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Subaru Legacy 1999 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 1999 Codes Chassis Codes: BD, BG, BK, BH Platform: Subaru Second Generation Legacy Platform 👋 Introduction Market Position Segment: Mid-size sedan and wagon, known for its AWD capabilities and practical design Competitive Analysis Competitors: Toyota Camry, Honda Accord, Nissan Maxima, Mazda 626, Ford Taurus Key Features Differentiators: Standard Symmetrical All-Wheel Drive, horizontally opposed ('Boxer') engine layout, robust build quality 📋 Manual Details Coverage Areas Service Scope: Comprehensive mechanical and electrical service, repair, and maintenance Page Count Estimated Pages: 1000+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (likely PDF or similar electronic format) 📖 Manual Coverage Systems Covered Engine: 2.2L EJ22, 2.5L EJ25 (Naturally Aspirated and Turbocharged) - DOHC and SOHC variants Transmission: 4-speed Automatic (4EAT), 5-speed Manual Drivetrain: All-Wheel Drive (AWD) system, differentials, driveshafts, CV joints Suspension: Front MacPherson struts, Rear multi-link, coil springs, shock absorbers, stabilizer bars Brakes: Front vented discs, Rear solid discs (or drums on some models), ABS system Steering: Power assisted rack and pinion Fuel System: Fuel injection, fuel pump, injectors, fuel tank, lines Cooling System: Radiator, coolant hoses, water pump, thermostat, cooling fan Exhaust System: Exhaust manifolds, catalytic converter, mufflers, pipes Electrical System: Battery, alternator, starter, ignition system, lighting, fuses, relays Climate Control: HVAC system, blower motor, heater core, A/C system components Body And Interior: Body panels, doors, windows, seats, trim, sound deadening Diagnostics: OBD-I and early OBD-II diagnostic procedures, fault code retrieval Procedures Included Routine Maintenance: Oil changes, filter replacements, tune-ups, fluid checks, tire rotation Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs Troubleshooting: Systematic diagnosis of common and uncommon faults with step-by-step guides Component Replacement: Detailed instructions for replacing nearly all mechanical and electrical components Wiring Diagrams: Complete electrical wiring schematics for all systems Technical Depth Depth: Detailed specifications, torque values, clearances, diagnostic procedures, and overhaul instructions 📊 Manual Specifications File Format Searchability: Likely searchable text for quick information retrieval Print Quality Illustrations: High-quality diagrams, schematics, and exploded views Binding Type Binding: N/A (assuming digital, but if printed, likely coil or perfect bound) Paper Type Paper: N/A (assuming digital) ⚙️ Engine Specifications Primary Engine Engine Options: 2.2L EJ22E SOHC (135 hp @ 5600 rpm, 137 lb-ft @ 4400 rpm), 2.5L EJ25D DOHC (165 hp @ 6000 rpm, 162 lb-ft @ 4000 rpm), 2.5L EJ25T DOHC Turbo (208 hp @ 5500 rpm, 240 lb-ft @ 4000 rpm - GT/GT-B models) Performance Bore X Stroke: EJ22: 96.0 mm x 75.0 mm; EJ25: 99.5 mm x 79.0 mm Compression Ratio: EJ22: 9.5:1; EJ25D: 9.7:1; EJ25T: 8.5:1 Fuel System Injection Type: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded gasoline (87 octane minimum, higher recommended for Turbo) Maintenance Timing Belt Replacement: Every 60,000 to 105,000 miles or 4-7 years (refer to manual for specific intervals and conditions) 🔧 Transmission Standard Standard Transmission: 5-speed Manual Optional Optional Transmission: 4-speed Automatic with Sportshift (4EAT) Features AWD Engagement: Full-time Symmetrical All-Wheel Drive Fluid Specs Automatic Transmission Fluid: Subaru ATF HP or Dexron III (check manual for exact specification) Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 (check manual for exact specification) 📐 Dimensions Exterior Wheelbase: Approx. 104.3 inches (2649 mm) Length: Approx. 187.2 inches (4755 mm) Width: Approx. 69.7 inches (1770 mm) Height: Approx. 56.7 inches (1440 mm) Weights Curb Weight: Approx. 3000-3400 lbs (1360-1540 kg), depending on body style and trim Gross Vehicle Weight Rating: Approx. 4300-4600 lbs 🛡️ Safety Features Ratings NHTSA Frontal Crash: Not rated or 4-star (Varies by specific test year and configuration) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Not typically available as standard in this generation Passive Features Airbags: Driver and passenger front airbags Seatbelts: Three-point front and rear seatbelts, driver's pretensioner 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD or Cassette player, optional premium audio Navigation: Not available on most models, aftermarket options only Driver Assistance Cruise Control: Available on most trims 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 to 7,500 miles or 6 months, depending on driving conditions and oil type used (refer to manual) Engine Air Filter: Inspect every 15,000 miles, replace as needed (typically every 30,000 miles) Cabin Air Filter: Not typically equipped in this generation Fluid Specifications Engine Oil Type: SAE 5W-30 or 10W-30 (refer to manual for specific viscosity based on temperature) Coolant Type: Subaru Super Coolant (Blue) or equivalent ethylene glycol-based coolant with corrosion inhibitors Brake Fluid Type: DOT 3 or DOT 4 Power Steering Fluid: ATF Dexron III or Subaru Power Steering Fluid Known Issues Head Gaskets: Common issue, especially on EJ25D, leading to coolant leaks or internal coolant contamination. Early detection is crucial. Oil Leaks: Can occur from valve cover gaskets, oil pan gaskets, and front/rear main seals due to age and heat. Automatic Transmission: Some units can experience hesitant shifting...
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Subaru Legacy 1999 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy
Year:
1999
Codes
Chassis Codes:
BD, BG, BK, BH
Platform:
Subaru Second Generation Legacy Platform
👋 Introduction
Market Position
Segment:
Mid-size sedan and wagon, known for its AWD capabilities and practical design
Competitive Analysis
Competitors:
Toyota Camry, Honda Accord, Nissan Maxima, Mazda 626, Ford Taurus
Key Features
Differentiators:
Standard Symmetrical All-Wheel Drive, horizontally opposed ('Boxer') engine layout, robust build quality
📋 Manual Details
Coverage Areas
Service Scope:
Comprehensive mechanical and electrical service, repair, and maintenance
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF or similar electronic format)
📖 Manual Coverage
Systems Covered
Engine:
2.2L EJ22, 2.5L EJ25 (Naturally Aspirated and Turbocharged) - DOHC and SOHC variants
Transmission:
4-speed Automatic (4EAT), 5-speed Manual
Drivetrain:
All-Wheel Drive (AWD) system, differentials, driveshafts, CV joints
Suspension:
Front MacPherson struts, Rear multi-link, coil springs, shock absorbers, stabilizer bars
Brakes:
Front vented discs, Rear solid discs (or drums on some models), ABS system
Steering:
Power assisted rack and pinion
Fuel System:
Fuel injection, fuel pump, injectors, fuel tank, lines
Cooling System:
Radiator, coolant hoses, water pump, thermostat, cooling fan
Exhaust System:
Exhaust manifolds, catalytic converter, mufflers, pipes
Electrical System:
Battery, alternator, starter, ignition system, lighting, fuses, relays
Climate Control:
HVAC system, blower motor, heater core, A/C system components
Body And Interior:
Body panels, doors, windows, seats, trim, sound deadening
Diagnostics:
OBD-I and early OBD-II diagnostic procedures, fault code retrieval
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, tune-ups, fluid checks, tire rotation
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs
Troubleshooting:
Systematic diagnosis of common and uncommon faults with step-by-step guides
Component Replacement:
Detailed instructions for replacing nearly all mechanical and electrical components
Wiring Diagrams:
Complete electrical wiring schematics for all systems
Technical Depth
Depth:
Detailed specifications, torque values, clearances, diagnostic procedures, and overhaul instructions
📊 Manual Specifications
File Format
Searchability:
Likely searchable text for quick information retrieval
Print Quality
Illustrations:
High-quality diagrams, schematics, and exploded views
Binding Type
Binding:
N/A (assuming digital, but if printed, likely coil or perfect bound)
Paper Type
Paper:
N/A (assuming digital)
⚙️ Engine Specifications
Primary Engine
Engine Options:
2.2L EJ22E SOHC (135 hp @ 5600 rpm, 137 lb-ft @ 4400 rpm), 2.5L EJ25D DOHC (165 hp @ 6000 rpm, 162 lb-ft @ 4000 rpm), 2.5L EJ25T DOHC Turbo (208 hp @ 5500 rpm, 240 lb-ft @ 4000 rpm - GT/GT-B models)
Performance
Bore X Stroke:
EJ22: 96.0 mm x 75.0 mm; EJ25: 99.5 mm x 79.0 mm
Compression Ratio:
EJ22: 9.5:1; EJ25D: 9.7:1; EJ25T: 8.5:1
Fuel System
Injection Type:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (87 octane minimum, higher recommended for Turbo)
Maintenance
Timing Belt Replacement:
Every 60,000 to 105,000 miles or 4-7 years (refer to manual for specific intervals and conditions)
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual
Optional
Optional Transmission:
4-speed Automatic with Sportshift (4EAT)
Features
AWD Engagement:
Full-time Symmetrical All-Wheel Drive
Fluid Specs
Automatic Transmission Fluid:
Subaru ATF HP or Dexron III (check manual for exact specification)
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 (check manual for exact specification)
📐 Dimensions
Exterior
Wheelbase:
Approx. 104.3 inches (2649 mm)
Length:
Approx. 187.2 inches (4755 mm)
Width:
Approx. 69.7 inches (1770 mm)
Height:
Approx. 56.7 inches (1440 mm)
Weights
Curb Weight:
Approx. 3000-3400 lbs (1360-1540 kg), depending on body style and trim
Gross Vehicle Weight Rating:
Approx. 4300-4600 lbs
🛡️ Safety Features
Ratings
NHTSA Frontal Crash:
Not rated or 4-star (Varies by specific test year and configuration)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Not typically available as standard in this generation
Passive Features
Airbags:
Driver and passenger front airbags
Seatbelts:
Three-point front and rear seatbelts, driver's pretensioner
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD or Cassette player, optional premium audio
Navigation:
Not available on most models, aftermarket options only
Driver Assistance
Cruise Control:
Available on most trims
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 to 7,500 miles or 6 months, depending on driving conditions and oil type used (refer to manual)
Engine Air Filter:
Inspect every 15,000 miles, replace as needed (typically every 30,000 miles)
Cabin Air Filter:
Not typically equipped in this generation
Fluid Specifications
Engine Oil Type:
SAE 5W-30 or 10W-30 (refer to manual for specific viscosity based on temperature)
Coolant Type:
Subaru Super Coolant (Blue) or equivalent ethylene glycol-based coolant with corrosion inhibitors
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid:
ATF Dexron III or Subaru Power Steering Fluid
Known Issues
Head Gaskets:
Common issue, especially on EJ25D, leading to coolant leaks or internal coolant contamination. Early detection is crucial.
Oil Leaks:
Can occur from valve cover gaskets, oil pan gaskets, and front/rear main seals due to age and heat.
Automatic Transmission:
Some units can experience hesitant shifting or premature wear; regular fluid changes are vital.
Oxygen Sensors:
Can become fouled or fail over time, affecting fuel economy and emissions.
Cv Joint Boots:
Can degrade and tear, leading to grease loss and premature CV joint wear.
📚 Vehicle History
Brand Heritage
Manufacturer:
Fuji Heavy Industries (now Subaru Corporation)
Model Evolution
Generation:
Second Generation (1995-1999)
Body Styles:
4-door Sedan, 5-door Wagon (Outback Sport/Outback models)
Production
Production Years:
1995-1999
🏆 Awards & Recognition
Recognitions
Safety Awards:
Subaru vehicles generally received good safety ratings for their time, emphasizing AWD benefits.
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