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Download (103 MB) 1996 Subaru Legacy Original Factory Service Manual(FSM) (+ Owners Manual INCLUDED) / Repair Manual 96 - (ZIP - PDF Format)
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Basic Information Identification Make: Subaru Model: Legacy Year: 1996 Production Code: BD/BG/BK Series Chassis Code: BD (Sedan), BG (Wagon) Generation Generation Name: Second Generation (Second Facelift) Generation Years: 1993-1999 (Global;...
Type: Car
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Sku: 24321
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| Basic Information | |
| Identification | |
| Make: | Subaru |
| Model: | Legacy |
| Year: | 1996 |
| Production Code: | BD/BG/BK Series |
| Chassis Code: | BD (Sedan), BG (Wagon) |
| Generation | |
| Generation Name: | Second Generation (Second Facelift) |
| Generation Years: | 1993-1999 (Global; 1996 marks a facelift) |
| Codes | |
| Engine Code Primary: | EJ22 (2.2L Naturally Aspirated) |
| Engine Code Optional 1: | EJ25D (2.5L Naturally Aspirated DOHC) |
| Engine Code Optional 2: | EJ20 (2.0L Turbocharged - Primarily JDM/European) |
| Transmission Code Primary: | 4EAT (4-speed Automatic Transaxle) |
| Transmission Code Optional: | 5MT (5-speed Manual Transaxle) |
| Introduction | |
| Market Position | |
| Market Positioning: | The 1996 Subaru Legacy represented Subaru's offering in the mid-size sedan and wagon segment, known for its standard Symmetrical All-Wheel Drive system, boxer engines, and reputation for durability and safety, particularly in adverse weather conditions. |
| Competitive Analysis | |
| Competitors: | Competed against vehicles like the Toyota Camry, Honda Accord, Nissan Altima, and Ford Taurus. Subaru differentiated itself with its AWD standard across most models and its boxer engine layout. |
| Key Features | |
| Key Features Vehicle: | Standard Symmetrical All-Wheel Drive, Boxer engine for low center of gravity, available sedan and wagon body styles, safety focus, comfortable ride, improved interior and exterior styling from the facelift. |
| Key Features Manual: | Factory-developed, comprehensive coverage, includes owner's manual, detailed diagrams, diagnostic procedures, and all factory specifications, providing a definitive resource for maintenance and repair. |
| Manual Details | |
| Coverage Areas | |
| Coverage Areas Summary: | Comprehensive coverage for all mechanical, electrical, body, and diagnostic systems of the 1996 Subaru Legacy. Includes maintenance, repair, troubleshooting, and specifications for all factory-fitted components and variants. |
| Page Count | |
| Estimated Page Count: | Extensive (precise number not specified, but FSMs are typically 1000+ pages when compiled) |
| Manual Type | |
| Manual Type: | Original Factory Service Manual (FSM) & Owner's Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | Digital (ZIP - PDF) |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Detailed breakdown of EJ22, EJ25D engines including component identification, disassembly, assembly, torque specifications, diagnostics, and troubleshooting for fuel, ignition, lubrication, cooling, and emission control systems. |
| Transmission: | Complete coverage for 4EAT automatic transaxle and 5MT manual transaxle, including operation, diagnostics, maintenance, overhaul procedures, clutch system, and driveline components (CV joints, driveshafts). |
| Brakes: | ABS system, hydraulic circuits, brake caliper and rotor service, master cylinder, brake booster, parking brake, and fluid specifications. |
| Suspension: | Front and rear suspension components (struts, springs, control arms, ball joints, bushings), alignment specifications, and component replacement procedures. |
| Steering: | Power steering system components, rack and pinion service, steering column, and troubleshooting. |
| Electrical: | Complete wiring diagrams, component locations, fuse box layouts, lighting systems, starting and charging systems, power windows, mirrors, and accessory systems. |
| HVAC: | Air conditioning system operation, refrigerant handling, compressor, condenser, evaporator, heater core, blower motor, and climate control module diagnostics. |
| Body: | Body panel removal and installation, door mechanisms, glass replacement, interior trim, bumper covers, and exterior trim components. |
| Body Control Modules: | Accessory control units, power door locks, remote keyless entry (if equipped). |
| Safety Restraints: | Airbag system components, SRS module, pre-tensioners, and related safety features. |
| Procedures Included | |
| Maintenance: | Oil changes, filter replacements, spark plug service, coolant flushes, brake fluid changes, transmission fluid changes, differential fluid changes, timing belt replacement (for EJ25D), and belt tensioner service. |
| Troubleshooting: | System-by-system diagnostic flowcharts and fault code interpretation (OBD-I specific for some systems, though OBD-II was becoming standard). |
| Repair: | Detailed step-by-step instructions for component removal, repair, and reinstallation for all major vehicle systems. |
| Diagnostics: | Component testing, sensor readings, voltage drop tests, continuity checks, and diagnostic tool usage (where applicable). |
| Calibration: | Wheel alignment procedures and specifications. |
| Technical Depth | |
| Depth: | Expert/Professional level. Covers everything from basic fluid checks and filter replacements to complete engine and transmission overhauls, complex electrical diagnostics, and body repair. |
| Diagnostic Capability: | Advanced. Enables diagnosis of complex intermittent faults, electrical shorts/opens, and mechanical performance issues. |
| Rebuild Procedures: | Comprehensive. Includes detailed steps for engine and transmission rebuilding, including tolerances and specifications. |
| Manual Specifications | |
| File Format | |
| File Format: | ZIP (containing PDF files) |
| PDF Quality: | High Resolution (assumed for FSMs, enabling clear text and diagrams) |
| Searchable Text: | Likely searchable text within PDFs, allowing for quick keyword access to information. |
| Print Quality | |
| Printable: | Yes, PDF format allows for printing of individual pages or sections. |
| Binding Type | |
| Binding Type: | Not Applicable (Digital Download) |
| Paper Type | |
| Paper Type: | Not Applicable (Digital Download) |
| Engine Specifications | |
| Primary Engine | |
| Engine Name: | EJ22 |
| Engine Type: | Horizontally Opposed (Boxer), SOHC, Naturally Aspirated |
| Displacement: | 2.2 Liters (2212 cc) |
| Bore X Stroke: | 96.0 mm x 75.0 mm |
| Compression Ratio: | 9.5:1 |
| Horsepower Net Est: | 135 hp @ 5600 rpm |
| Torque Net Est: | 140 lb-ft @ 4000 rpm |
| Fuel System: | Multi-Port Fuel Injection (MPFI) |
| Ignition System: | Distributorless Electronic Ignition (Phase II System) |
| Cooling System: | Pressurized liquid cooling system |
| Performance | |
| Fuel Type: | Unleaded Regular Gasoline (87 Octane) |
| Fuel System | |
| Fuel Tank Capacity: | 60 Liters (15.9 US Gallons) |
| Optional Engine | |
| Engine Name 25: | EJ25D |
| Engine Type 25: | Horizontally Opposed (Boxer), DOHC, Naturally Aspirated |
| Displacement 25: | 2.5 Liters (2457 cc) |
| Horsepower Net Est 25: | 165 hp @ 5600 rpm |
| Torque Net Est 25: | 170 lb-ft @ 4400 rpm |
| Timing Belt Interval: | Every 60,000 miles or 4 years (critical maintenance item) |
| Transmission | |
| Standard | |
| Transmission Type: | 4EAT (4-Speed Electronically Controlled Automatic Transaxle) |
| Drivetrain: | Symmetrical All-Wheel Drive (AWD) |
| Transmission Fluid Type: | Subaru ATF (Dexron II compatible) |
| Optional | |
| Transmission Type Optional: | 5MT (5-Speed Manual Transaxle) |
| Drivetrain Optional: | Symmetrical All-Wheel Drive (AWD) |
| Clutch Fluid Type: | DOT 3 Brake Fluid |
| Features | |
| AWD System Description: | Continuously variable transfer clutch (CVT) for automatic AWD operation on 4EAT models; viscous coupling center differential on 5MT models. |
| Dimensions | |
| Exterior | |
| Length Sedan: | 4675 mm (184.1 inches) |
| Length Wagon: | 4690 mm (184.6 inches) |
| Width: | 1730 mm (68.1 inches) |
| Height Sedan: | 1410 mm (55.5 inches) |
| Height Wagon: | 1470 mm (57.9 inches) |
| Wheelbase: | 2630 mm (103.5 inches) |
| Track Width Front: | 1475 mm (58.1 inches) |
| Track Width Rear: | 1470 mm (57.9 inches) |
| Ground Clearance: | Approx. 150 mm (5.9 inches) depending on model/trim |
| Weights | |
| Curb Weight Sedan Est: | 1370 - 1500 kg (3020 - 3300 lbs) |
| Curb Weight Wagon Est: | 1420 - 1550 kg (3130 - 3417 lbs) |
| Wheel Bolt Pattern: | 5x100 mm |
| Wheel Size Standard: | 15 inches (Steel or Alloy) |
| Tire Size Standard Ej22: | 205/60R15 |
| Tire Size Optional Ej25D: | 205/55R15 or 205/60R15 depending on trim |
| Cargo | |
| Cargo Volume Sedan: | Approx. 15 cubic feet |
| Cargo Volume Wagon: | Approx. 34 cubic feet (seats up), 68 cubic feet (seats down) |
| Safety Features | |
| Ratings | |
| NHTSA Frontal Impact Driver: | 4 Stars (1996 Model Year, US Spec) |
| NHTSA Frontal Impact Passenger: | 4 Stars (1996 Model Year, US Spec) |
| IIHS Frontal Offset: | Good (for its era, reflecting Subaru's early commitment to crashworthiness) |
| Active Features | |
| Active Safety: | Standard Symmetrical All-Wheel Drive for enhanced traction and stability, Anti-lock Braking System (ABS) available on select models/trims. |
| Passive Features | |
| Passive Safety: | Driver and passenger front airbags, front seatbelt pretensioners, reinforced passenger cabin, side impact door beams. |
| Technology Features | |
| Infotainment | |
| Infotainment System: | Base AM/FM stereo with cassette player. Optional CD player available on higher trims. Manual covers basic operation and replacement of head units. |
| Driver Assistance | |
| Driver Assistance Features: | ABS (Anti-lock Braking System) was an optional feature, enhancing braking control. AWD is a primary stability enhancement system. |
| Connectivity | |
| Connectivity Features: | Limited by modern standards. Basic power accessories (windows, mirrors on higher trims). Manual covers wiring for these systems. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Every 7,500 miles or 6 months (using synthetic oil), or 3,750 miles/6 months (using conventional oil) under severe driving conditions. |
| Air Filter Replacement: | Every 15,000 miles or 12 months. |
| Cabin Air Filter Replacement: | Not equipped on most 1996 models. |
| Spark Plug Replacement: | Every 60,000 miles (for EJ22 and EJ25D). Consult manual for specific plug types. |
| Coolant Flush: | Every 30,000 miles or 24 months. |
| Brake Fluid Flush: | Every 30,000 miles or 24 months. |
| Transmission Fluid Change 4Eat: | Every 30,000 miles (preferred) or 45,000 miles. Check for filter replacement. |
| Differential Fluid Change: | Every 30,000 miles. |
| Fluid Specifications | |
| Engine Oil Specification: | API Service SG, SH, or SJ; SAE 5W-30 or 10W-30 (depending on ambient temperature). Consult manual for specific viscosity range. |
| Engine Oil Capacity: | 4.5 US Quarts (4.2 Liters) with filter for EJ22/EJ25D. |
| Coolant Specification: | Subaru Super Coolant (50/50 mix with distilled water) or equivalent P-HOAT coolant. |
| Brake Fluid Specification: | DOT 3. |
| Known Issues | |
| Head Gaskets: | While less prevalent on the EJ22 than the EJ25D, head gasket leaks can occur, especially on the EJ25D due to its dual overhead cams and different gasket design. Early diagnosis and repair are crucial. |
| O2 Sensors: | Oxygen sensors can fail over time, leading to increased emissions and reduced fuel economy. The manual provides diagnostic procedures for testing these. |
| Automatic Transmission: | The 4EAT is generally robust but can experience wear over time. Regular fluid changes are essential. Specific diagnostic codes covered in the manual can help pinpoint issues. |
| Suspension Bushings: | Rubber suspension bushings can degrade with age, leading to clunks or imprecise handling. The manual details replacement procedures. |
| Timing Belt Ej25D: | Critical replacement item for the EJ25D. Failure can lead to catastrophic engine damage. The manual provides correct installation and tensioning procedures. |
| Vehicle History | |
| Brand Heritage | |
| Brand Heritage: | Subaru, a division of Fuji Heavy Industries, has a history rooted in aerospace engineering, which influenced its signature boxer engine and AWD systems, emphasizing durability, safety, and capability. |
| Model Evolution | |
| Second Gen Evolution: | The second generation Legacy (BD/BG) introduced a more aerodynamic design and a larger chassis. The 1996 model year marked a significant facelift, with redesigned front and rear fascias, updated interior elements, and revisions to engine and transmission options, including the introduction of the 2.5L DOHC engine in North America. |
| Production | |
| Production Location: | Japan (Gunma Plant) |
| Production Period: | 1993-1999 (Second Generation) |
| Awards & Recognition | |
| Recognitions | |
| Safety Awards Era: | The Subaru Legacy, as part of the Subaru brand, consistently received praise for its safety features and AWD capabilities, making it a favored choice for adverse weather. While specific awards for the '96 model aren't universally cited, the platform was recognized for its engineering. |
| Consumer Reports Reputation: | Subaru models of this era generally held a reputation for reliability and durability, contributing to strong owner satisfaction, though certain engine variants sometimes had specific maintenance concerns (e.g., head gaskets on the EJ25D). |