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SUBARU LEGACY 1996 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 1996 Codes Chassis Code: BD/BG/BK Generation Generation Name: Second Generation (Second Facelift) 👋 Introduction Market Position Segment: Mid-size Sedan/Wagon Competitors: Toyota Camry, Honda Accord, Ford Taurus, Nissan Maxima Competitive Analysis Key Selling Points: Standard Symmetrical All-Wheel Drive, boxer engine layout, reliable reputation, durable construction Key Features All Wheel Drive: Standard Symmetrical All-Wheel Drive system offering superior traction and stability in various conditions. Engine Layout: Horizontally opposed (Boxer) engine for a lower center of gravity and improved handling. Body Styles: Offered in Sedan and Wagon body styles. Trim Levels: Available in various trim levels like RS, LS, GT, Outback (wagon variant). 📋 Manual Details Coverage Areas Primary Markets Covered: North America, Europe, Japan 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 overhaul, cylinder head, block, crankshaft, pistons, connecting rods, timing belt, oil pump, lubrication system, cooling system Engine Performance: Fuel injection system, ignition system, emission control systems (catalytic converter, EGR, PCV), engine diagnostics, performance tuning Transmission Manual: Clutch system, gearbox overhaul, gear selection, synchronizers, bearings Transmission Automatic: Automatic transmission overhaul, hydraulic control systems, torque converter, valve body, shift control Drivetrain: All-Wheel Drive (AWD) system, viscous coupling, differentials (front and rear), driveshafts, CV joints, axle shafts Suspension: Front and rear suspension components, struts, shock absorbers, springs, control arms, ball joints, bushings, sway bars Steering: Power steering system, steering rack, tie rods, steering column, wheel alignment specifications Brakes: Front and rear brake systems, disc brakes, drum brakes, hydraulic lines, master cylinder, brake booster, ABS system (if equipped), parking brake Electrical System: Battery, charging system (alternator, starter), lighting systems, wiring diagrams, fuses, relays, ignition switch Body And Chassis: Body panel removal and installation, interior trim, exterior trim, glass, doors, hood, trunk, chassis diagnostics, rust prevention HVAC: Heating, ventilation, and air conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, climate controls Diagnostics Troubleshooting: Diagnostic Trouble Codes (DTCs), OBD-I (On-Board Diagnostics) system, troubleshooting flowcharts, common fault diagnosis Procedures Included Maintenance Routines: Oil change, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid flush, power steering fluid flush Repair Procedures: Step-by-step repair instructions for all major vehicle systems, component removal and installation, reassembly, torquing specifications Troubleshooting Guide: Systematic approach to identifying and resolving common and uncommon vehicle issues, symptom-based diagnosis Wiring Diagrams: Detailed electrical wiring diagrams for all vehicle systems, component locations, connector pinouts Diagnostic Procedures: Procedures for using diagnostic tools, reading sensor data, testing electrical components, checking fuel pressure, ignition timing adjustments Technical Depth Depth: Comprehensive from basic scheduled maintenance to complete engine and transmission rebuilds, including advanced diagnostics and component-level repair. 📊 Manual Specifications File Format File Type: PDF Searchability: Fully searchable text for quick information retrieval Print Quality Image Resolution: High-resolution images and diagrams for clarity Printable: Printable pages for workshop use Binding Type Binding: N/A (Digital PDF) Paper Type Paper Quality: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code 1: EJ22 Engine Description 1: 2.2L SOHC 16-valve Boxer-4 Displacement 1: 2211 cc Bore Stroke 1: 97.0 mm x 75.0 mm Compression Ratio 1: 9.5:1 Horsepower 1: 135 hp @ 5600 rpm Torque 1: 140 lb-ft @ 4400 rpm Fuel Induction 1: Multi-port Fuel Injection (MPI) Ignition System 1: Distributorless Ignition System (DIS) / Direct Ignition (DI) Engine Code 2 Engine Code 2: EJ25D Engine Description 2 Engine Description 2: 2.5L DOHC 16-valve Boxer-4 (Optional on some models, more common in later years but may be present) Displacement 2 Displacement 2: 2457 cc Performance 2 Horsepower 2: 165 hp @ 5600 rpm Torque 2: 155 lb-ft @ 4000 rpm Fuel System Fuel Type Requirement: Unleaded gasoline, 87 octane (minimum) Fuel Tank Capacity: 15.9 US gallons (60 liters) 🔧 Transmission Standard Standard Transmission: 5-Speed Manual Optional Optional Transmission: 4-Speed Automatic (with lock-up torque converter) Features AWD Integration: Integrated with standard Symmetrical All-Wheel Drive system. Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 Automatic Transmission Fluid: Subaru ATF HP (or equivalent) 📐 Dimensions Exterior Sedan Length Sedan: 183.1 in (4650 mm) Width Sedan: 67.7 in (1720 mm) Height Sedan: 56.1 in (1425 mm) Exterior Wagon Length Wagon: 185.4 in (4710 mm) Width Wagon: 67.7 in (1720 mm) Height Wagon: 57.5 in (1460 mm) (standard), 60.0 in (1525 mm) (Outback) Wheelbase Wheelbase: 104.3 in (2650 mm) Weights Curb Weight Manual: Approx. 3100-3300 lbs (1400-1500 kg) Curb Weight Automatic: Approx. 3200-3400 lbs (1450-1550 kg) Gross Vehicle Weight Rating Gvwr: Approx. 4300 lbs (1950 kg) Cargo Cargo Volume Sedan: Approx. 14.1 cu ft (399 liters) Cargo Volume Wagon: Approx. 37.5 cu ft (1062 liters) (rear seats up) Cargo Volume Wagon Seats Folded: Approx. 70.0 cu ft (1982 liters) (rear seats folded) 🛡️ Safety Features Ratings NHTSA Driver Front Impact Rating: Not...
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SUBARU LEGACY 1996 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy
Year:
1996
Codes
Chassis Code:
BD/BG/BK
Generation
Generation Name:
Second Generation (Second Facelift)
👋 Introduction
Market Position
Segment:
Mid-size Sedan/Wagon
Competitors:
Toyota Camry, Honda Accord, Ford Taurus, Nissan Maxima
Competitive Analysis
Key Selling Points:
Standard Symmetrical All-Wheel Drive, boxer engine layout, reliable reputation, durable construction
Key Features
All Wheel Drive:
Standard Symmetrical All-Wheel Drive system offering superior traction and stability in various conditions.
Engine Layout:
Horizontally opposed (Boxer) engine for a lower center of gravity and improved handling.
Body Styles:
Offered in Sedan and Wagon body styles.
Trim Levels:
Available in various trim levels like RS, LS, GT, Outback (wagon variant).
📋 Manual Details
Coverage Areas
Primary Markets Covered:
North America, Europe, Japan
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 overhaul, cylinder head, block, crankshaft, pistons, connecting rods, timing belt, oil pump, lubrication system, cooling system
Engine Performance:
Fuel injection system, ignition system, emission control systems (catalytic converter, EGR, PCV), engine diagnostics, performance tuning
Transmission Manual:
Clutch system, gearbox overhaul, gear selection, synchronizers, bearings
Transmission Automatic:
Automatic transmission overhaul, hydraulic control systems, torque converter, valve body, shift control
Drivetrain:
All-Wheel Drive (AWD) system, viscous coupling, differentials (front and rear), driveshafts, CV joints, axle shafts
Suspension:
Front and rear suspension components, struts, shock absorbers, springs, control arms, ball joints, bushings, sway bars
Steering:
Power steering system, steering rack, tie rods, steering column, wheel alignment specifications
Brakes:
Front and rear brake systems, disc brakes, drum brakes, hydraulic lines, master cylinder, brake booster, ABS system (if equipped), parking brake
Electrical System:
Battery, charging system (alternator, starter), lighting systems, wiring diagrams, fuses, relays, ignition switch
Body And Chassis:
Body panel removal and installation, interior trim, exterior trim, glass, doors, hood, trunk, chassis diagnostics, rust prevention
HVAC:
Heating, ventilation, and air conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, climate controls
Diagnostics Troubleshooting:
Diagnostic Trouble Codes (DTCs), OBD-I (On-Board Diagnostics) system, troubleshooting flowcharts, common fault diagnosis
Procedures Included
Maintenance Routines:
Oil change, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid flush, power steering fluid flush
Repair Procedures:
Step-by-step repair instructions for all major vehicle systems, component removal and installation, reassembly, torquing specifications
Troubleshooting Guide:
Systematic approach to identifying and resolving common and uncommon vehicle issues, symptom-based diagnosis
Wiring Diagrams:
Detailed electrical wiring diagrams for all vehicle systems, component locations, connector pinouts
Diagnostic Procedures:
Procedures for using diagnostic tools, reading sensor data, testing electrical components, checking fuel pressure, ignition timing adjustments
Technical Depth
Depth:
Comprehensive from basic scheduled maintenance to complete engine and transmission rebuilds, including advanced diagnostics and component-level repair.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Fully searchable text for quick information retrieval
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity
Printable:
Printable pages for workshop use
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Quality:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
EJ22
Engine Description 1:
2.2L SOHC 16-valve Boxer-4
Displacement 1:
2211 cc
Bore Stroke 1:
97.0 mm x 75.0 mm
Compression Ratio 1:
9.5:1
Horsepower 1:
135 hp @ 5600 rpm
Torque 1:
140 lb-ft @ 4400 rpm
Fuel Induction 1:
Multi-port Fuel Injection (MPI)
Ignition System 1:
Distributorless Ignition System (DIS) / Direct Ignition (DI)
Engine Code 2
Engine Code 2:
EJ25D
Engine Description 2
Engine Description 2:
2.5L DOHC 16-valve Boxer-4 (Optional on some models, more common in later years but may be present)
Displacement 2
Displacement 2:
2457 cc
Performance 2
Horsepower 2:
165 hp @ 5600 rpm
Torque 2:
155 lb-ft @ 4000 rpm
Fuel System
Fuel Type Requirement:
Unleaded gasoline, 87 octane (minimum)
Fuel Tank Capacity:
15.9 US gallons (60 liters)
🔧 Transmission
Standard
Standard Transmission:
5-Speed Manual
Optional
Optional Transmission:
4-Speed Automatic (with lock-up torque converter)
Features
AWD Integration:
Integrated with standard Symmetrical All-Wheel Drive system.
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90
Automatic Transmission Fluid:
Subaru ATF HP (or equivalent)
📐 Dimensions
Exterior Sedan
Length Sedan:
183.1 in (4650 mm)
Width Sedan:
67.7 in (1720 mm)
Height Sedan:
56.1 in (1425 mm)
Exterior Wagon
Length Wagon:
185.4 in (4710 mm)
Width Wagon:
67.7 in (1720 mm)
Height Wagon:
57.5 in (1460 mm) (standard), 60.0 in (1525 mm) (Outback)
Wheelbase
Wheelbase:
104.3 in (2650 mm)
Weights
Curb Weight Manual:
Approx. 3100-3300 lbs (1400-1500 kg)
Curb Weight Automatic:
Approx. 3200-3400 lbs (1450-1550 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 4300 lbs (1950 kg)
Cargo
Cargo Volume Sedan:
Approx. 14.1 cu ft (399 liters)
Cargo Volume Wagon:
Approx. 37.5 cu ft (1062 liters) (rear seats up)
Cargo Volume Wagon Seats Folded:
Approx. 70.0 cu ft (1982 liters) (rear seats folded)
🛡️ Safety Features
Ratings
NHTSA Driver Front Impact Rating:
Not rated or unavailable for this model year.
NHTSA Passenger Front Impact Rating:
Not rated or unavailable for this model year.
Active Features
ABS:
Anti-lock Braking System (ABS) available on select trims.
Passive Features
Airbags:
Driver and passenger front airbags.
Seatbelts:
Three-point front and rear seatbelts. Pretensioners for front seatbelts.
Child Seat Anchors:
LATCH/ISOFIX not standard on this model year, but provisions for child seats may exist.
Construction
Body Structure:
Reinforced body structure with crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM stereo with cassette player. Optional CD player available on higher trims. Speaker configurations vary by trim.
Climate Control:
Manual climate control with A/C standard on most models. Automatic climate control was an option.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
Auxiliary Inputs:
No factory auxiliary inputs or Bluetooth connectivity. Aftermarket solutions available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 3 months, whichever comes first. Use synthetic oil for extended intervals.
Air Filter Replacement Interval:
Every 15,000 miles (24,000 km) or 12 months.
Fuel Filter Replacement Interval:
Every 30,000 miles (48,000 km).
Spark Plug Replacement Interval:
Every 30,000 miles (48,000 km) for standard plugs, or 60,000 miles (96,000 km) for platinum/iridium plugs (check specific plug type).
Timing Belt Replacement Interval:
Every 60,000 miles (96,000 km) or 5 years, critical to prevent catastrophic engine damage.
Coolant Flush Interval:
Every 30,000 miles (48,000 km) or 2 years.
Brake Fluid Flush Interval:
Every 24,000 miles (38,000 km) or 2 years.
Fluid Specifications
Engine Oil Specification:
API SG or SH, SAE 5W-30 (preferred), 10W-30, or 10W-40 depending on climate.
Engine Oil Capacity Ej22:
4.5 US quarts (4.3 liters) with filter change.
Coolant Specification:
Subaru Super Coolant (blue) or equivalent ethylene glycol based coolant, 50/50 mix with distilled water.
Power Steering Fluid:
Subaru power steering fluid or Dexron II/III ATF.
Known Issues
Head Gaskets:
While less prevalent than in later EJ series engines, early EJ25D engines (if present) were known for head gasket failures. The EJ22 is generally more robust.
Suspension Bushings:
Wear and tear on suspension bushings and ball joints is common with age and mileage.
Oil Leaks:
Rear main seal and valve cover gasket leaks can occur over time.
Catalytic Converter:
Can become clogged or fail over time, especially with poor maintenance.
Maintenance Schedule Summary
Basic Checks:
Tire pressure, fluid levels, belts, hoses, lights should be checked regularly (monthly).
📚 Vehicle History
Brand Heritage
Subaru Philosophy:
Subaru is known for its emphasis on safety, durability, and its unique Symmetrical All-Wheel Drive system.
Model Evolution
Second Generation Intro:
The second generation Legacy (BD/BG/BK) was introduced for the 1995 model year, evolving from the first generation. The 1996 model represents a continuation of this generation, with minor updates.
Second Generation Facelift:
The second generation received a significant facelift for the 1997 model year, meaning the 1996 model is the pre-facelift version of the second generation.
Outback Variant:
The Outback variant, a lifted and more rugged version of the Legacy wagon, gained popularity during this generation.
Production
Production Locations:
Primarily manufactured in Japan.
Production Years Second Gen:
1995-1999
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
Subaru Legacy models, particularly the Outback variants, have been recognized by Car and Driver in their '10Best' lists in various years, acknowledging their practicality and capability.
Ratings
Ieda Safety Award:
Subaru often received high safety ratings from organizations like the Insurance Institute for Highway Safety (IIHS) for its durable construction.
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