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Subaru Legacy 1997 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 1997 Codes Chassis Code: BD/BG/BK Generation: Second Generation (BG/BK) 👋 Introduction Market Position Segment: Mid-size sedan and wagon, known for its standard AWD and rally heritage. Competitive Analysis Key Competitors: Toyota Camry, Honda Accord, Ford Taurus, Nissan Altima. Key Features Standard AWD: Symmetrical All-Wheel Drive system was a defining feature, offering superior traction. Horizontally Opposed Engine: Subaru's signature Boxer engine provided a lower center of gravity. Durability: Reputation for robust construction and reliability. 📋 Manual Details Coverage Areas Manual Type: Service Repair Workshop Manual Language: English Format: Digital (assumed PDF) Page Count Estimated Page Count: 1000+ Completeness: Comprehensive 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, and overhaul for all 1997 Legacy engine variants (EJ22, EJ25D). Transmission: Coverage for 5-speed manual and 4-speed automatic transmissions, including fluid types, overhaul procedures, and shift control. Drivetrain: Subaru's Symmetrical All-Wheel Drive (AWD) system, including center differential, front and rear axles, and related components. Suspension: Front and rear suspension systems, including struts, springs, control arms, bushings, and alignment procedures. Brakes: Front disc and rear drum or disc brakes (depending on trim), including hydraulic system, rotor/pad replacement, parking brake. Steering: Power steering system, steering rack, column, and associated components. Cooling System: Radiator, hoses, thermostat, water pump, and coolant specifications. Fuel System: Fuel pump, injectors, fuel filter, pressure regulator, and EFI system diagnostics. Electrical System: Battery, alternator, starter, ignition system, lighting, and wiring diagrams. HVAC: Heating, Ventilation, and Air Conditioning system components and service. Body And Chassis: Body panel removal/installation, chassis components, interior trim, and exterior features. Procedures Included Maintenance: Oil changes, filter replacements, spark plug service, belt adjustments, fluid checks, and general tune-ups. Troubleshooting: Diagnostic procedures, symptom-based troubleshooting guides, and common issue resolution. Repair: Step-by-step instructions for component removal, installation, and repair across all major vehicle systems. Rebuilds: Detailed instructions for engine and transmission overhauls, including specifications for internal components. Diagnostics: OBD-I troubleshooting, sensor testing, and electrical system diagnostics. Technical Depth Depth Level: Factory-level, detailed diagnostic and repair procedures. Specifications: Includes torque values, clearances, fluid capacities, and electrical resistance readings. Wiring Diagrams: Comprehensive, system-specific wiring schematics. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Searchability: Text-searchable (if OCR'd) Print Quality Printability: Printable pages for on-demand use. Binding Type Physical Binding: N/A (Digital Format) Paper Type Physical Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code 1: EJ22 Engine Type 1: 2.2L SOHC Flat-4 (Boxer) Horsepower 1: 135 hp @ 5600 rpm Torque 1: 135 lb-ft @ 4400 rpm Bore Stroke 1: 96.9 mm x 75.0 mm Compression Ratio 1: 9.0:1 Secondary Engine Engine Code 2: EJ25D Engine Type 2: 2.5L DOHC Flat-4 (Boxer) Horsepower 2: 165 hp @ 6000 rpm Torque 2: 166 lb-ft @ 4000 rpm Bore Stroke 2: 99.5 mm x 79.0 mm Compression Ratio 2: 9.5:1 Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (87 octane recommended) Ignition System: Distributorless Ignition System (DIS) or Distributor-based (depending on market/spec) 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Optional Transmission Type: 4-speed Electronically Controlled Automatic Transmission Features AWD System: All-Wheel Drive (AWD) standard on all models. Center Differential: Viscous coupling limited-slip center differential (5-speed manual) or electronically controlled clutch pack (automatic). Fluid Specifications Manual Transmission Fluid: Subaru Extra S API GL-5 75W-90 (or equivalent) Automatic Transmission Fluid: Subaru ATF HP (or equivalent) 📐 Dimensions Exterior Wheelbase: 2575 mm (101.4 in) Length: 4595 mm (180.9 in) Width: 1700 mm (66.9 in) Height: 1425 mm (56.1 in) Weights Curb Weight: 1350 - 1450 kg (approx.) Gross Vehicle Weight Rating: Varies by model and configuration Cargo Trunk Capacity Sedan: Approx. 14 cu ft Cargo Capacity Wagon: Approx. 33 cu ft (rear seats up) 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: 4 stars NHTSA Frontal Impact Passenger: 4 stars Active Features ABS: Available Anti-lock Braking System (ABS) AWD Traction: Standard Symmetrical All-Wheel Drive for enhanced traction and stability. Passive Features Airbags: Driver and front passenger airbags Seatbelts: 3-point front and rear seatbelts, pre-tensioners for front occupants Rollover Protection: Reinforced chassis and body structure. 💡 Technology Features Infotainment Audio System: Factory-installed AM/FM stereo with cassette player, optional CD player. Speakers: Typically 4 or 6 speaker configurations. Driver Assistance Cruise Control: Standard on most models. All Wheel Drive: The primary technological advantage, offering enhanced stability and traction. 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles or 6 months, whichever comes first. Engine Oil Filter: Replace with every oil change. Air Filter Replacement: Every 30,000 miles or 2 years. Spark Plug Replacement: Every 60,000 miles (Platinum or Iridium plugs recommended). Timing Belt Replacement: Crucial: Every 90,000 miles or 7 years. Failure can cause catastrophic engine damage. Fluid Specifications Engine Oil Type: API SG or higher, SAE 10W-30 (or 5W-30 in very cold climates) Coolant Type: Subaru Genuine Antifreeze/Coolant (Blue)...
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Subaru Legacy 1997 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy
Year:
1997
Codes
Chassis Code:
BD/BG/BK
Generation:
Second Generation (BG/BK)
👋 Introduction
Market Position
Segment:
Mid-size sedan and wagon, known for its standard AWD and rally heritage.
Competitive Analysis
Key Competitors:
Toyota Camry, Honda Accord, Ford Taurus, Nissan Altima.
Key Features
Standard AWD:
Symmetrical All-Wheel Drive system was a defining feature, offering superior traction.
Horizontally Opposed Engine:
Subaru's signature Boxer engine provided a lower center of gravity.
Durability:
Reputation for robust construction and reliability.
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Workshop Manual
Language:
English
Format:
Digital (assumed PDF)
Page Count
Estimated Page Count:
1000+
Completeness:
Comprehensive
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, and overhaul for all 1997 Legacy engine variants (EJ22, EJ25D).
Transmission:
Coverage for 5-speed manual and 4-speed automatic transmissions, including fluid types, overhaul procedures, and shift control.
Drivetrain:
Subaru's Symmetrical All-Wheel Drive (AWD) system, including center differential, front and rear axles, and related components.
Suspension:
Front and rear suspension systems, including struts, springs, control arms, bushings, and alignment procedures.
Brakes:
Front disc and rear drum or disc brakes (depending on trim), including hydraulic system, rotor/pad replacement, parking brake.
Steering:
Power steering system, steering rack, column, and associated components.
Cooling System:
Radiator, hoses, thermostat, water pump, and coolant specifications.
Fuel System:
Fuel pump, injectors, fuel filter, pressure regulator, and EFI system diagnostics.
Electrical System:
Battery, alternator, starter, ignition system, lighting, and wiring diagrams.
HVAC:
Heating, Ventilation, and Air Conditioning system components and service.
Body And Chassis:
Body panel removal/installation, chassis components, interior trim, and exterior features.
Procedures Included
Maintenance:
Oil changes, filter replacements, spark plug service, belt adjustments, fluid checks, and general tune-ups.
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting guides, and common issue resolution.
Repair:
Step-by-step instructions for component removal, installation, and repair across all major vehicle systems.
Rebuilds:
Detailed instructions for engine and transmission overhauls, including specifications for internal components.
Diagnostics:
OBD-I troubleshooting, sensor testing, and electrical system diagnostics.
Technical Depth
Depth Level:
Factory-level, detailed diagnostic and repair procedures.
Specifications:
Includes torque values, clearances, fluid capacities, and electrical resistance readings.
Wiring Diagrams:
Comprehensive, system-specific wiring schematics.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Searchability:
Text-searchable (if OCR'd)
Print Quality
Printability:
Printable pages for on-demand use.
Binding Type
Physical Binding:
N/A (Digital Format)
Paper Type
Physical Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
EJ22
Engine Type 1:
2.2L SOHC Flat-4 (Boxer)
Horsepower 1:
135 hp @ 5600 rpm
Torque 1:
135 lb-ft @ 4400 rpm
Bore Stroke 1:
96.9 mm x 75.0 mm
Compression Ratio 1:
9.0:1
Secondary Engine
Engine Code 2:
EJ25D
Engine Type 2:
2.5L DOHC Flat-4 (Boxer)
Horsepower 2:
165 hp @ 6000 rpm
Torque 2:
166 lb-ft @ 4000 rpm
Bore Stroke 2:
99.5 mm x 79.0 mm
Compression Ratio 2:
9.5:1
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 octane recommended)
Ignition System:
Distributorless Ignition System (DIS) or Distributor-based (depending on market/spec)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission
Optional
Transmission Type:
4-speed Electronically Controlled Automatic Transmission
Features
AWD System:
All-Wheel Drive (AWD) standard on all models.
Center Differential:
Viscous coupling limited-slip center differential (5-speed manual) or electronically controlled clutch pack (automatic).
Fluid Specifications
Manual Transmission Fluid:
Subaru Extra S API GL-5 75W-90 (or equivalent)
Automatic Transmission Fluid:
Subaru ATF HP (or equivalent)
📐 Dimensions
Exterior
Wheelbase:
2575 mm (101.4 in)
Length:
4595 mm (180.9 in)
Width:
1700 mm (66.9 in)
Height:
1425 mm (56.1 in)
Weights
Curb Weight:
1350 - 1450 kg (approx.)
Gross Vehicle Weight Rating:
Varies by model and configuration
Cargo
Trunk Capacity Sedan:
Approx. 14 cu ft
Cargo Capacity Wagon:
Approx. 33 cu ft (rear seats up)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4 stars
NHTSA Frontal Impact Passenger:
4 stars
Active Features
ABS:
Available Anti-lock Braking System (ABS)
AWD Traction:
Standard Symmetrical All-Wheel Drive for enhanced traction and stability.
Passive Features
Airbags:
Driver and front passenger airbags
Seatbelts:
3-point front and rear seatbelts, pre-tensioners for front occupants
Rollover Protection:
Reinforced chassis and body structure.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with cassette player, optional CD player.
Speakers:
Typically 4 or 6 speaker configurations.
Driver Assistance
Cruise Control:
Standard on most models.
All Wheel Drive:
The primary technological advantage, offering enhanced stability and traction.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 6 months, whichever comes first.
Engine Oil Filter:
Replace with every oil change.
Air Filter Replacement:
Every 30,000 miles or 2 years.
Spark Plug Replacement:
Every 60,000 miles (Platinum or Iridium plugs recommended).
Timing Belt Replacement:
Crucial: Every 90,000 miles or 7 years. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 10W-30 (or 5W-30 in very cold climates)
Coolant Type:
Subaru Genuine Antifreeze/Coolant (Blue) or equivalent ethylene glycol-based coolant (50/50 mix).
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Head Gasket Failure:
A common issue, particularly on EJ25D engines, due to design limitations. Early detection and replacement is critical.
Catalytic Converter:
Can fail over time, leading to reduced performance and emissions issues.
Suspension Wear:
Bushings and struts can wear out, leading to noise and handling issues.
Automatic Transmission Slippage:
Can occur with age and mileage; regular fluid changes are important.
📚 Vehicle History
Brand Heritage
Subaru History:
Founded in 1953, Subaru (Fuji Heavy Industries) has a history rooted in aviation and a unique focus on horizontally opposed engines and All-Wheel Drive technology.
Model Evolution
Legacy Introduction:
The Subaru Legacy was introduced in 1989 as a replacement for the Subaru Leone.
Second Generation:
The second generation (BD/BG/BK) debuted for the 1995 model year, featuring updated styling, a larger chassis, and the introduction of the 2.5L EJ25D engine.
Production
Manufacturing Location:
Gunma Plant, Japan
Production Years For Gen 2:
1995-1999
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Subaru Legacy models (including earlier generations) frequently appeared on Car and Driver's 10Best list for their performance and value.
Ratings
Consumer Reports Reliability:
Generally considered average to good reliability, with specific model years and engines having known issues (e.g., head gaskets).
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