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Subaru Legacy 1995-1999 Online Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Generation Generation: Third Generation (BD/BG/BK/BH) Codes Chassis Codes: BD (Sedan), BG (Wagon) 👋 Introduction Market Position Market Positioning: The Subaru Legacy in this era was positioned as a mid-size sedan and wagon known for its standard All-Wheel Drive (AWD) capability, offering a balance of comfort, practicality, and Subaru's signature driving dynamics. Competitive Analysis Key Competitors: Honda Accord, Toyota Camry, Nissan Altima, Ford Taurus, Chevrolet Lumina, Mazda 626 Key Features Vehicle Highlights: Standard Symmetrical All-Wheel Drive, horizontally opposed Boxer engines, comfortable ride, spacious interior for its class, available wagon body style offering practicality. AWD System Benefits: The Symmetrical AWD system provided superior traction and stability in various weather conditions compared to many front-wheel-drive competitors, a significant selling point for Subaru. 📋 Manual Details Coverage Areas Covered Years: 1995, 1996, 1997, 1998, 1999 Page Count Estimated Page Count: 1500+ Manual Type Type: Online Service and Repair Manual Language Language: English Format Format: Digital (likely PDF or web-based) Access Method: Online access, likely downloadable or viewable via a web browser. May offer search functionality for quick information retrieval. 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel injection, ignition, exhaust, cooling, lubrication, manual and automatic transmissions, AWD system (Active AWD/Viscous coupling center differential) Chassis: Suspension (front struts/coilovers, rear multi-link), steering, brakes (front ventilated discs, rear discs/drums), wheel bearings, driveline components Electrical: Wiring diagrams, lighting, charging system, starting system, instrumentation, comfort controls, power accessories, ABS, SRS (Airbag) systems Body And Trim: Exterior body panels, interior trim, doors, glass, seats, HVAC system, body control modules Fuel And Emissions: Fuel pump testing, injector cleaning and testing, evaporative emission control (EVAP) system diagnostics, oxygen sensor testing, EGR system service. Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, fluid checks), brake pad replacement, spark plug replacement, belt replacement, air filter replacement Repair: Engine disassembly/reassembly, transmission overhaul, brake caliper replacement, suspension component replacement, electrical component diagnosis and replacement, body panel repair Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, electrical system diagnostics, mechanical component diagnostics Special Procedures: Timing belt replacement, head gasket replacement (if applicable to specific engines), AWD system servicing, airbag system servicing (safety precautions) Engine Mechanical Procedures: Cylinder head removal/installation, piston and connecting rod servicing, crankshaft bearing replacement, valve stem seal replacement, oil pump servicing. Transmission Repair Procedures: Clutch replacement, torque converter replacement, valve body servicing (automatic), gear inspection and replacement (manual). Technical Depth Depth: Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications. Diagnostic Information: Includes detailed diagnostic flowcharts, component testing procedures, resistance values, voltage checks, and reference specifications for diagnosing faults. 📊 Manual Specifications File Format Digital Format Details: Likely a searchable PDF, allowing for quick access to information via keywords. May include high-resolution diagrams and images. Print Quality Print Quality Notes: While digital, if printable, expect clear text and sharp diagrams. Designed for clarity in diagnostic and repair processes. Binding Type Binding Type: Not applicable (digital format) Paper Type Paper Type: Not applicable (digital format) Completeness Manual Scope: Comprehensive coverage of all major mechanical, electrical, and body systems. Intended for professional technicians and advanced DIYers. ⚙️ Engine Specifications Primary Engine Engine Options: 2.2L EJ22 SOHC (1995-1996), 2.5L EJ25 DOHC (1997-1999), 2.5L EJ25 SOHC (GT models) Performance 2.2L Ej22 Hp Torque: 135 hp @ 5600 rpm, 140 lb-ft @ 4400 rpm (approximate) 2.5L Ej25 DOHc Hp Torque: 165 hp @ 6000 rpm, 162 lb-ft @ 4000 rpm (approximate) 2.5L Ej25 Sohc Gt Hp Torque: 165 hp @ 5600 rpm, 177 lb-ft @ 4000 rpm (approximate, GT Turbo) - Note: Base 2.5L SOHC also existed without turbo Fuel System Fuel System Type: Multi-port Fuel Injection (MPI) Engine Design Configuration: Horizontally Opposed (Boxer) Valvetrain: SOHC (2.2L, some 2.5L) or DOHC (some 2.5L) Engine Maintenance Timing Belt Replacement Interval: Typically every 60,000 to 105,000 miles or 5-7 years, depending on model year and specific engine. Crucial for EJ series engines. 🔧 Transmission Standard Standard Transmission Type: 5-speed Manual Transmission Optional Optional Transmission Type: 4-speed Automatic Transmission (with AWD) Features AWD System Type: Symmetrical All-Wheel Drive (Active AWD or Viscous Coupling Center Differential depending on transmission and trim) Fluid Specifications Automatic Transmission Fluid Type: Subaru ATF HP or equivalent Dexron-III/Mercon compatible fluid (verify specific year/model) Manual Transmission Fluid Type: API GL-5, SAE 75W-90 gear oil (verify specific year/model) 📐 Dimensions Exterior Wheelbase: 104.3 inches Length: Sedan: 185.0 inches, Wagon: 187.0 inches (approximate) Width: 69.7 inches (approximate) Height: Sedan: 56.1 inches, Wagon: 58.7 inches (approximate) Weights Curb Weight: Approximately 3,000 - 3,400 lbs, depending on body style and drivetrain 🛡️ Safety Features Ratings NHTSA Front Crash Test Rating: 4/5 stars (driver and passenger) for models equipped with airbags (verify specific year) IIHS Front Offset Crash Rating: Good for models tested (verify specific year and report) Active Features Active Safety Features: Standard All-Wheel...
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Subaru Legacy 1995-1999 Online Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy
Generation
Generation:
Third Generation (BD/BG/BK/BH)
Codes
Chassis Codes:
BD (Sedan), BG (Wagon)
👋 Introduction
Market Position
Market Positioning:
The Subaru Legacy in this era was positioned as a mid-size sedan and wagon known for its standard All-Wheel Drive (AWD) capability, offering a balance of comfort, practicality, and Subaru's signature driving dynamics.
Competitive Analysis
Key Competitors:
Honda Accord, Toyota Camry, Nissan Altima, Ford Taurus, Chevrolet Lumina, Mazda 626
Key Features
Vehicle Highlights:
Standard Symmetrical All-Wheel Drive, horizontally opposed Boxer engines, comfortable ride, spacious interior for its class, available wagon body style offering practicality.
AWD System Benefits:
The Symmetrical AWD system provided superior traction and stability in various weather conditions compared to many front-wheel-drive competitors, a significant selling point for Subaru.
📋 Manual Details
Coverage Areas
Covered Years:
1995, 1996, 1997, 1998, 1999
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Online Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF or web-based)
Access Method:
Online access, likely downloadable or viewable via a web browser. May offer search functionality for quick information retrieval.
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel injection, ignition, exhaust, cooling, lubrication, manual and automatic transmissions, AWD system (Active AWD/Viscous coupling center differential)
Chassis:
Suspension (front struts/coilovers, rear multi-link), steering, brakes (front ventilated discs, rear discs/drums), wheel bearings, driveline components
Electrical:
Wiring diagrams, lighting, charging system, starting system, instrumentation, comfort controls, power accessories, ABS, SRS (Airbag) systems
Body And Trim:
Exterior body panels, interior trim, doors, glass, seats, HVAC system, body control modules
Fuel And Emissions:
Fuel pump testing, injector cleaning and testing, evaporative emission control (EVAP) system diagnostics, oxygen sensor testing, EGR system service.
Procedures Included
Maintenance:
Scheduled maintenance (oil changes, filter replacements, fluid checks), brake pad replacement, spark plug replacement, belt replacement, air filter replacement
Repair:
Engine disassembly/reassembly, transmission overhaul, brake caliper replacement, suspension component replacement, electrical component diagnosis and replacement, body panel repair
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, electrical system diagnostics, mechanical component diagnostics
Special Procedures:
Timing belt replacement, head gasket replacement (if applicable to specific engines), AWD system servicing, airbag system servicing (safety precautions)
Engine Mechanical Procedures:
Cylinder head removal/installation, piston and connecting rod servicing, crankshaft bearing replacement, valve stem seal replacement, oil pump servicing.
Transmission Repair Procedures:
Clutch replacement, torque converter replacement, valve body servicing (automatic), gear inspection and replacement (manual).
Technical Depth
Depth:
Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds. Includes detailed diagnostic procedures and specifications.
Diagnostic Information:
Includes detailed diagnostic flowcharts, component testing procedures, resistance values, voltage checks, and reference specifications for diagnosing faults.
📊 Manual Specifications
File Format
Digital Format Details:
Likely a searchable PDF, allowing for quick access to information via keywords. May include high-resolution diagrams and images.
Print Quality
Print Quality Notes:
While digital, if printable, expect clear text and sharp diagrams. Designed for clarity in diagnostic and repair processes.
Binding Type
Binding Type:
Not applicable (digital format)
Paper Type
Paper Type:
Not applicable (digital format)
Completeness
Manual Scope:
Comprehensive coverage of all major mechanical, electrical, and body systems. Intended for professional technicians and advanced DIYers.
⚙️ Engine Specifications
Primary Engine
Engine Options:
2.2L EJ22 SOHC (1995-1996), 2.5L EJ25 DOHC (1997-1999), 2.5L EJ25 SOHC (GT models)
Performance
2.2L Ej22 Hp Torque:
135 hp @ 5600 rpm, 140 lb-ft @ 4400 rpm (approximate)
2.5L Ej25 DOHc Hp Torque:
165 hp @ 6000 rpm, 162 lb-ft @ 4000 rpm (approximate)
2.5L Ej25 Sohc Gt Hp Torque:
165 hp @ 5600 rpm, 177 lb-ft @ 4000 rpm (approximate, GT Turbo) - Note: Base 2.5L SOHC also existed without turbo
Fuel System
Fuel System Type:
Multi-port Fuel Injection (MPI)
Engine Design
Configuration:
Horizontally Opposed (Boxer)
Valvetrain:
SOHC (2.2L, some 2.5L) or DOHC (some 2.5L)
Engine Maintenance
Timing Belt Replacement Interval:
Typically every 60,000 to 105,000 miles or 5-7 years, depending on model year and specific engine. Crucial for EJ series engines.
🔧 Transmission
Standard
Standard Transmission Type:
5-speed Manual Transmission
Optional
Optional Transmission Type:
4-speed Automatic Transmission (with AWD)
Features
AWD System Type:
Symmetrical All-Wheel Drive (Active AWD or Viscous Coupling Center Differential depending on transmission and trim)
Fluid Specifications
Automatic Transmission Fluid Type:
Subaru ATF HP or equivalent Dexron-III/Mercon compatible fluid (verify specific year/model)
Manual Transmission Fluid Type:
API GL-5, SAE 75W-90 gear oil (verify specific year/model)
📐 Dimensions
Exterior
Wheelbase:
104.3 inches
Length:
Sedan: 185.0 inches, Wagon: 187.0 inches (approximate)
Width:
69.7 inches (approximate)
Height:
Sedan: 56.1 inches, Wagon: 58.7 inches (approximate)
Weights
Curb Weight:
Approximately 3,000 - 3,400 lbs, depending on body style and drivetrain
🛡️ Safety Features
Ratings
NHTSA Front Crash Test Rating:
4/5 stars (driver and passenger) for models equipped with airbags (verify specific year)
IIHS Front Offset Crash Rating:
Good for models tested (verify specific year and report)
Active Features
Active Safety Features:
Standard All-Wheel Drive (enhances traction and stability), Anti-lock Braking System (ABS) available on many trims.
Passive Features
Passive Safety Features:
Dual front airbags (SRS), crumple zones, reinforced safety cage, side-impact door beams, available pretensioner seatbelts.
💡 Technology Features
Infotainment
Infotainment Features:
Basic AM/FM/CD or cassette player, analog climate controls, power windows and locks on higher trims. Limited in-car technology by modern standards.
Driver Assistance
Driver Assistance Features:
ABS (available), standard AWD for stability. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane-keeping assist.
Connectivity
Connectivity Features:
Typically none beyond a 12V power outlet. No USB, Bluetooth, or integrated smartphone connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 6 months (severe conditions) / 7,500 miles or 12 months (normal conditions), using synthetic oil recommended for optimal performance.
Tire Rotation Interval:
Every 7,500 miles or as recommended by tire manufacturer.
Coolant Flush Interval:
Every 30,000 miles or 2-3 years, using Subaru Super Coolant or equivalent.
Fluid Specifications
Engine Oil Type:
API Service SG or higher. Viscosity: 5W-30 or 5W-40 recommended (refer to owner's manual for specific temperature ranges). Subaru explicitly recommends their synthetic oil.
Coolant Type:
Subaru Super Coolant (blue) or equivalent ethylene glycol-based coolant with Subaru additive package. Do not mix coolant types.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (verify specific year/model).
Known Issues
Common Issues:
Head gasket leaks (especially on early EJ25 DOHC), oil leaks from seals and gaskets, A/C compressor failures, radiator leaks, catalytic converter issues, worn suspension components (bushings, struts).
Engine Internal Wear:
Piston slap and oil consumption can occur on higher mileage EJ engines. The manual would provide detailed diagnosis for these.
📚 Vehicle History
Brand Heritage
Subaru Heritage Highlights:
Subaru has a long history of developing durable vehicles, with a strong emphasis on AWD technology and Boxer engines, rooted in aircraft manufacturing.
Model Evolution
Third Generation Introduction:
The third generation (BD/BG/BK/BH) was introduced in late 1994 for the 1995 model year, representing a significant redesign with improved styling, chassis, and interior.
Updates During Generation:
Key updates included the introduction of the 2.5L DOHC engine and GT models in 1997, offering more power. Styling revisions also occurred during this generation.
Production
Production Locations:
Primarily manufactured in Japan (Gunma Plant).
🏆 Awards & Recognition
Recognitions
Safety Awards:
Many models from this era received good safety ratings from NHTSA and IIHS, contributing to Subaru's reputation for safety.
Ratings
Consumer Reports Ratings:
Generally received average to good ratings for reliability in its class during its production years, with some specific engine variants having known issues (e.g., head gaskets).
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