines and All-Wheel Drive systems, often associated with rally racing and outdoor lifestyles.

Model Evolution

Generation Introduction:

The third generation (BD/BG/BK) of the Subaru Legacy was introduced for the 1995 model year and continued through 2000, receiving a facelift in 1998.

Facelift Details:

The 1998 facelift brought revised styling, including new headlights, grille, bumpers, and updated interior trim.

Trim Levels:

Common trims included L, LS, GT, and Outback (wagon variant with increased ground clearance).

Production

Production Period:

1995-2000

Manufacturing Location:

Gunma, Japan

🏆 Awards & Recognition

Recognitions

Model Recognition 1:

The Subaru Legacy was consistently praised for its standard AWD system, offering superior traction compared to many front-wheel-drive competitors.

Model Recognition 2:

Consumer Reports often rated the Legacy well for reliability and all-weather capability during this period.

Saftey Awards:

Achieved good safety ratings from IIHS and NHTSA for its class and era, particularly noted for its standard AWD's contribution to accident avoidance.