1990-1994 Subaru Liberty-Legacy Service Repair Manual
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๐ท๏ธ Basic Information Identification Make: Subaru Model: Liberty / Legacy Model Generation: Second Generation (BD/BG/BK/BJ) Applicable Years: 1990, 1991, 1992, 1993, 1994 Codes Chassis Codes: BD (Sedan), BG (Wagon), BK (GT Wagon - Japan), BJ (Outback - North America) ๐ Introduction Market Position Market Position: Compact/Mid-size family car known for its Symmetrical All-Wheel Drive system, practicality, and robust engineering. Competed against vehicles like the Toyota Camry, Honda Accord, and Mazda 626. Competitive Analysis Competitive Analysis: The second-generation Liberty/Legacy solidified Subaru's reputation for AWD capability in adverse weather conditions, a significant differentiator. Its boxer engine layout offered a low center of gravity, enhancing handling. Key Features Key Features: Standard Symmetrical AWD, horizontally-opposed 'boxer' engines, comfortable ride, spacious interior (especially wagon), durable build quality, optional turbocharging (GT models). ๐ Manual Details Coverage Areas Coverage Areas: Global markets (primarily Australia, North America, Japan, Europe) Page Count Page Count: Estimated 1000+ pages (comprehensive) Manual Type Manual Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Format: PDF ๐ Manual Coverage Systems Covered Systems Covered: Engine (EJ20, EJ22, EJ25, EJ22E, EJ25D), Automatic & Manual Transmissions (4EAT, 5MT/4MT), Drivetrain (Symmetrical AWD System, Viscous Coupling Centre Differential), Suspension (Front McPherson Strut, Rear Multi-link), Brakes (Front Ventilated Discs, Rear Discs/Drums), Steering (Power Rack and Pinion), Fuel System (EFI), Cooling System, Exhaust System, Electrical System (12V, Battery, Alternator, Starter, ECU), HVAC System, Body & Chassis, Restraints (SRS Airbag - early systems), Exterior & Interior Trim Procedures Included Procedures Included: Scheduled Maintenance, Routine Inspections, Diagnostics (troubleshooting charts), Component Removal & Installation, Reassembly & Adjustment, Torque Specifications, Wiring Diagrams, Fluid Capacities & Specifications, Engine Rebuilding Procedures, Transmission Overhaul, Brake Service, Suspension Component Replacement, Steering System Repairs, HVAC Service, Bodywork Repair, Electrical Component Testing & Replacement Technical Depth Technical Depth: Comprehensive: Covers basic maintenance to full engine/transmission rebuilds, detailed diagnostic procedures, and electrical system tracing. Suitable for professional mechanics and advanced DIY enthusiasts. ๐ Manual Specifications File Format File Format: Searchable PDF, high-resolution scans Print Quality Print Quality: Optimized for printing, clear diagrams and text Binding Type Binding Type: N/A (CD-ROM Delivery) Paper Type Paper Type: N/A (Digital Format) โ๏ธ Engine Specifications Primary Engine Primary Engine: EJ22E SOHC 16-valve flat-four Performance Engine Variants: 2.0L EJ20 (DOHC, SOHC, Turbo), 2.2L EJ22 (SOHC), 2.5L EJ25D (DOHC, EJ25 Twin-Cam) Horsepower Range: 130-165 hp (Naturally Aspirated), 220-250 hp (Turbocharged GT models) Torque Range: 137-145 lb-ft (Naturally Aspirated), 230-270 lb-ft (Turbocharged GT models) Fuel System Fuel System: Electronic Fuel Injection (EFI), Multi-point Fuel Injection (MPI) Engine Management Engine Management: ECU controlled ignition and fuel injection timing ๐ง Transmission Standard Standard Transmission: 5-Speed Manual Transmission (4WD) Optional Optional Transmission: 4-Speed Automatic Transmission with Lock-up Torque Converter (4EAT - AWD) Features Transmission Features: Full-time Symmetrical All-Wheel Drive with viscous coupling center differential, optional limited-slip rear differential (GT models). Fluid Specs Manual Transmission Fluid: API GL-5, SAE 75W-90 (typically) Automatic Transmission Fluid: Subaru ATF-HP or equivalent DEXRON-III (check specific model year for exact spec) ๐ Dimensions Exterior Wheelbase: 2625 mm (103.3 in) Length: Sedan: 4635 mm (182.5 in), Wagon: 4710 mm (185.4 in) Width: 1730 mm (68.1 in) Height: Sedan: 1410 mm (55.5 in), Wagon: 1470 mm (57.9 in) Weights Curb Weight: Approx. 1350-1550 kg (2976-3417 lbs) ๐ก๏ธ Safety Features Ratings Safety Ratings: Refer to NHTSA/IIHS for specific year/model data; typically performed well for its era in frontal impacts. Active Features Active Features: All-Wheel Drive (standard), ABS (Anti-lock Braking System) often optional or standard on higher trims. Passive Features Passive Features: Front airbags (driver and passenger, often standard on later models), seatbelt pretensioners, crumple zones. ๐ก Technology Features Infotainment Infotainment Features: Basic AM/FM/Cassette stereo system, optional CD player. Manual tuning, basic speaker configuration. Driver Assistance Driver Assistance Features: Limited. ABS was optional. Cruise control often available. Connectivity Connectivity Features: N/A (No advanced connectivity options typical of modern vehicles) ๐ง Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first. Refer to manual for specific recommendations based on driving conditions. Spark Plug Replacement: Approx. 60,000-100,000 miles (depends on plug type - copper vs. platinum) Timing Belt Replacement: Critical. Every 60,000-90,000 miles (96,000-144,000 km) or 5-7 years. Failure leads to catastrophic engine damage. Includes idler pulleys and tensioner. Fluid Specifications Engine Oil Type: API SG or SH, SAE 10W-30 or 10W-40 (check owner's manual for exact viscosity and specification) Coolant Type: Subaru Super Coolant (blue) or equivalent ethylene glycol-based coolant, mixed 50/50 with distilled water. Brake Fluid Type: DOT 3 or DOT 4 Known Issues Known Issues: Head gasket leaks (especially EJ25D engines), radiator leaks, power steering pump leaks, AC compressor failures, O2 sensor failures, minor electrical gremlins, strut mount wear. Common Wear Items: Brake pads and rotors, exhaust system components, suspension bushings, CV joint boots. ๐ Vehicle History Brand Heritage Brand Heritage: Subaru, a division of Fuji Heavy Industries, has a...
BD (Sedan), BG (Wagon), BK (GT Wagon - Japan), BJ (Outback - North America)
๐ Introduction
Market Position
Market Position:
Compact/Mid-size family car known for its Symmetrical All-Wheel Drive system, practicality, and robust engineering. Competed against vehicles like the Toyota Camry, Honda Accord, and Mazda 626.
Competitive Analysis
Competitive Analysis:
The second-generation Liberty/Legacy solidified Subaru's reputation for AWD capability in adverse weather conditions, a significant differentiator. Its boxer engine layout offered a low center of gravity, enhancing handling.
Comprehensive: Covers basic maintenance to full engine/transmission rebuilds, detailed diagnostic procedures, and electrical system tracing. Suitable for professional mechanics and advanced DIY enthusiasts.
4-Speed Automatic Transmission with Lock-up Torque Converter (4EAT - AWD)
Features
Transmission Features:
Full-time Symmetrical All-Wheel Drive with viscous coupling center differential, optional limited-slip rear differential (GT models).
Fluid Specs
Manual Transmission Fluid:
API GL-5, SAE 75W-90 (typically)
Automatic Transmission Fluid:
Subaru ATF-HP or equivalent DEXRON-III (check specific model year for exact spec)
๐ Dimensions
Exterior
Wheelbase:
2625 mm (103.3 in)
Length:
Sedan: 4635 mm (182.5 in), Wagon: 4710 mm (185.4 in)
Width:
1730 mm (68.1 in)
Height:
Sedan: 1410 mm (55.5 in), Wagon: 1470 mm (57.9 in)
Weights
Curb Weight:
Approx. 1350-1550 kg (2976-3417 lbs)
๐ก๏ธ Safety Features
Ratings
Safety Ratings:
Refer to NHTSA/IIHS for specific year/model data; typically performed well for its era in frontal impacts.
Active Features
Active Features:
All-Wheel Drive (standard), ABS (Anti-lock Braking System) often optional or standard on higher trims.
Passive Features
Passive Features:
Front airbags (driver and passenger, often standard on later models), seatbelt pretensioners, crumple zones.
๐ก Technology Features
Infotainment
Infotainment Features:
Basic AM/FM/Cassette stereo system, optional CD player. Manual tuning, basic speaker configuration.
Driver Assistance
Driver Assistance Features:
Limited. ABS was optional. Cruise control often available.
Connectivity
Connectivity Features:
N/A (No advanced connectivity options typical of modern vehicles)
๐ง Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first. Refer to manual for specific recommendations based on driving conditions.
Spark Plug Replacement:
Approx. 60,000-100,000 miles (depends on plug type - copper vs. platinum)
Timing Belt Replacement:
Critical. Every 60,000-90,000 miles (96,000-144,000 km) or 5-7 years. Failure leads to catastrophic engine damage. Includes idler pulleys and tensioner.
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 10W-30 or 10W-40 (check owner's manual for exact viscosity and specification)
Coolant Type:
Subaru Super Coolant (blue) or equivalent ethylene glycol-based coolant, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Known Issues:
Head gasket leaks (especially EJ25D engines), radiator leaks, power steering pump leaks, AC compressor failures, O2 sensor failures, minor electrical gremlins, strut mount wear.
Common Wear Items:
Brake pads and rotors, exhaust system components, suspension bushings, CV joint boots.
๐ Vehicle History
Brand Heritage
Brand Heritage:
Subaru, a division of Fuji Heavy Industries, has a long history in aviation and automotive manufacturing. Known for its distinctive boxer engines and Symmetrical All-Wheel Drive systems.
Model Evolution
Model Evolution:
The Liberty/Legacy replaced the Subaru Leone. The second generation (BD/BG) introduced more aerodynamic styling, improved interior comfort, and enhanced performance features, including turbocharging and updated AWD systems.
Production
Production Locations:
Japan (Gunma Manufacturing Plant)
Production Years Generation:
1993-1999 (This manual covers the early years of this generation)
๐ Awards & Recognition
Recognitions
Recognitions:
The second-generation Legacy received praise for its AWD system and build quality. While specific awards for this exact year range might be scattered, the model line consistently performed well in comparison tests for its class, especially in inclement weather.