🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 1991 Codes Chassis Code: BC/BF/BJ 👋 Introduction Market Position Vehicle Segment: Mid-size Sedan/Wagon Usp: Standard All-Wheel Drive (AWD), reputation for reliability and durability Competitive Analysis Competitors: Toyota Camry, Honda Accord, Mazda 626, Nissan Stanza Key Features Powertrain Emphasis: Horizontally-opposed (Boxer) engine, Symmetrical All-Wheel Drive Design Philosophy: Functional, symmetrical engineering for stability and traction Manual Value Benefit For Technicians: Provides factory-level accuracy for efficient diagnostics and repairs. Benefit For Enthusiasts: Empowers owners with the knowledge to perform complex maintenance and repairs, saving money and understanding their vehicle deeply. 📋 Manual Details Coverage Areas Manual Type: Factory Service Manual / Repair Manual Language: English Format: PDF Download Page Count: Estimated 1000+ pages (typical for factory service manuals of this era) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, tuning, fuel injection, ignition system, cooling system, lubrication system Transmission: Manual (5-speed), Automatic (4-speed) overhaul, adjustment, and repair; clutch system Drivetrain: All-Wheel Drive (AWD) system, differentials, driveshafts, CV joints Suspension: Front MacPherson struts, Rear independent suspension, shock absorbers, springs, bushings, alignment procedures Brakes: Front ventilated discs, Rear discs/drums (model dependent), ABS (if equipped), hydraulic system, parking brake Steering: Power steering system, steering rack, tie rods, steering column Electrical: Wiring diagrams, charging system, starting system, lighting, gauges, instrumentation, power windows, door locks, ECU diagnostics Bodywork: Body panel repair, interior trim, glass replacement, corrosion prevention HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, spark plug replacement, belt adjustments Troubleshooting: Diagnostic procedures, common problems and their solutions, DTC (Diagnostic Trouble Code) interpretation (for applicable systems) Repair: Step-by-step repair instructions for all major vehicle systems, component removal and installation Diagnostics: Engine diagnostics, electrical system troubleshooting, component testing Specifications: Torque specifications, fluid capacities, tolerances, wear limits Technical Depth Depth Level: Comprehensive (from basic maintenance to complete engine and transmission rebuilds) Target Audience: Professional Technicians, experienced DIY enthusiasts 📊 Manual Specifications File Format File Type: Digital PDF Searchable: Yes (typically, depending on scan quality) Printable: Yes Resolution: High-resolution scans ensuring clarity of diagrams and text Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code 1: EJ22 Engine Type 1: Naturally Aspirated, SOHC Boxer-4 Displacement 1: 2.2 Liters (2212 cc) Bore X Stroke 1: 92.0 mm x 83.0 mm Compression Ratio 1: 9.5:1 Horsepower 1: 110 hp @ 5000 rpm Torque 1: 137 lb-ft @ 4000 rpm Fuel System 1: Multi-point Fuel Injection (MPI) Engine Variants Engine Code 2: EJ22T (Turbocharged) Engine Type 2: Turbocharged, SOHC Boxer-4 Horsepower 2: 165 hp @ 5600 rpm Torque 2: 181 lb-ft @ 3200 rpm Fuel System 2: Multi-point Fuel Injection (MPI) with Turbocharger Fuel Type Recommended Fuel: Unleaded Regular (87 Octane), Premium for Turbo models is recommended 🔧 Transmission Standard Transmission Type Std: 5-speed Manual Drivetrain Std: Symmetrical All-Wheel Drive (AWD) Optional Transmission Type Opt: 4-speed Automatic Drivetrain Opt: Full-time All-Wheel Drive (AWD) with Lockable Center Differential Features Clutch Type: Dry, Single Plate Transmission Fluid Manual: API GL-4, SAE 75W-90 Gear Oil Transmission Fluid Automatic: Subaru ATF-HP or equivalent DEXRON-III/MERCON 📐 Dimensions Exterior Wheelbase: 101.4 inches (2575 mm) Length: 178.1 inches (4525 mm) Width: 67.1 inches (1705 mm) Height: 55.3 inches (1405 mm) (Sedan) / 58.1 inches (1475 mm) (Wagon) Weights Curb Weight Min: Approx. 2760 lbs (1250 kg) (2.2L Manual Sedan) Curb Weight Max: Approx. 3100 lbs (1406 kg) (2.2L Turbo Automatic Wagon) Gross Vehicle Weight Rating: Varies by model and configuration Towing Capacity: Not specified by manufacturer for this model year 🛡️ Safety Features Ratings NHTSA Frontal Impact: Not rated by NHTSA in 1991 IIHS Crash Tests: Not tested by IIHS in 1991 Active Features ABS: Optional on some models AWD System: Standard Symmetrical All-Wheel Drive Passive Features Airbags: Driver-side airbag standard on most models Seatbelts: 3-point front seatbelts, 2-point rear seatbelts (later models may have 3-point rear) Crumple Zones: Designed with front and rear crumple zones 💡 Technology Features Infotainment Audio System: Factory AM/FM Cassette player, optional CD player on higher trims Speakers: Typically 4 to 6 speakers depending on trim level Driver Assistance Cruise Control: Optional Connectivity Connectivity Features: None from factory (pre-internet era) 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 - 5,000 miles (5,000 - 8,000 km) or 6 months, whichever comes first Air Filter Replacement: Every 15,000 - 30,000 miles (24,000 - 48,000 km) Spark Plug Replacement: Every 30,000 miles (48,000 km) Timing Belt Replacement: Every 60,000 miles (96,000 km) or 4 years (critical for interference engines) Coolant Flush: Every 2 years or 30,000 miles (48,000 km) Fluid Specifications Engine Oil Capacity: 4.7 US quarts (4.4 liters) with filter (EJ22) Engine Oil Viscosity: 10W-30 or 10W-40 recommended for most climates Coolant Type: Ethylene Glycol based coolant, 50/50 mix with distilled water Brake...
Approx. 3100 lbs (1406 kg) (2.2L Turbo Automatic Wagon)
Gross Vehicle Weight Rating:
Varies by model and configuration
Towing Capacity:
Not specified by manufacturer for this model year
🛡️ Safety Features
Ratings
NHTSA Frontal Impact:
Not rated by NHTSA in 1991
IIHS Crash Tests:
Not tested by IIHS in 1991
Active Features
ABS:
Optional on some models
AWD System:
Standard Symmetrical All-Wheel Drive
Passive Features
Airbags:
Driver-side airbag standard on most models
Seatbelts:
3-point front seatbelts, 2-point rear seatbelts (later models may have 3-point rear)
Crumple Zones:
Designed with front and rear crumple zones
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM Cassette player, optional CD player on higher trims
Speakers:
Typically 4 to 6 speakers depending on trim level
Driver Assistance
Cruise Control:
Optional
Connectivity
Connectivity Features:
None from factory (pre-internet era)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 5,000 miles (5,000 - 8,000 km) or 6 months, whichever comes first
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km)
Spark Plug Replacement:
Every 30,000 miles (48,000 km)
Timing Belt Replacement:
Every 60,000 miles (96,000 km) or 4 years (critical for interference engines)
Coolant Flush:
Every 2 years or 30,000 miles (48,000 km)
Fluid Specifications
Engine Oil Capacity:
4.7 US quarts (4.4 liters) with filter (EJ22)
Engine Oil Viscosity:
10W-30 or 10W-40 recommended for most climates
Coolant Type:
Ethylene Glycol based coolant, 50/50 mix with distilled water
Brake Fluid:
DOT 3
Power Steering Fluid:
ATF DEXRON-II or equivalent
Known Issues
Head Gaskets:
While not as prevalent as later generations, some EJ series engines can develop head gasket leaks.
Crankshaft Position Sensor:
Early models may experience CPS failure leading to no-start or stalling.
Idler Pulley Bearing:
The idler pulley bearing on the timing belt can fail prematurely, requiring replacement to avoid catastrophic engine damage.
Rust Corrosion:
Like many vehicles of this era, body panels, especially around wheel wells and rocker panels, can be susceptible to rust.
Part Numbers
Oil Filter Example:
Subaru Part Number: 15208AA031 (or aftermarket equivalent like Fram PH7317, Wix 51515)
Air Filter Example:
Subaru Part Number: 16546AA020 (or aftermarket equivalent like Fram CA8529)
Spark Plug Example:
NGK BKR6E (or equivalent)
Timing Belt Example:
Subaru Part Number: 13028AA070 (or aftermarket equivalent kit)
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Japan
Founding Year:
1953
Model Evolution
First Generation Start:
1989
First Generation End:
1994
Chassis Codes Gen1:
BC (Sedan), BF (Wagon), BJ (Hardtop Coupe)
Facelift Timing:
Minor styling updates occurred throughout the generation, particularly for 1992 and 1993 models.
Production
Manufacturing Plant:
Ota, Gunma, Japan
Production Run 1991:
Significant production volume as it was a core model for Subaru in North America and other markets.
🏆 Awards & Recognition
Recognitions
Historical Accolades:
Subaru's reputation for AWD and durability was building during this era, though specific model awards for the '91 Legacy are less prominent than later generations. Often lauded for its handling and all-weather capability.
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