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Subaru Legacy 2000-2007 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy / Liberty Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Generation Generation Name: Fourth Generation (BP/BL) Codes Chassis Codes:...
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UGS: 268584
Subaru Legacy 2000-2007 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy / Liberty
Model Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007
Generation
Generation Name:
Fourth Generation (BP/BL)
Codes
Chassis Codes:
BP (Wagon), BL (Sedan)
👋 Introduction
Market Position
Segment:
Mid-size sedan and wagon, known for All-Wheel Drive and boxer engines
Usp:
Standard Symmetrical All-Wheel Drive, boxer engine configuration, reputation for durability and safety
Competitive Analysis
Competitors:
Toyota Camry, Honda Accord, Nissan Altima, Mazda6, Ford Fusion
Key Features
Powertrain Options:
Horizontally-opposed (boxer) engines, Symmetrical All-Wheel Drive
Design Philosophy:
Emphasis on practicality, safety, and all-weather capability
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive workshop service and repair
Page Count
Estimated Page Count:
Extensive, likely 1000+ pages (typical for full workshop manuals)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital Download (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, pistons, crankshaft, camshafts, timing systems, lubrication, cooling
Engine Performance:
Fuel injection, ignition system, emissions control, turbocharging (if applicable)
Transmission:
Manual and automatic transmission repair, clutch, torque converter, gear shift mechanisms, transfer case (AWD)
Drivetrain:
All-Wheel Drive (AWD) system, differentials, driveshafts, CV joints, wheel bearings
Brakes:
Hydraulic system, calipers, rotors, pads, ABS system, parking brake
Steering:
Power steering system, steering column, steering rack/gearbox
Suspension:
Front and rear suspension, shock absorbers, struts, springs, control arms, anti-roll bars
Electrical System:
Battery, charging system, starter, lighting, power windows, locks, mirrors, wipers, horn
HVAC:
Heating, ventilation, air conditioning system diagnosis and repair
Body And Interior:
Body panel repair, doors, hood, trunk, glass, interior trim, seats
Chassis And Frame:
Frame construction, mounting points, structural components
Diagnostic Troubleshooting:
Systematic troubleshooting guides, symptom-based diagnostics, DTC (Diagnostic Trouble Code) interpretation
Electronic Systems:
ECU (Engine Control Unit), TCU (Transmission Control Unit), Body Control Module (BCM), CAN bus communication
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, brake pad replacement
Major Repairs:
Engine rebuilds, transmission overhaul, suspension component replacement, brake system bleeding
Diagnostics:
Step-by-step diagnostic procedures for all major systems, including electrical and electronic faults
Troubleshooting:
Detailed guides for identifying and resolving common and uncommon vehicle problems
Component Replacement:
Instructions for removing and installing virtually all vehicle components
Specification Data:
Torque specifications, clearances, alignments, fluid capacities, wiring diagrams
Technical Depth
Depth:
Expert-level, suitable for professional technicians and advanced DIY mechanics
Detail Level:
Provides detailed assembly/disassembly procedures, internal component descriptions, and precise measurements
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Typically searchable text for efficient information retrieval
Print Quality
Quality:
High-resolution for clear text and diagrams
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code 2.5I:
EJ253 (Naturally Aspirated)
Engine Displacement 2.5I:
2.5 Liters (2498cc)
Engine Configuration 2.5I:
2.5L SOHC or DOHC Flat-4 (Boxer)
Horsepower 2.5I:
Approx. 165-175 hp (varies by year and spec)
Torque 2.5I:
Approx. 162-166 lb-ft (varies by year and spec)
Optional Engine
Engine Code 3.0R:
EZ30D (Naturally Aspirated)
Engine Displacement 3.0R:
3.0 Liters (2999cc)
Engine Configuration 3.0R:
3.0L DOHC Flat-6 (Boxer)
Horsepower 3.0R:
Approx. 245 hp
Torque 3.0R:
Approx. 217 lb-ft
Performance
Redline 2.5I:
Approx. 6500 RPM
Redline 3.0R:
Approx. 7000 RPM
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline, 87 octane recommended (higher may be specified for 3.0R)
Emission Controls:
Catalytic converters, EGR (Exhaust Gas Recirculation), PCV (Positive Crankcase Ventilation)
🔧 Transmission
Standard
Type 2.5I:
5-speed Manual Transmission
Optional
Type Auto:
4-speed Automatic Transmission
Type 3.0R Auto:
5-speed Automatic Transmission (with manual mode)
Features
AWD System:
Symmetrical All-Wheel Drive (Active Torque Split AWD for manuals, Variable Valve Timing AWD for automatics)
Manual Clutch:
Hydraulically actuated single dry plate clutch
Fluid Specs
Manual Transmission Fluid:
API GL-5, SAE 75W-90 (specific Subaru specs should be confirmed)
Automatic Transmission Fluid:
Subaru ATF-HP (Highly recommended, specific part number 40216AA070 or equivalent)
📐 Dimensions
Exterior
Wheelbase:
Approx. 104.0 inches (2640 mm)
Length Sedan:
Approx. 187.2 inches (4755 mm)
Length Wagon:
Approx. 188.8 inches (4800 mm)
Width:
Approx. 68.1 inches (1730 mm)
Height Sedan:
Approx. 56.1 inches (1425 mm)
Height Wagon:
Approx. 56.7 inches (1440 mm)
Weights
Curb Weight:
Approx. 3200-3500 lbs (1450-1600 kg), varies by model and options
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Driver:
5-Star (2005 model year)
NHTSA Frontal Crash Passenger:
5-Star (2005 model year)
IIHS Front Small Overlap Driver:
Good (for models tested later in the generation, specific year tested needed)
Active Features
AWD:
Standard Symmetrical All-Wheel Drive for enhanced traction and stability
ABS:
Standard Anti-lock Braking System
Ebd:
Electronic Brake-force Distribution
Traction Control:
Available (often integrated with VDC - Vehicle Dynamics Control)
Passive Features
Airbags:
Front airbags, side curtain airbags, front side airbags (depending on trim and year)
Seatbelts:
3-point height-adjustable front seatbelts with pretensioners and load limiters, rear 3-point seatbelts
Child Anchors:
LATCH (Lower Anchors and Tethers for Children) system
💡 Technology Features
Infotainment
Head Unit:
Factory-installed AM/FM/CD audio system, optional premium audio with subwoofer and amplifier
Display:
Basic LCD display for audio and climate information, no integrated navigation on most models
Driver Assistance
Cruise Control:
Standard electronic cruise control
Vdc:
Vehicle Dynamics Control (traction and stability control) available on higher trims or as an option
Connectivity
Auxiliary Input:
Often available as an aftermarket addition or on later models, not standard on all trims.
Bluetooth:
Not standard on most models in this generation, typically requires aftermarket installation.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 3 months for severe conditions, 7,500 miles (12,000 km) or 6 months for normal (check owner's manual for specifics)
Engine Air Filter:
Replace every 15,000-30,000 miles (24,000-48,000 km)
Cabin Air Filter:
Replace every 15,000-30,000 miles (24,000-48,000 km)
Spark Plugs 2.5I:
Iridium type, replace every 100,000 miles (160,000 km)
Timing Belt:
Timing chain (2.5L EJ253) - no scheduled replacement. Timing belt on older EJ engines, but this generation primarily uses chains or belts depending on specific engine variant (confirm with manual)
Fluid Specifications
Engine Oil:
SAE 5W-30, API SG or higher (check owner's manual for specific grade and certifications like ILSAC GF-3/GF-4)
Coolant:
Subaru Super Coolant (Blue) or equivalent silicate-free, ethylene glycol-based coolant, 50/50 mix with distilled water
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Head Gaskets:
Less common on this generation compared to earlier Subaru models, but still a potential concern, especially on older EJ25 engines. Look for coolant leaks or milky oil.
Ac Compressor:
Some reports of AC compressor failures
Wheel Bearings:
Can wear out prematurely, especially on AWD models due to increased load.
Catalytic Converter:
Can fail over time, leading to performance issues and check engine lights.
Automatic Transmission:
Some models may experience harsh shifting or torque converter issues over time, proper fluid maintenance is crucial.
📚 Vehicle History
Brand Heritage
Manufacturer:
Subaru Corporation (formerly Fuji Heavy Industries)
Key Technologies:
Pioneered boxer engines and All-Wheel Drive in passenger cars
Model Evolution
Generation Introduction:
Fourth Generation (BP/BL) introduced for the 2005 model year, replacing the third generation (BE/BH)
Styling Update:
Significant redesign from the previous generation, featuring a more modern and aerodynamic profile
Production
Production Period:
2004-2009 (for this generation)
Manufacturing Locations:
Japan (Ota Plant, Gunma Prefecture)
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick:
Subaru Legacy models from this generation often received good safety ratings, check specific model year IIHS reports for 'Top Safety Pick' status.
Konsumen Reports Ratings:
Generally received above-average reliability ratings from Consumer Reports in its segment, though specific year ratings vary.
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