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Subaru Legacy 1997 Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 1997 Generation Generation Designation: Second Generation (BD/BG/BK) Codes Chassis Codes: BD (sedan), BG (wagon) 👋 Introduction Market Position Vehicle Segment: Mid-size sedan and wagon, often positioned as an affordable all-wheel-drive alternative Target Demographic: Families, individuals seeking reliable transportation, those valuing AWD capability Competitive Analysis Key Competitors: Toyota Camry, Honda Accord, Ford Taurus, Nissan Altima Unique Selling Proposition: Standard Symmetrical All-Wheel Drive (AWD) system across most trims Key Features All Wheel Drive: Standard Symmetrical AWD providing enhanced traction and stability Boxer Engine: Horizontally-opposed (Boxer) engine for a lower center of gravity Durability Reliability: Reputation for robust engineering and longevity Body Styles: Available as a 4-door sedan and a 5-door wagon 📋 Manual Details Coverage Areas All Systems: Yes Engine Coverage: Detailed coverage of all engine variants Transmission Coverage: Manual and automatic transmissions Chassis Suspension Coverage: Front and rear suspension, steering, brakes Electrical Coverage: Wiring diagrams, component testing, ECUs Body Interior Coverage: Body panels, interior trim, HVAC, safety systems Page Count Estimated Page Count: 1000+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Management: Fuel injection, ignition system, emissions control, engine mechanicals Powertrain: Engine repair, transmission overhaul, drivetrain components (CVT, AWD) Braking System: Hydraulic system, ABS (if equipped), parking brake Steering Suspension: Power steering, steering rack, front/rear suspension components, wheel alignment Body Chassis: Frame repair, body panel replacement, rust prevention HVAC: Air conditioning, heating, ventilation system diagnosis and repair Safety Systems: Airbag system (SRS), seatbelt mechanisms Electrical Components: Lighting, wipers, power accessories, audio system, battery, alternator Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks, tune-ups Diagnostic Troubleshooting: Step-by-step diagnostic procedures for common and uncommon faults Engine Repair: Complete engine rebuilds, component replacement (pistons, valves, head gaskets) Transmission Repair: Clutch replacement, automatic transmission fluid changes, internal component repair Brake Service: Brake pad replacement, rotor machining, brake bleeding, caliper repair Suspension Steering Repair: Strut/shock replacement, ball joint replacement, tie rod end replacement Electrical Troubleshooting: Wiring diagram interpretation, circuit testing, sensor diagnosis Body Repair: Panel alignment, glass replacement, interior trim removal/installation Technical Depth Depth: Comprehensive, from basic maintenance to complete engine/transmission overhaul and complex diagnostics Diagnostic Codes: Includes interpretation of diagnostic trouble codes (DTCs) where applicable Torque Specifications: Detailed torque specifications for all critical fasteners Alignment Specifications: Wheel alignment specifications (camber, caster, toe) Wiring Diagrams: Complete, detailed electrical wiring diagrams for all systems 📊 Manual Specifications File Format File Type: Digital PDF Searchability: Fully searchable text content Printable: Yes, printable pages Image Quality: High-resolution images and diagrams Print Quality Resolution: N/A (Digital Format) Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code 1: EJ25D Engine Type 1: 2.5L SOHC Naturally Aspirated Flat-4 (Boxer) Displacement 1: 2457 cc Bore Stroke 1: 99.5 mm x 80.0 mm Compression Ratio 1: 9.7:1 Horsepower 1: 165 hp @ 5,500 rpm (approx.) Torque 1: 200 lb-ft @ 4,000 rpm (approx.) Fuel System Fuel Delivery 1: Multi-point Fuel Injection (MPI) Fuel Type 1: Unleaded Regular (87 Octane) Engine Code 2 Engine Code 2: EJ22E Engine Type 2 Engine Type 2: 2.2L SOHC Naturally Aspirated Flat-4 (Boxer) Displacement 2 Displacement 2: 2212 cc Horsepower 2 Horsepower 2: 135 hp @ 5,600 rpm (approx.) Torque 2 Torque 2: 140 lb-ft @ 4,400 rpm (approx.) Fuel Delivery 2 Fuel Delivery 2: Multi-point Fuel Injection (MPI) 🔧 Transmission Standard Transmission Standard: 5-speed Manual Transmission Optional Transmission Optional: 4-speed Automatic Transmission with Lock-up Torque Converter Features Drivetrain: Symmetrical All-Wheel Drive (AWD) standard on most models AWD System Type: Viscous coupling center differential with mechanical limited-slip rear differential (manual) or electronically controlled clutch pack (automatic) 📐 Dimensions Exterior Wheelbase: 104.3 inches (2649 mm) Length Sedan: 185.2 inches (4704 mm) Length Wagon: 185.8 inches (4719 mm) Width: 69.1 inches (1755 mm) Height Sedan: 54.9 inches (1395 mm) Height Wagon: 55.3 inches (1405 mm) Weights Curb Weight Min: 3150 lbs (1429 kg) approx. Curb Weight Max: 3400 lbs (1542 kg) approx. Wheels Tires Wheelbase Bolt Pattern: 5 x 100 mm Standard Tire Size: P205/55R16 Standard Wheel Size: 16 x 6.0 inches 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Not rated (vehicle predates extensive NHTSA testing standards) NHTSA Front Impact Passenger: Not rated (vehicle predates extensive NHTSA testing standards) IIHS Ratings: Limited data available for this model year Active Features ABS: Anti-lock Braking System (ABS) available on select trims Traction Control: Traction Control System (TCS) not commonly available, but possible on higher trims Passive Features Airbags: Driver and front passenger airbags standard Seatbelts: Three-point front and rear seatbelts, driver's pretensioner Structure: Reinforced body structure, side impact beams 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette player, optional CD player. Basic speaker configurations (4-6 speakers). Climate Control: Manual climate controls for heating...
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Subaru Legacy 1997 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy
Year:
1997
Generation
Generation Designation:
Second Generation (BD/BG/BK)
Codes
Chassis Codes:
BD (sedan), BG (wagon)
👋 Introduction
Market Position
Vehicle Segment:
Mid-size sedan and wagon, often positioned as an affordable all-wheel-drive alternative
Target Demographic:
Families, individuals seeking reliable transportation, those valuing AWD capability
Competitive Analysis
Key Competitors:
Toyota Camry, Honda Accord, Ford Taurus, Nissan Altima
Unique Selling Proposition:
Standard Symmetrical All-Wheel Drive (AWD) system across most trims
Key Features
All Wheel Drive:
Standard Symmetrical AWD providing enhanced traction and stability
Boxer Engine:
Horizontally-opposed (Boxer) engine for a lower center of gravity
Durability Reliability:
Reputation for robust engineering and longevity
Body Styles:
Available as a 4-door sedan and a 5-door wagon
📋 Manual Details
Coverage Areas
All Systems:
Yes
Engine Coverage:
Detailed coverage of all engine variants
Transmission Coverage:
Manual and automatic transmissions
Chassis Suspension Coverage:
Front and rear suspension, steering, brakes
Electrical Coverage:
Wiring diagrams, component testing, ECUs
Body Interior Coverage:
Body panels, interior trim, HVAC, safety systems
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Management:
Fuel injection, ignition system, emissions control, engine mechanicals
Powertrain:
Engine repair, transmission overhaul, drivetrain components (CVT, AWD)
Braking System:
Hydraulic system, ABS (if equipped), parking brake
Steering Suspension:
Power steering, steering rack, front/rear suspension components, wheel alignment
Body Chassis:
Frame repair, body panel replacement, rust prevention
HVAC:
Air conditioning, heating, ventilation system diagnosis and repair
Safety Systems:
Airbag system (SRS), seatbelt mechanisms
Electrical Components:
Lighting, wipers, power accessories, audio system, battery, alternator
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, fluid checks, tune-ups
Diagnostic Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon faults
Engine Repair:
Complete engine rebuilds, component replacement (pistons, valves, head gaskets)
Transmission Repair:
Clutch replacement, automatic transmission fluid changes, internal component repair
Brake Service:
Brake pad replacement, rotor machining, brake bleeding, caliper repair
Suspension Steering Repair:
Strut/shock replacement, ball joint replacement, tie rod end replacement
Electrical Troubleshooting:
Wiring diagram interpretation, circuit testing, sensor diagnosis
Body Repair:
Panel alignment, glass replacement, interior trim removal/installation
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine/transmission overhaul and complex diagnostics
Diagnostic Codes:
Includes interpretation of diagnostic trouble codes (DTCs) where applicable
Torque Specifications:
Detailed torque specifications for all critical fasteners
Alignment Specifications:
Wheel alignment specifications (camber, caster, toe)
Wiring Diagrams:
Complete, detailed electrical wiring diagrams for all systems
📊 Manual Specifications
File Format
File Type:
Digital PDF
Searchability:
Fully searchable text content
Printable:
Yes, printable pages
Image Quality:
High-resolution images and diagrams
Print Quality
Resolution:
N/A (Digital Format)
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
EJ25D
Engine Type 1:
2.5L SOHC Naturally Aspirated Flat-4 (Boxer)
Displacement 1:
2457 cc
Bore Stroke 1:
99.5 mm x 80.0 mm
Compression Ratio 1:
9.7:1
Horsepower 1:
165 hp @ 5,500 rpm (approx.)
Torque 1:
200 lb-ft @ 4,000 rpm (approx.)
Fuel System
Fuel Delivery 1:
Multi-point Fuel Injection (MPI)
Fuel Type 1:
Unleaded Regular (87 Octane)
Engine Code 2
Engine Code 2:
EJ22E
Engine Type 2
Engine Type 2:
2.2L SOHC Naturally Aspirated Flat-4 (Boxer)
Displacement 2
Displacement 2:
2212 cc
Horsepower 2
Horsepower 2:
135 hp @ 5,600 rpm (approx.)
Torque 2
Torque 2:
140 lb-ft @ 4,400 rpm (approx.)
Fuel Delivery 2
Fuel Delivery 2:
Multi-point Fuel Injection (MPI)
🔧 Transmission
Standard
Transmission Standard:
5-speed Manual Transmission
Optional
Transmission Optional:
4-speed Automatic Transmission with Lock-up Torque Converter
Features
Drivetrain:
Symmetrical All-Wheel Drive (AWD) standard on most models
AWD System Type:
Viscous coupling center differential with mechanical limited-slip rear differential (manual) or electronically controlled clutch pack (automatic)
📐 Dimensions
Exterior
Wheelbase:
104.3 inches (2649 mm)
Length Sedan:
185.2 inches (4704 mm)
Length Wagon:
185.8 inches (4719 mm)
Width:
69.1 inches (1755 mm)
Height Sedan:
54.9 inches (1395 mm)
Height Wagon:
55.3 inches (1405 mm)
Weights
Curb Weight Min:
3150 lbs (1429 kg) approx.
Curb Weight Max:
3400 lbs (1542 kg) approx.
Wheels Tires
Wheelbase Bolt Pattern:
5 x 100 mm
Standard Tire Size:
P205/55R16
Standard Wheel Size:
16 x 6.0 inches
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Not rated (vehicle predates extensive NHTSA testing standards)
NHTSA Front Impact Passenger:
Not rated (vehicle predates extensive NHTSA testing standards)
IIHS Ratings:
Limited data available for this model year
Active Features
ABS:
Anti-lock Braking System (ABS) available on select trims
Traction Control:
Traction Control System (TCS) not commonly available, but possible on higher trims
Passive Features
Airbags:
Driver and front passenger airbags standard
Seatbelts:
Three-point front and rear seatbelts, driver's pretensioner
Structure:
Reinforced body structure, side impact beams
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player. Basic speaker configurations (4-6 speakers).
Climate Control:
Manual climate controls for heating and air conditioning. Automatic climate control not typically available.
Driver Assistance
Cruise Control:
Electronic cruise control system standard or optional on most trims.
Instrument Cluster:
Analog gauges for speedometer, tachometer, fuel level, engine temperature. Warning lights for various systems.
Connectivity
Connectivity Options:
Limited connectivity by modern standards. Primarily focused on basic audio and vehicle systems. No Bluetooth or USB ports standard.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (under severe conditions, every 3,000 miles).
Air Filter Replacement:
Every 30,000 miles (48,000 km) or 24 months.
Spark Plug Replacement:
Every 60,000 miles (96,000 km) for platinum-tipped plugs, or 30,000 miles for standard copper plugs.
Timing Belt Replacement:
Every 90,000 miles (144,000 km) or 7 years (critical on EJ25D due to interference design).
Coolant Flush:
Every 30,000 miles (48,000 km) or 24 months.
Transmission Fluid Change Auto:
Every 30,000 miles (48,000 km) or 24 months.
Transmission Fluid Change Manual:
Every 60,000 miles (96,000 km) or 48 months.
Fluid Specifications
Engine Oil Type 1:
API SG or higher, SAE 10W-30 recommended
Engine Oil Capacity 1:
4.5 US quarts (4.3 liters) with filter
Engine Oil Type 2:
API SG or higher, SAE 5W-30 recommended for colder climates
Engine Oil Capacity 2:
4.5 US quarts (4.3 liters) with filter
Coolant Type:
Subaru Super Coolant (50/50 mix with distilled water) or equivalent (silicate-free)
Brake Fluid:
DOT 3 or DOT 4
Power Steering Fluid:
Subaru genuine power steering fluid or ATF Dexron II/III
Automatic Transmission Fluid:
ATF Dexron II/III
Manual Transmission Fluid:
API GL-5, SAE 75W-90 gear oil
Known Issues
Head Gasket Failure:
The EJ25D engine is known for prone head gasket failure due to coolant leaks and internal weaknesses. This manual will detail inspection and replacement procedures.
Crankshaft Reluctor Ring Failure:
The reluctor ring on the crankshaft can fail, leading to no-start or intermittent stalling issues. Diagnosis is covered.
Oil Leaks:
Common oil leaks can occur from valve cover gaskets, oil pan gaskets, and front crankshaft seals. The manual details their replacement.
Cv Joint Wear:
Front and rear CV joints can wear over time, especially in AWD systems, leading to clicking noises. The manual covers CV axle inspection and replacement.
Ejector Seat Sensor Failure:
For models equipped with certain airbag systems, the ejector seat sensor could fail, affecting airbag deployment.
📚 Vehicle History
Brand Heritage
Subaru Foundation:
Founded in 1953 as Fuji Heavy Industries, focused on aviation initially.
Subaru Identity:
Known for its commitment to AWD technology and boxer engines.
Model Evolution
First Generation:
First generation Legacy introduced in 1989.
Second Generation Intro:
Second generation (BD/BG/BK) introduced for the 1995 model year.
Styling Changes 1997:
Minor styling updates for 1997, including revised grille and headlights.
Outback Introduction:
The Outback variant, with increased ground clearance and ruggedized styling, was introduced for the 1995 model year as an option package on the wagon.
Production
Manufacturing Location:
Mainly produced in Gunma, Japan.
Sales Positioning:
Marketed globally, with significant presence in North America and Japan.
🏆 Awards & Recognition
Recognitions
Consumer Reports Ratings:
Typically rated average to above average for reliability, with some specific model years receiving praise for AWD performance and value.
Car And Driver Awards:
Subaru Legacy models were often featured on Car and Driver's '10Best' lists in earlier generations, highlighting its competitive performance and value.
Certifications
Emissions Standards:
Meets EPA and CARB emissions standards for the respective model year.
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