1993-1999 SUBARU LEGACY & OUTBACK ( 1993 1994 1995 1996 1997 1998 1999 ) DIY Service/Repair Manual ( 93 94 95 96 97 98 99 )-PDF

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Model Variant: Outback Production Years: 1993-1999 Generation Chassis Code: BD/BG/BK (Second Generation) Codes Engine Codes: EJ22, EJ25D, EJ251 (early models may have EJ25E in some markets, though less common for this specific range) 👋 Introduction Market Position Segment: Mid-size Sedan/Wagon, Crossover Utility Vehicle (Outback variant). Known for its standard All-Wheel Drive system, distinctive styling, and practical utility. Competitive Analysis Competitors: Toyota Camry/Avensis, Honda Accord, Nissan Altima/Maxima, Mazda 626/Millenia, Ford Taurus/Mercury Sable, Chevrolet Lumina/Oldsmobile Cutlass Supreme. The Outback specifically competed with SUVs and higher-riding wagons. Key Features AWD System: Symmetrical All-Wheel Drive (standard on most models) provided superior traction and stability in varied weather conditions, a hallmark of Subaru vehicles. Outback Styling: The Outback introduced a more rugged appearance with increased ground clearance, fender cladding, and unique roof rails, differentiating it from the standard Legacy. Target Audience Demographics: Individuals and families seeking reliable, safe, and capable transportation, particularly those in climates with inclement weather or those who appreciate a more adventurous lifestyle. Value Proposition Manual Utility: Empowers DIY enthusiasts and professional mechanics alike to perform comprehensive maintenance and repairs, reducing labor costs and extending vehicle lifespan. 📋 Manual Details Coverage Areas Vehicle Coverage: All Subaru Legacy and Outback models from 1993 to 1999, including all engine and transmission variants offered within this period. Page Count Estimated Pages: Over 2000 (typical for factory service manuals of this era, though exact count varies by specific publication) Manual Type Type: Factory Service Manual / Repair Manual / Maintenance Manual / DIY Guide Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (including disassembly, assembly, inspection, and overhaul of EJ22 and EJ25D/EJ251 naturally aspirated and turbocharger systems where applicable), Fuel System (injection, pump, injectors, lines), Exhaust System, Cooling System (radiator, thermostat, water pump, hoses), Lubrication System (oil pump, oil filter, oil pressure), Ignition System (coils, plugs, wires, ECU control), Emissions Control Systems (catalytic converter, EGR, PCV). Transmission Drivetrain: Manual Transmissions (e.g., 5-speed) and Automatic Transmissions (e.g., 4-speed, likely 4EAT), Clutch system, Transfer Case, Driveshafts, CV Joints, Differentials (front and rear), AWD System operation and maintenance. Chassis Suspension Steering: Front Suspension (MacPherson struts, control arms, sway bar), Rear Suspension (Multi-link beam axle or independent rear suspension depending on model and year), Shock Absorbers/Struts, Springs, Bushings, Wheel Bearings, Steering Gearbox/Rack and Pinion, Power Steering System (pump, lines, fluid), Alignment specifications. Brakes: Front and Rear Brake Systems (Disc and Drum configurations), Brake Calipers, Rotors, Pads, Wheel Cylinders, Master Cylinder, ABS System (Anti-lock Braking System) diagnostics and repair, Parking Brake. Electrical Electronics: 12V Battery System, Charging System (Alternator), Starting System (Starter Motor), Lighting System (Headlights, Taillights, Interior), Fuses and Relays, Wiring Diagrams, Engine Control Unit (ECU) and related sensors, Instrument Cluster, Wiper/Washer System, Horn, Power Windows/Locks/Mirrors, Audio System. Body Interior Exterior: Body Panel Repair and Replacement, Door mechanisms, Hood, Trunk/Liftgate, Bumpers, Glass Replacement, Interior Trim and Upholstery, HVAC System (Heating, Ventilation, and Air Conditioning) components and service, Seats, Dashboard assembly. Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, fluid checks and changes), Tune-up procedures, Spark plug replacement, Air filter replacement, Fuel filter replacement, Brake pad/shoe replacement, Belt inspection and replacement (timing belt, accessory belts), Coolant flush and replacement, Transmission fluid service, Differential fluid service, Power steering fluid service. Repair Overhaul: Engine disassembly and reassembly, Cylinder head removal and repair, Piston and connecting rod service, Crankshaft and bearing inspection, Transmission removal and overhaul, Clutch replacement, Brake caliper/rotor replacement, Wheel bearing replacement, CV joint replacement, Strut and shock absorber replacement, Alternator and starter motor replacement, Radiator and water pump replacement, Fuel pump replacement, Ignition coil replacement, ABS sensor replacement. Diagnostics Troubleshooting: Diagnostic trouble codes (DTCs) interpretation, Symptom-based troubleshooting guides, Electrical system diagnostics using multimeters and wiring diagrams, Fuel system pressure testing, Ignition system testing, Engine performance troubleshooting, Transmission shifting issues troubleshooting, ABS system diagnostics. Technical Depth Level: Comprehensive Factory Level. Covers from basic routine maintenance to complete engine and transmission rebuilds. Includes detailed torque specifications, clearances, and repair procedures. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Print Quality Quality: High Resolution. Optimized for digital viewing and printing. Includes clear diagrams, schematics, and photographs where available in the original source. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) Searchability Text Search: Searchable Text Enabled PDF. Allows for quick keyword searches to locate specific information. Compatibility Operating Systems: Compatible with all versions of Windows, macOS, Linux, iOS, and Android devices with PDF reader software. Delivery Method: Instant Download ⚙️ Engine Specifications Primary Engine Engine Type 1: 2.2L Naturally Aspirated Flat-4 (EJ22) Displacement 1: 2212 cc Bore X Stroke 1: 96.9 mm x 75.0 mm Compression Ratio 1: 9.5:1 Horsepower 1: 135 hp @ 5600 rpm (approx.) Torque 1: 140 lb-ft @ 4400 rpm (approx.) Secondary Engine Engine Type 2: 2.5L Naturally Aspirated...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy

Model Variant:

Outback

Production Years:

1993-1999

Generation

Chassis Code:

BD/BG/BK (Second Generation)

Codes

Engine Codes:

EJ22, EJ25D, EJ251 (early models may have EJ25E in some markets, though less common for this specific range)

👋 Introduction

Market Position

Segment:

Mid-size Sedan/Wagon, Crossover Utility Vehicle (Outback variant). Known for its standard All-Wheel Drive system, distinctive styling, and practical utility.

Competitive Analysis

Competitors:

Toyota Camry/Avensis, Honda Accord, Nissan Altima/Maxima, Mazda 626/Millenia, Ford Taurus/Mercury Sable, Chevrolet Lumina/Oldsmobile Cutlass Supreme. The Outback specifically competed with SUVs and higher-riding wagons.

Key Features

AWD System:

Symmetrical All-Wheel Drive (standard on most models) provided superior traction and stability in varied weather conditions, a hallmark of Subaru vehicles.

Outback Styling:

The Outback introduced a more rugged appearance with increased ground clearance, fender cladding, and unique roof rails, differentiating it from the standard Legacy.

Target Audience

Demographics:

Individuals and families seeking reliable, safe, and capable transportation, particularly those in climates with inclement weather or those who appreciate a more adventurous lifestyle.

Value Proposition

Manual Utility:

Empowers DIY enthusiasts and professional mechanics alike to perform comprehensive maintenance and repairs, reducing labor costs and extending vehicle lifespan.

📋 Manual Details

Coverage Areas

Vehicle Coverage:

All Subaru Legacy and Outback models from 1993 to 1999, including all engine and transmission variants offered within this period.

Page Count

Estimated Pages:

Over 2000 (typical for factory service manuals of this era, though exact count varies by specific publication)

Manual Type

Type:

Factory Service Manual / Repair Manual / Maintenance Manual / DIY Guide

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical (including disassembly, assembly, inspection, and overhaul of EJ22 and EJ25D/EJ251 naturally aspirated and turbocharger systems where applicable), Fuel System (injection, pump, injectors, lines), Exhaust System, Cooling System (radiator, thermostat, water pump, hoses), Lubrication System (oil pump, oil filter, oil pressure), Ignition System (coils, plugs, wires, ECU control), Emissions Control Systems (catalytic converter, EGR, PCV).

Transmission Drivetrain:

Manual Transmissions (e.g., 5-speed) and Automatic Transmissions (e.g., 4-speed, likely 4EAT), Clutch system, Transfer Case, Driveshafts, CV Joints, Differentials (front and rear), AWD System operation and maintenance.

Chassis Suspension Steering:

Front Suspension (MacPherson struts, control arms, sway bar), Rear Suspension (Multi-link beam axle or independent rear suspension depending on model and year), Shock Absorbers/Struts, Springs, Bushings, Wheel Bearings, Steering Gearbox/Rack and Pinion, Power Steering System (pump, lines, fluid), Alignment specifications.

Brakes:

Front and Rear Brake Systems (Disc and Drum configurations), Brake Calipers, Rotors, Pads, Wheel Cylinders, Master Cylinder, ABS System (Anti-lock Braking System) diagnostics and repair, Parking Brake.

Electrical Electronics:

12V Battery System, Charging System (Alternator), Starting System (Starter Motor), Lighting System (Headlights, Taillights, Interior), Fuses and Relays, Wiring Diagrams, Engine Control Unit (ECU) and related sensors, Instrument Cluster, Wiper/Washer System, Horn, Power Windows/Locks/Mirrors, Audio System.

Body Interior Exterior:

Body Panel Repair and Replacement, Door mechanisms, Hood, Trunk/Liftgate, Bumpers, Glass Replacement, Interior Trim and Upholstery, HVAC System (Heating, Ventilation, and Air Conditioning) components and service, Seats, Dashboard assembly.

Procedures Included

Maintenance:

Scheduled maintenance (oil changes, filter replacements, fluid checks and changes), Tune-up procedures, Spark plug replacement, Air filter replacement, Fuel filter replacement, Brake pad/shoe replacement, Belt inspection and replacement (timing belt, accessory belts), Coolant flush and replacement, Transmission fluid service, Differential fluid service, Power steering fluid service.

Repair Overhaul:

Engine disassembly and reassembly, Cylinder head removal and repair, Piston and connecting rod service, Crankshaft and bearing inspection, Transmission removal and overhaul, Clutch replacement, Brake caliper/rotor replacement, Wheel bearing replacement, CV joint replacement, Strut and shock absorber replacement, Alternator and starter motor replacement, Radiator and water pump replacement, Fuel pump replacement, Ignition coil replacement, ABS sensor replacement.

Diagnostics Troubleshooting:

Diagnostic trouble codes (DTCs) interpretation, Symptom-based troubleshooting guides, Electrical system diagnostics using multimeters and wiring diagrams, Fuel system pressure testing, Ignition system testing, Engine performance troubleshooting, Transmission shifting issues troubleshooting, ABS system diagnostics.

Technical Depth

Level:

Comprehensive Factory Level. Covers from basic routine maintenance to complete engine and transmission rebuilds. Includes detailed torque specifications, clearances, and repair procedures.

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format)

Print Quality

Quality:

High Resolution. Optimized for digital viewing and printing. Includes clear diagrams, schematics, and photographs where available in the original source.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

Searchability

Text Search:

Searchable Text Enabled PDF. Allows for quick keyword searches to locate specific information.

Compatibility

Operating Systems:

Compatible with all versions of Windows, macOS, Linux, iOS, and Android devices with PDF reader software.

Delivery

Method:

Instant Download

⚙️ Engine Specifications

Primary Engine

Engine Type 1:

2.2L Naturally Aspirated Flat-4 (EJ22)

Displacement 1:

2212 cc

Bore X Stroke 1:

96.9 mm x 75.0 mm

Compression Ratio 1:

9.5:1

Horsepower 1:

135 hp @ 5600 rpm (approx.)

Torque 1:

140 lb-ft @ 4400 rpm (approx.)

Secondary Engine

Engine Type 2:

2.5L Naturally Aspirated Flat-4 (EJ25D - DOHC, Phase I)

Displacement 2:

2457 cc

Bore X Stroke 2:

99.5 mm x 79.0 mm

Compression Ratio 2:

9.7:1

Horsepower 2:

165 hp @ 5600 rpm (approx.)

Torque 2:

175 lb-ft @ 4000 rpm (approx.)

Engine Variants Included

Turbocharged:

GT models may feature a turbocharged variant (e.g., EJ25DET or similar), but the primary focus of the manual is typically naturally aspirated engines unless specified otherwise.

Performance

0 60 Mph:

Approximately 8-10 seconds, depending on engine and transmission.

Fuel System

Type:

Multi-point Fuel Injection (MPI), Electronic Fuel Injection (EFI).

Recommended Octane:

87 AKI (Regular Unleaded) for naturally aspirated EJ22/EJ25D. Higher octane may be specified for turbocharged variants.

Engine Management

Subaru Engine Control Unit (ECU) with diagnostic capabilities.

Timing Drive

System:

Timing Belt Driven SOHC or DOHC (depending on engine). Critical maintenance item with specified replacement interval.

🔧 Transmission

Standard

Type 1:

5-Speed Manual Transmission

Optional

Type 2:

4-Speed Automatic Transmission (4EAT - Electronic Automatic Transmission)

Features

AWD Integration:

Both transmissions are integrated with Subaru's Symmetrical All-Wheel Drive system. The 4EAT typically featured a viscous coupling center differential with a default 50/50 torque split, adjusting under slip. Manual transmissions often featured a viscous coupling limited-slip center differential.

Fluid Type

Automatic:

Subaru ATF (Automatic Transmission Fluid) or Dexron II/III equivalent. Manual transmission uses GL-5 gear oil, e.g., 75W-90.

Clutch

Type:

Dry single-plate clutch (for manual transmission models).

📐 Dimensions

Exterior

Length:

Approx. 185.4 inches (Legacy Sedan), 187.8 inches (Legacy Wagon/Outback)

Width:

Approx. 67.3 inches

Height:

Approx. 54.9 inches (Legacy Sedan), 57.3 inches (Legacy Wagon), 61.4 inches (Outback)

Wheelbase:

104.1 inches

Ground Clearance:

Approx. 5.7 inches (Legacy), 7.7 inches (Outback)

Weights

Curb Weight:

Approx. 3100-3500 lbs, depending on trim and drivetrain.

Towing Capacity:

Typically not specified or recommended for significant towing in this generation.

Cargo

Volume Wagon:

Approx. 37.1 cubic feet (rear seats up), 67.4 cubic feet (rear seats folded)

🛡️ Safety Features

Ratings

NHTSA Front Crash Test:

No specific 1993-1999 ratings readily available from NHTSA for this exact model generation, but generally considered safe for its era.

IIHS Ratings:

Not extensively rated by IIHS for this period in a way that aligns with current standards.

Active Features

Anti-lock Braking System (ABS) available or standard on higher trims and later years.

Passive Features

Airbags:

Driver and Passenger Airbags (standard).

Seatbelts:

Three-point front and rear seatbelts.

Chassis Design

Subaru Safety Philosophy:

Designed with a focus on passive safety through crumple zones and a reinforced chassis, combined with the active safety benefits of standard AWD.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette with optional CD player. Speaker configurations vary by trim level. Upgrades are common.

Driver Assistance

Anti-lock Braking System (ABS) was an available option, providing enhanced braking control during emergencies.

Comfort Convenience

HVAC:

Manual or automatic climate control systems, depending on trim. Air conditioning refrigerant type will be R134a for most of this period.

Lighting

Headlights:

Composite halogen headlights. Manual will cover bulb replacement and aiming procedures.

🔧 Maintenance

Service Intervals

Oil Change:

Every 3,750 miles or 3 months, whichever comes first, using conventional oil. Synthetic oil may extend to 7,500 miles/6 months, consult manual.

Timing Belt:

Replace every 105,000 miles or 7 years, whichever comes first. This is a critical maintenance item to prevent catastrophic engine damage.

Coolant Flush:

Every 30,000 miles or 2 years, whichever comes first.

Transmission Fluid Change:

Automatic: Every 30,000 miles or 2 years. Manual: Every 60,000 miles or 4 years. Differential fluid: Every 30,000 miles.

Fluid Specifications

Engine Oil:

API SG or higher. Viscosity: 5W-30 or 10W-30 (check manual for temperature-specific recommendations).

Coolant:

Subaru Super Coolant or equivalent ethylene glycol based coolant, 50/50 mix with distilled water.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

ATF Dexron II/III compatible fluid.

Known Issues

Head Gaskets:

Early EJ25D engines (1996-1998) were prone to head gasket failures due to coolant seal design. This manual will detail diagnosis and replacement procedures.

Oil Leaks:

Valve cover gaskets and oil pan gaskets can develop leaks over time. Crankshaft seals are also potential leak points.

Cv Joints:

Front and rear CV boots can tear, leading to joint wear and failure, especially on Outback models subjected to rougher use.

Radiator:

Plastic end tanks on radiators can become brittle and crack, leading to coolant leaks.

Suspension Bushings:

Worn suspension bushings (control arm, sway bar, trailing arm) can lead to noise, poor handling, and alignment issues.

Common Repairs

Alternator:

Alternators can be a common replacement item as vehicles age.

📚 Vehicle History

Brand Heritage

Subaru Legacy Introduction:

The Subaru Legacy was introduced globally in 1989 as a replacement for the Subaru Leone. It was positioned as Subaru's flagship model, showcasing their boxer engine technology and Symmetrical All-Wheel Drive.

Model Evolution

Second Generation:

The 1990-1999 model range represents the second generation (BD/BG/BK chassis). This generation saw significant styling updates, improved chassis rigidity, and introduction of the Outback variant.

Outback Introduction:

The Outback was first introduced for the 1995 model year as a more rugged, lifted version of the Legacy wagon. It quickly became a core Subaru model.

Facelifts:

The second generation Legacy received a significant facelift for the 1997 model year, featuring redesigned front and rear fascias, updated interior elements, and powertrain refinements (e.g., introduction of the EJ251 in later years of the generation).

Production

Manufacturing Locations:

Primarily manufactured in Japan by Subaru Corporation (formerly Fuji Heavy Industries).

Production Run:

1993-1999 Model Years

🏆 Awards & Recognition

Recognitions

Road And Track:

Subaru Legacy models, particularly the GT variants, often received favorable reviews for performance and handling from automotive publications like Road & Track.

Car And Driver:

The Legacy and Outback were frequently praised by Car and Driver for their AWD capabilities and practicality, often appearing on 'Ten Best' lists in various categories over the years.

Ratings

Outback Utility:

The Outback was instrumental in establishing the 'crossover' vehicle segment and was lauded for blending the utility of a wagon with the capability of an SUV.