Download (51 MB) 2000 Subaru Legacy Original Factory Service Manual(FSM) / Repair Manual / Workshop Manual 00 (ZIP - PDF Format)

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 2000 Codes Chassis Code: BD/BG/BK Platform: Subaru Second Generation Legacy Platform 👋 Introduction Market Position Segment: Mid-size sedan and wagon, known for its standard All-Wheel Drive and boxer engine configuration Competitive Analysis Competitors: Toyota Camry, Honda Accord, Nissan Altima, Ford Taurus, Chevrolet Malibu, Volkswagen Passat Key Features Drivetrain Advantage: Symmetrical All-Wheel Drive as standard across most trims, providing superior traction and stability Engine Layout: Horizontally opposed (boxer) engine, contributing to a lower center of gravity and balanced handling Body Styles: Offered as a 4-door sedan and a 5-door wagon (Outback variant in later stages of this generation) Target Audience Demographic: Drivers seeking dependable, all-weather capability, often in regions with variable weather conditions 📋 Manual Details Coverage Areas Regions Covered: Global (primarily North American specification for detailed data, but covers core mechanicals applicable worldwide) Page Count Estimated Page Count: Approximately 1800-2500 pages (typical for FSMs of this era, actual count may vary based on specific engine/trim distribution within the file) Manual Type Type: Factory Service Manual (FSM) / Repair Manual / Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: 2.5L EJ25D (SOHC), 2.5L EJ251 (DOHC, Phase II), 2.2L EJ22E (SOHC - less common for 2000 model year in many markets, but FSM likely includes for broader coverage) Fuel System: EFI (Electronic Fuel Injection), fuel pump, injectors, pressure regulator, EVAP system Ignition System: Distributorless Ignition System (DIS) / Coil-on-plug (depending on engine variant), spark plugs, ignition coils, timing Cooling System: Radiator, coolant hoses, thermostat, water pump, cooling fan control Exhaust System: Manifolds, catalytic converter, mufflers, oxygen sensors Transmission Automatic: 4-speed automatic (4EAT), hydraulic control, valve body, torque converter, fluid specifications, troubleshooting Transmission Manual: 5-speed manual (all-wheel drive standard), clutch system, gear ratios, lubrication, troubleshooting Drivetrain: Symmetrical All-Wheel Drive (AWD) system, front/rear differentials, viscous coupling, driveshafts, CV joints Suspension: Front MacPherson struts, rear multi-link, springs, shock absorbers, control arms, stabilizer bars, alignment specifications Steering: Power-assisted rack and pinion, steering column, steering linkage Brakes: Front vented discs, rear discs, ABS (Anti-lock Braking System) components, hydraulic lines, master cylinder, brake pads, rotors Body Chassis: Frame structure, body panels, doors, hood, trunk, glass, seals, corrosion protection HVAC: Air conditioning system, heater core, blower motor, climate controls, refrigerant handling Electrical System: 12V battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting (headlights, taillights, interior) ECU PCM: Engine Control Unit (ECU) / Powertrain Control Module (PCM) functions, diagnostic trouble codes (DTCs), sensor inputs/outputs Instrument Panel: Gauges (speedometer, tachometer, fuel, temp), warning lights, odometer, trip computer Safety Systems: Airbags (SRS - Supplemental Restraint System), seat belts, ABS Procedures Included General Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspection, belt inspection/replacement Engine Overhaul: Engine disassembly, cleaning, inspection, machining specifications, reassembly, torque sequences, timing belt replacement (if applicable), head gasket replacement Transmission Repair: Automatic transmission overhaul (valve body, clutch packs, seals), manual transmission rebuild (gears, bearings, synchros) Drivetrain Service: Differential fluid changes, CV axle replacement, AWD system component service Suspension Steering Service: Shock/strut replacement, ball joint and tie rod end replacement, power steering pump and rack service, wheel bearing replacement Brake System Service: Brake pad and rotor replacement, caliper service, brake bleeding, ABS component diagnosis and replacement Electrical Diagnosis: Troubleshooting electrical faults using wiring diagrams, component testing, sensor diagnostics HVAC Service: Refrigerant handling and recharging, A/C compressor replacement, heater core replacement, evaporator service Bodywork Repair: Panel removal and installation, glass replacement, bumper repair, door mechanism adjustment Diagnostic Troubleshooting: System-by-system troubleshooting guides, symptom-based diagnostic trees, diagnostic trouble codes (DTCs) interpretation and resolution Torque Specifications: Detailed torque values for all major fasteners and components Technical Depth Depth: Comprehensive (covers everything from basic maintenance to complete engine and transmission rebuilds) Diagnostics: Advanced electronic diagnostics with specific procedures for sensor testing and ECU troubleshooting Wiring Diagrams: Detailed, system-specific wiring diagrams with pinouts and wire colors Emissions Controls: Detailed information on emission control systems, components, and diagnosis Special Tools: Lists and descriptions of required special Subaru tools for specific procedures 📊 Manual Specifications File Format Format: ZIP (containing PDF files) File Size: 51 MB Print Quality Quality: High-resolution scans suitable for clear viewing and printing Searchability: Likely text-searchable PDF content (assuming OCR was applied to original scans) Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: EJ25D (Phase I SOHC) Engine Type: 2.5L Boxer-4 SOHC Displacement: 2457 cc (2.5 Liters) Bore X Stroke: 99.5 mm x 79.0 mm Compression Ratio: 9.5:1 Horsepower: 165 hp @ 5,500 rpm Torque: 184 lb-ft @ 4,000 rpm Alternative Engine Engine Code: EJ251 (Phase II DOHC) Engine Type: 2.5L Boxer-4 DOHC Displacement: 2457 cc (2.5 Liters) Compression Ratio: 10.0:1 Horsepower: 165 hp @ 5,500 rpm (slight increase in mid-range torque often noted) Torque: 184 lb-ft @ 4,000 rpm Fuel System Injection...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy

Year:

Codes

Chassis Code:

BD/BG/BK

Platform:

Subaru Second Generation Legacy Platform

👋 Introduction

Market Position

Segment:

Mid-size sedan and wagon, known for its standard All-Wheel Drive and boxer engine configuration

Competitive Analysis

Competitors:

Toyota Camry, Honda Accord, Nissan Altima, Ford Taurus, Chevrolet Malibu, Volkswagen Passat

Key Features

Drivetrain Advantage:

Symmetrical All-Wheel Drive as standard across most trims, providing superior traction and stability

Engine Layout:

Horizontally opposed (boxer) engine, contributing to a lower center of gravity and balanced handling

Body Styles:

Offered as a 4-door sedan and a 5-door wagon (Outback variant in later stages of this generation)

Target Audience

Demographic:

Drivers seeking dependable, all-weather capability, often in regions with variable weather conditions

📋 Manual Details

Coverage Areas

Regions Covered:

Global (primarily North American specification for detailed data, but covers core mechanicals applicable worldwide)

Page Count

Estimated Page Count:

Approximately 1800-2500 pages (typical for FSMs of this era, actual count may vary based on specific engine/trim distribution within the file)

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual / Workshop Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

2.5L EJ25D (SOHC), 2.5L EJ251 (DOHC, Phase II), 2.2L EJ22E (SOHC - less common for 2000 model year in many markets, but FSM likely includes for broader coverage)

Fuel System:

EFI (Electronic Fuel Injection), fuel pump, injectors, pressure regulator, EVAP system

Ignition System:

Distributorless Ignition System (DIS) / Coil-on-plug (depending on engine variant), spark plugs, ignition coils, timing

Cooling System:

Radiator, coolant hoses, thermostat, water pump, cooling fan control

Exhaust System:

Manifolds, catalytic converter, mufflers, oxygen sensors

Transmission Automatic:

4-speed automatic (4EAT), hydraulic control, valve body, torque converter, fluid specifications, troubleshooting

Transmission Manual:

5-speed manual (all-wheel drive standard), clutch system, gear ratios, lubrication, troubleshooting

Drivetrain:

Symmetrical All-Wheel Drive (AWD) system, front/rear differentials, viscous coupling, driveshafts, CV joints

Suspension:

Front MacPherson struts, rear multi-link, springs, shock absorbers, control arms, stabilizer bars, alignment specifications

Steering:

Power-assisted rack and pinion, steering column, steering linkage

Brakes:

Front vented discs, rear discs, ABS (Anti-lock Braking System) components, hydraulic lines, master cylinder, brake pads, rotors

Body Chassis:

Frame structure, body panels, doors, hood, trunk, glass, seals, corrosion protection

HVAC:

Air conditioning system, heater core, blower motor, climate controls, refrigerant handling

Electrical System:

12V battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting (headlights, taillights, interior)

ECU PCM:

Engine Control Unit (ECU) / Powertrain Control Module (PCM) functions, diagnostic trouble codes (DTCs), sensor inputs/outputs

Instrument Panel:

Gauges (speedometer, tachometer, fuel, temp), warning lights, odometer, trip computer

Safety Systems:

Airbags (SRS - Supplemental Restraint System), seat belts, ABS

Procedures Included

General Maintenance:

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

Engine Overhaul:

Engine disassembly, cleaning, inspection, machining specifications, reassembly, torque sequences, timing belt replacement (if applicable), head gasket replacement

Transmission Repair:

Automatic transmission overhaul (valve body, clutch packs, seals), manual transmission rebuild (gears, bearings, synchros)

Drivetrain Service:

Differential fluid changes, CV axle replacement, AWD system component service

Suspension Steering Service:

Shock/strut replacement, ball joint and tie rod end replacement, power steering pump and rack service, wheel bearing replacement

Brake System Service:

Brake pad and rotor replacement, caliper service, brake bleeding, ABS component diagnosis and replacement

Electrical Diagnosis:

Troubleshooting electrical faults using wiring diagrams, component testing, sensor diagnostics

HVAC Service:

Refrigerant handling and recharging, A/C compressor replacement, heater core replacement, evaporator service

Bodywork Repair:

Panel removal and installation, glass replacement, bumper repair, door mechanism adjustment

Diagnostic Troubleshooting:

System-by-system troubleshooting guides, symptom-based diagnostic trees, diagnostic trouble codes (DTCs) interpretation and resolution

Torque Specifications:

Detailed torque values for all major fasteners and components

Technical Depth

Depth:

Comprehensive (covers everything from basic maintenance to complete engine and transmission rebuilds)

Diagnostics:

Advanced electronic diagnostics with specific procedures for sensor testing and ECU troubleshooting

Wiring Diagrams:

Detailed, system-specific wiring diagrams with pinouts and wire colors

Emissions Controls:

Detailed information on emission control systems, components, and diagnosis

Special Tools:

Lists and descriptions of required special Subaru tools for specific procedures

📊 Manual Specifications

File Format

Format:

ZIP (containing PDF files)

File Size:

51 MB

Print Quality

Quality:

High-resolution scans suitable for clear viewing and printing

Searchability:

Likely text-searchable PDF content (assuming OCR was applied to original scans)

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

EJ25D (Phase I SOHC)

Engine Type:

2.5L Boxer-4 SOHC

Displacement:

2457 cc (2.5 Liters)

Bore X Stroke:

99.5 mm x 79.0 mm

Compression Ratio:

9.5:1

Horsepower:

165 hp @ 5,500 rpm

Torque:

184 lb-ft @ 4,000 rpm

Alternative Engine

Engine Code:

EJ251 (Phase II DOHC)

Engine Type:

2.5L Boxer-4 DOHC

Displacement:

2457 cc (2.5 Liters)

Compression Ratio:

10.0:1

Horsepower:

165 hp @ 5,500 rpm (slight increase in mid-range torque often noted)

Torque:

184 lb-ft @ 4,000 rpm

Fuel System

Injection Type:

Multi-point Electronic Fuel Injection (MPI-EFI)

Fuel Type:

Unleaded Gasoline (87 octane recommended, 91 octane for optimal performance)

Engine Management

ECU Type:

Subaru proprietary ECU with OBD-II diagnostics

🔧 Transmission

Standard

Type:

5-speed Manual Transmission (all-wheel drive standard)

Optional

Type:

4-speed Automatic Transmission (4EAT) with electronically controlled AWD

Features

AWD System:

Active All-Wheel Drive System (mechanical center differential with viscous coupling on manual; electronically controlled clutch pack on automatic)

Gear Ratios Manual:

Refer to FSM for specific ratios (typically around 3.55:1 for 1st, 2.50:1 for 2nd, 1.77:1 for 3rd, 1.25:1 for 4th, 0.92:1 for 5th, 4.11:1 final drive)

Fluid Specs

Manual Transmission Fluid:

GL-5 75W-90 Synthetic Gear Oil (Subaru Extra-S or equivalent)

Automatic Transmission Fluid:

Subaru ATF (Genuine Subaru or equivalent meeting spec)

📐 Dimensions

Exterior

Length:

4600 mm (181.1 in)

Width:

1730 mm (68.1 in)

Height:

1440 mm (56.7 in) (Sedan) / 1470 mm (57.9 in) (Wagon)

Wheelbase:

2630 mm (103.5 in)

Front Track:

1480 mm (58.3 in)

Rear Track:

1475 mm (58.1 in)

Weights

Curb Weight:

Approx. 1450-1550 kg (3200-3400 lbs) depending on trim and transmission

Gross Vehicle Weight Rating:

Refer to vehicle VIN plate or FSM for exact GVWR

Cargo

Trunk Volume Sedan:

Approx. 0.39 m³ (13.8 cu ft)

Cargo Volume Wagon:

Approx. 0.73 m³ (25.9 cu ft) (with rear seats up) / 1.73 m³ (61.2 cu ft) (with rear seats folded)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4 Stars (Driver), 4 Stars (Passenger) for 2000 Model Year (US Spec)

IIHS Side Impact:

Good (for models equipped with side airbags, though less common for this year)

Active Features

Standard (4-wheel Anti-lock Braking System)

Standard Symmetrical All-Wheel Drive

Passive Features

Airbags:

Standard front driver and passenger airbags. Optional side airbags (less common).

Seat Belts:

Three-point inertia-reel seat belts with pretensioners (front)

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system in rear seats (introduced in late production models or specific markets)

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional cassette player. Speaker configurations vary by trim. Standard 4 or 6 speaker systems.

Navigation:

Not available on any trim for the 2000 model year.

Driver Assistance

Cruise Control:

Standard on most trims.

Traction Control:

Not typically available on this model year.

Connectivity

Bluetooth:

Not available.

Usb Ports:

Not available.

Other Features

Power Windows Locks:

Standard on most trims, manual windows/locks on base models.

Keyless Entry:

Optional on higher trim levels.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 3 months (whichever comes first) under normal driving conditions; 3,000 miles or 3 months under severe driving conditions. Refer to FSM for specific definitions.

Air Filter Replacement:

Every 15,000 miles or 12 months. Inspect more frequently.

Cabin Air Filter Replacement:

Not standard on all trims; if equipped, every 15,000 miles or 12 months.

Spark Plug Replacement:

Platinum tipped plugs: 60,000 miles. Standard plugs (less common): 30,000 miles. Refer to FSM for specific plug type.

Coolant Replacement:

First change at 30,000 miles or 24 months. Subsequent changes at 30,000 miles or 24 months. Use Subaru Super Coolant or equivalent.

Transmission Fluid Change Automatic:

Every 30,000 miles or 24 months under severe conditions. Every 60,000 miles or 48 months under normal conditions. Consult FSM for definition of severe/normal.

Transmission Fluid Change Manual:

Every 30,000 miles or 24 months. Inspect for leaks.

Differential Fluid Change Front Rear:

Every 30,000 miles or 24 months.

Timing Belt Replacement:

Critical component! 105,000 miles or 7 years (whichever comes first). FSM details procedure and necessary related components (tensioner, idlers, water pump).

Fluid Specifications

Engine Oil Type And Viscosity:

API SG/SH/SJ, SAE 5W-30. Check FSM for specific requirements for EJ25D vs. EJ251.

Engine Oil Capacity:

4.8 US quarts (4.5 Liters) with filter change (EJ25D/EJ251)

Coolant Type:

Subaru Super Coolant (Blue) or equivalent ethylene glycol-based coolant with corrosion inhibitors. Do NOT mix coolant types.

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Head Gaskets:

EJ25D engines (Phase I) are known for premature head gasket failure. The EJ251 (Phase II) improved upon this, but it can still occur. FSM details inspection and replacement procedures.

Crankshaft Thrust Bearing:

Early EJ25 engines (especially automatic transmission equipped) could experience crankshaft walk due to thrust bearing failure. This is a severe issue. FSM will have diagnostic methods.

Oil Leaks:

Common leak points include valve cover gaskets, oil pan gaskets, and front crankshaft seals.

Automatic Transmission Harsh Shifts:

Can sometimes be related to fluid condition or solenoids within the valve body. FSM provides diagnostic steps.

Ac Compressor Failure:

Early failure of the AC compressor can occur, often related to clutch issues or internal wear. FSM covers AC system diagnostics.

📚 Vehicle History

Brand Heritage

Manufacturer:

Subaru Corporation (formerly Fuji Heavy Industries), Japan

Core Technologies:

Boxer engine layout, Symmetrical All-Wheel Drive

Model Evolution

Generation:

Second Generation Legacy (BD/BG/BK platform)

Production Start Year:

Facelift:

1997 (for the 1998 model year) - minor styling updates, engine upgrades (EJ251 Phase II introduction)

Introduction Year For This Manual:

Production

Manufacturing Locations:

Ota, Gunma Prefecture, Japan

Model Run:

1993-1999 (This FSM covers the final year of the second generation)

🏆 Awards & Recognition

Recognitions

Car And Driver તિહાસ:

Car and Driver's 10Best list multiple times in previous generations, establishing a reputation for value and capability.

Iiihs Crash Test Performance:

Rated 'Good' for frontal offset crashworthiness by the IIHS.

Ratings

Consumer Reports:

Generally rated as average to above-average for reliability in its class for the 2000 model year, with noted concerns for specific engine variants as detailed in maintenance section.