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2004-2005 Subaru Legacy Workshop 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 Segment: Mid-size sedan and wagon, competing with vehicles like the Toyota Camry, Honda Accord, Mazda6 Differentiation: Standard Symmetrical All-Wheel Drive, boxer engine layout, reputation for reliability and safety Competitive Analysis Strengths: AWD capability in challenging weather, comfortable ride, spacious interior for its class Key Features Engine Layout: Horizontally opposed (Boxer) engines Drivetrain Layout: Standard Symmetrical All-Wheel Drive (AWD) on most models Body Styles: Sedan (BL) and Sport Wagon (BP) 📋 Manual Details Coverage Areas Vehicle Generations: Fifth Generation (BP/BL) Market Regions: North America (implied by product description context) Page Count Estimated Page Count: 1500+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, exhaust system, lubrication system, engine control system (ECU/ECM) Drivetrain: Transmission (manual & automatic), clutch, drive shafts, differentials, axles, AWD system (Symmetrical All-Wheel Drive) Chassis: Suspension (front & rear), steering system, braking system (ABS, EBD), wheels and tires Electrical: Starting & charging system, lighting, instruments & gauges, wipers & washers, HVAC controls, power accessories (windows, locks, mirrors), audio system, SRS (airbag) system, body control module (BCM) Body: Exterior body panels, interior trim, doors, hood, trunk, windows, seals, structural components Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, belt inspections and replacements Diagnostics: Troubleshooting guides, symptom-based diagnostics, DTC (Diagnostic Trouble Code) interpretation, wiring diagrams Repair: Component removal and installation, sub-assembly repair, seal and gasket replacement, part specification and torque values Special Procedures: Engine timing belt replacement, clutch replacement, brake bleeding, suspension alignment, airbag system servicing Technical Depth Diagnostic Capability: Advanced diagnostic procedures, including specific testing methods for sensors and actuators Rebuild Information: Detailed procedures for engine and transmission overhauls, including component specifications and tolerances Wiring Diagrams: Comprehensive electrical wiring diagrams for all vehicle systems, color-coded and clearly labeled 📊 Manual Specifications File Format Searchability: Fully searchable text for quick information retrieval Navigation: Hyperlinked table of contents and index for easy navigation Print Quality Resolution: High-resolution, suitable for clear printing of all diagrams and text Binding Type Type: N/A (Digital Format) Paper Type Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code 2 5I: EJ253 Engine Displacement 2 5I: 2.5 Liters (2457 cc) Engine Cylinders 2 5I: 4 Engine Configuration 2 5I: Naturally Aspirated, Boxer Horsepower 2 5I: 168 hp @ 5600 rpm Torque 2 5I: 166 lb-ft @ 4000 rpm Engine Variants Engine Code Gt: EJ255 Engine Displacement Gt: 2.5 Liters (2457 cc) Engine Configuration Gt: Turbocharged, Boxer Horsepower Gt: 250 hp @ 6000 rpm Torque Gt: 250 lb-ft @ 3600 rpm Performance Fuel Type: Unleaded gasoline Fuel System Induction: Electronic Port Fuel Injection (MPI) Turbocharger Gt: IHI VF38 (or similar) 🔧 Transmission Standard Type 2 5I: 5-speed Manual Transmission Type Gt: 6-speed Manual Transmission Optional Type 2 5I: 4-speed Automatic Transmission (with Sportshift) Type Gt: 5-speed Automatic Transmission (with Sportshift) Features AWD System Type: Symmetrical All-Wheel Drive (with viscous coupling center differential for manual, electronic control for automatic) Clutch Type: Hydraulically operated, single dry plate 📐 Dimensions Exterior Wheelbase Sedan: 104.0 inches (2642 mm) Wheelbase Wagon: 104.3 inches (2649 mm) Length Sedan: 189.2 inches (4806 mm) Length Wagon: 189.0 inches (4800 mm) Width: 69.1 inches (1755 mm) Height Sedan: 56.7 inches (1440 mm) Height Wagon: 57.1 inches (1450 mm) Interior Passenger Volume: Approx. 96.0 cu ft (Sedan), 98.0 cu ft (Wagon) Cargo Cargo Volume Sedan: Approx. 14.7 cu ft Cargo Volume Wagon: Approx. 31.7 cu ft (behind rear seats), 67.0 cu ft (with rear seats folded) Weights Curb Weight 2 5I Sedan Manual: 3270 lbs (1483 kg) Curb Weight Gt Sedan Manual: 3445 lbs (1563 kg) Wheel Bolt Pattern: 5 x 100 mm Tire Size 2 5I Standard: 205/55R16 Tire Size Gt Standard: 215/45R17 🛡️ Safety Features Ratings NHTSA Frontal Driver 2004: 5 Stars NHTSA Frontal Passenger 2004: 5 Stars IIHS Frontal Offset 2004: Good Active Features ABS: Standard (Anti-lock Braking System) Ebd: Standard (Electronic Brake-force Distribution) Traction Control: Available (TCS) on some models Stability Control: Available (VDC - Vehicle Dynamics Control) on some models Passive Features Airbags: Frontal airbags, front side-impact airbags (standard on many trims), available side curtain airbags Seatbelts: 3-point seatbelts with pretensioners and load limiters, LATCH system for child seats 💡 Technology Features Infotainment Audio System: Standard AM/FM/CD player, optional premium audio systems with subwoofer, available navigation system on higher trims/optional. Driver Assistance Cruise Control: Standard electronic cruise control Keyless Entry: Available keyless entry and remote start systems Connectivity Auxiliary Input: Not standard; some later models or aftermarket units may feature auxiliary audio input or USB ports. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 miles or 6 months (severe service) / 7,500...
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2004-2005 Subaru Legacy Workshop 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
Segment:
Mid-size sedan and wagon, competing with vehicles like the Toyota Camry, Honda Accord, Mazda6
Differentiation:
Standard Symmetrical All-Wheel Drive, boxer engine layout, reputation for reliability and safety
Competitive Analysis
Strengths:
AWD capability in challenging weather, comfortable ride, spacious interior for its class
Key Features
Engine Layout:
Horizontally opposed (Boxer) engines
Drivetrain Layout:
Standard Symmetrical All-Wheel Drive (AWD) on most models
Body Styles:
Sedan (BL) and Sport Wagon (BP)
📋 Manual Details
Coverage Areas
Vehicle Generations:
Fifth Generation (BP/BL)
Market Regions:
North America (implied by product description context)
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, cooling system, exhaust system, lubrication system, engine control system (ECU/ECM)
Drivetrain:
Transmission (manual & automatic), clutch, drive shafts, differentials, axles, AWD system (Symmetrical All-Wheel Drive)
Chassis:
Suspension (front & rear), steering system, braking system (ABS, EBD), wheels and tires
Electrical:
Starting & charging system, lighting, instruments & gauges, wipers & washers, HVAC controls, power accessories (windows, locks, mirrors), audio system, SRS (airbag) system, body control module (BCM)
Body:
Exterior body panels, interior trim, doors, hood, trunk, windows, seals, structural components
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, belt inspections and replacements
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, DTC (Diagnostic Trouble Code) interpretation, wiring diagrams
Repair:
Component removal and installation, sub-assembly repair, seal and gasket replacement, part specification and torque values
Special Procedures:
Engine timing belt replacement, clutch replacement, brake bleeding, suspension alignment, airbag system servicing
Technical Depth
Diagnostic Capability:
Advanced diagnostic procedures, including specific testing methods for sensors and actuators
Rebuild Information:
Detailed procedures for engine and transmission overhauls, including component specifications and tolerances
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all vehicle systems, color-coded and clearly labeled
📊 Manual Specifications
File Format
Searchability:
Fully searchable text for quick information retrieval
Navigation:
Hyperlinked table of contents and index for easy navigation
Print Quality
Resolution:
High-resolution, suitable for clear printing of all diagrams and text
Binding Type
Type:
N/A (Digital Format)
Paper Type
Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code 2 5I:
EJ253
Engine Displacement 2 5I:
2.5 Liters (2457 cc)
Engine Cylinders 2 5I:
4
Engine Configuration 2 5I:
Naturally Aspirated, Boxer
Horsepower 2 5I:
168 hp @ 5600 rpm
Torque 2 5I:
166 lb-ft @ 4000 rpm
Engine Variants
Engine Code Gt:
EJ255
Engine Displacement Gt:
2.5 Liters (2457 cc)
Engine Configuration Gt:
Turbocharged, Boxer
Horsepower Gt:
250 hp @ 6000 rpm
Torque Gt:
250 lb-ft @ 3600 rpm
Performance
Fuel Type:
Unleaded gasoline
Fuel System
Induction:
Electronic Port Fuel Injection (MPI)
Turbocharger Gt:
IHI VF38 (or similar)
🔧 Transmission
Standard
Type 2 5I:
5-speed Manual Transmission
Type Gt:
6-speed Manual Transmission
Optional
Type 2 5I:
4-speed Automatic Transmission (with Sportshift)
Type Gt:
5-speed Automatic Transmission (with Sportshift)
Features
AWD System Type:
Symmetrical All-Wheel Drive (with viscous coupling center differential for manual, electronic control for automatic)
Clutch Type:
Hydraulically operated, single dry plate
📐 Dimensions
Exterior
Wheelbase Sedan:
104.0 inches (2642 mm)
Wheelbase Wagon:
104.3 inches (2649 mm)
Length Sedan:
189.2 inches (4806 mm)
Length Wagon:
189.0 inches (4800 mm)
Width:
69.1 inches (1755 mm)
Height Sedan:
56.7 inches (1440 mm)
Height Wagon:
57.1 inches (1450 mm)
Interior
Passenger Volume:
Approx. 96.0 cu ft (Sedan), 98.0 cu ft (Wagon)
Cargo
Cargo Volume Sedan:
Approx. 14.7 cu ft
Cargo Volume Wagon:
Approx. 31.7 cu ft (behind rear seats), 67.0 cu ft (with rear seats folded)
Weights
Curb Weight 2 5I Sedan Manual:
3270 lbs (1483 kg)
Curb Weight Gt Sedan Manual:
3445 lbs (1563 kg)
Wheel Bolt Pattern:
5 x 100 mm
Tire Size 2 5I Standard:
205/55R16
Tire Size Gt Standard:
215/45R17
🛡️ Safety Features
Ratings
NHTSA Frontal Driver 2004:
5 Stars
NHTSA Frontal Passenger 2004:
5 Stars
IIHS Frontal Offset 2004:
Good
Active Features
ABS:
Standard (Anti-lock Braking System)
Ebd:
Standard (Electronic Brake-force Distribution)
Traction Control:
Available (TCS) on some models
Stability Control:
Available (VDC - Vehicle Dynamics Control) on some models
Passive Features
Airbags:
Frontal airbags, front side-impact airbags (standard on many trims), available side curtain airbags
Seatbelts:
3-point seatbelts with pretensioners and load limiters, LATCH system for child seats
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player, optional premium audio systems with subwoofer, available navigation system on higher trims/optional.
Driver Assistance
Cruise Control:
Standard electronic cruise control
Keyless Entry:
Available keyless entry and remote start systems
Connectivity
Auxiliary Input:
Not standard; some later models or aftermarket units may feature auxiliary audio input or USB ports.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 6 months (severe service) / 7,500 miles or 12 months (normal service), consult manual for exact details.
Engine Oil Type:
5W-30 (SAE viscosity grade), API certified, SYNTHETIC RECOMMENDED
Engine Oil Capacity 2 5I:
4.8 US quarts (4.5 liters) with filter change
Engine Oil Capacity Gt:
4.8 US quarts (4.5 liters) with filter change
Engine Oil Filter Part Number Example:
Subaru 15208AA031 (verify with VIN)
Transmission Fluid Type Manual:
GL-5 Gear Oil, SAE 75W-90 (refer to manual for specific Subaru specs)
Transmission Fluid Type Automatic:
Subaru ATF-HP (High Performance) Automatic Transmission Fluid (verify with VIN)
Coolant Type:
Subaru Super Coolant (Blue) or equivalent ethylene glycol-based coolant with Subaru additive
Coolant Capacity:
Approx. 7.6 US quarts (7.2 liters)
Timing Belt Replacement Interval:
Every 105,000 miles or 105 months (critical for interference engine)
Known Issues
Head Gaskets:
While less prevalent than earlier generations, some reports of external oil leaks from head gaskets exist, particularly on higher mileage vehicles. Internal coolant leaks are less common in this generation but still a possibility.
Turbocharger Gt:
Early turbo failures on GT models could occur due to oil starvation or neglect; proper maintenance is crucial.
Catalytic Converter:
Premature failure of the catalytic converter on some models, often due to misfires or rich fuel conditions.
Suspension Components:
Wear and tear on control arm bushings, sway bar links, and struts are common with age and mileage.
Automatic Transmission Behavior:
Some owners report slightly harsh shifts or occasional hesitations, which may be addressed by fluid changes and adaptive relearning procedures.
📚 Vehicle History
Brand Heritage
Subaru Heritage:
Subaru (part of Fuji Heavy Industries) has a history of producing innovative vehicles, known for their boxer engines and Symmetrical All-Wheel Drive systems since the 1970s.
Model Evolution
Legacy Introduction:
The Subaru Legacy was introduced in 1989 as a replacement for the Subaru Leone.
Bp Bl Generation:
The 2004-2005 models represent the fifth generation of the Subaru Legacy, codenamed BP for the wagon and BL for the sedan.
Key Changes Fifth Gen:
This generation saw a significant redesign with a more refined exterior and interior, improved chassis dynamics, and the introduction of the more powerful GT models.
Production
Manufacturing Location:
Gunma Plant, Japan
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick:
The 2004 Subaru Legacy models generally performed well in IIHS tests, earning 'Good' ratings for frontal offset impacts.
Consumer Reports Ratings:
Consumer Reports typically rated the Legacy favorably for its AWD system, ride comfort, and handling, though some model years had average or below-average predicted reliability for certain components.
Certifications
Emission Standards:
Meets EPA and CARB emission standards for its model years.
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