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Subaru Legacy 2004-2005 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 2004-2005 👋 Introduction Market Position Segment: Mid-size sedan/wagon, known for all-wheel-drive capability and reliability Competitive Analysis Competitors 2004-2005: Toyota Camry, Honda...
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Subaru Legacy 2004-2005 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy
Year:
2004-2005
👋 Introduction
Market Position
Segment:
Mid-size sedan/wagon, known for all-wheel-drive capability and reliability
Competitive Analysis
Competitors 2004-2005:
Toyota Camry, Honda Accord, Mazda 6, Nissan Altima, Ford Fusion
Key Features Vehicle
All Wheel Drive:
Standard Symmetrical All-Wheel Drive (except for specific base models or transmissions in some markets).
Engine Options:
Two primary engine options: naturally aspirated 2.5L Boxer-4 and turbocharged 2.5L Boxer-4 (GT models).
Manual Utility
Value Proposition:
Inexpensive way to maintain and repair the vehicle, extending its lifespan and performance.
📋 Manual Details
Coverage Areas
Engine Coverage:
2.5L H4 (Naturally Aspirated and Turbocharged)
Transmission Coverage:
4-speed Automatic, 5-speed Manual
Body Styles Covered:
Sedan, Wagon
Page Count
Estimated Pages:
Approximately 1500-2000 (typical for comprehensive workshop manuals)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, engine electrical, fuel system, exhaust system, transmission (automatic and manual), drivetrain (AWD components)
Chassis:
Suspension (front and rear), steering, brakes (hydraulic, ABS), wheels and tires
Electrical:
Body electrical systems, lighting, instrumentation, comfort and convenience, audio systems, wiring diagrams
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication
Repair:
Engine overhaul, transmission overhaul, brake component replacement, suspension component replacement, electrical component diagnosis and repair
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), electrical schematics interpretation
Technical Depth
Depth:
Comprehensive: from basic fluid checks to full engine and transmission rebuilds, including detailed diagnostic procedures and specifications
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, fully searchable text and images
Printable:
Yes, printable pages
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Quality:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code Na:
EJ253 (2.5L SOHC NA)
Engine Code Turbo:
EJ255 (2.5L DOHC Turbocharged - GT models)
Performance Na
Horsepower Na:
Approximately 165-170 hp @ 5600-6000 rpm
Torque Na:
Approximately 166-170 lb-ft @ 3600-4000 rpm
Performance Turbo
Horsepower Turbo:
Approximately 210-225 hp @ 5600 rpm
Torque Turbo:
Approximately 236-250 lb-ft @ 3600-4000 rpm
Fuel System
Injection Type:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane recommended for NA, 91 octane recommended for Turbocharged)
Engine Management
ECU Type:
Engine Control Unit (ECU) with OBD-II diagnostics
🔧 Transmission
Standard
Automatic Transmission:
4EAT (4-speed Electronically Controlled Automatic Transmission with AWD) - Standard on many models
Optional
Manual Transmission:
5-speed Manual Transmission - Optional on some models, standard on GT models with manual transmission.
Features
AWD System:
Symmetrical All-Wheel Drive system integrated with transmission, varying in configuration between manual and automatic transmissions.
Fluid Specs Automatic
Automatic Transmission Fluid:
Subaru ATF HP (or equivalent approved fluid)
Fluid Specs Manual
Manual Transmission Fluid:
API GL-5, SAE 75W-90 Gear Oil (Subaru Genuine Gear Oil recommended)
📐 Dimensions
Exterior Sedan Approx
Length:
187.4 inches
Width:
68.1 inches
Height:
57.7 inches
Exterior Wagon Approx
Length:
190.4 inches
Width:
68.1 inches
Height:
57.7 inches
Weights Approx
Curb Weight Start:
3200 lbs
Curb Weight End:
3500 lbs (depending on trim and drivetrain)
Wheelbase
Wheelbase:
104.1 inches
Track Width
Front Track:
59.1 inches
Rear Track:
58.7 inches
🛡️ Safety Features
Ratings Nhtsa 2004
Driver Front Impact:
5 Stars
Passenger Front Impact:
5 Stars
Driver Side Impact:
5 Stars
Passenger Side Impact:
5 Stars
Rear Passenger Side Impact:
5 Stars
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS) on some models
Passive Features
Airbags Front:
Front advanced airbags
Airbags Side:
Available front side-impact airbags, available front and rear side-curtain airbags (on select models/trims)
Seatbelts:
3-point seatbelts for all seating positions, pretensioners and load limiters for front seats
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with CD player. Higher trims may feature premium audio systems.
Navigation:
Optional factory navigation system on some higher trims.
Driver Assistance
Cruise Control:
Standard cruise control
Connectivity
Auxiliary Input:
Typically no standard auxiliary input; aftermarket solutions available.
🔧 Maintenance
Service Intervals General
Oil Change Interval:
Every 3,750 miles or 6 months (severe conditions) / 7,500 miles or 12 months (normal conditions) with synthetic oil. Check manual for specific recommendation.
Air Filter Replacement:
Every 15,000-30,000 miles, or as needed based on driving conditions.
Spark Plug Replacement Na:
Approx. 60,000 miles (Iridium spark plugs)
Spark Plug Replacement Turbo:
Approx. 30,000 miles (Platinum spark plugs)
Fluid Specifications
Engine Oil Capacity:
Approx. 4.5-4.8 quarts (with filter, 2.5L)
Engine Oil Type:
SAE 5W-30 Synthetic (API SM or higher)
Coolant Type:
Subaru Super Coolant (or equivalent HOAT-compliant coolant)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Head Gaskets:
While less prevalent than in earlier generations, some EJ25 engines can still be susceptible to head gasket leaks, particularly if overheated or poorly maintained. The manual will detail inspection and replacement procedures.
Turbocharger Issues Gt:
Turbocharged models (GT) may experience turbo wear or oil seal failures if oil changes are neglected or if the turbo is subjected to extreme heat cycles. Manual covers turbo diagnosis and repair.
Automatic Transmission Behavior:
Some users report occasional hesitant shifting; manual provides diagnostic steps for transmission control module (TCM) and hydraulic system issues.
📚 Vehicle History
Brand Heritage
Subaru Philosophy:
Known for its engineering prowess, particularly its horizontally opposed ('Boxer') engines and Symmetrical All-Wheel Drive systems.
Model Evolution
Legacy Generation 2004-2005:
Fourth Generation (BP/BL chassis), introduced for the 2005 model year, with the 2004 model often considered the end of the third generation (BE/BH chassis) or an overlap depending on market introduction timing. This manual primarily covers the transition and the start of the fourth generation.
Production
Manufacturing Plant:
Subaru of Indiana Automotive, Inc. (USA) and Gunma Plant (Japan)
🏆 Awards & Recognition
Recognitions
Iiihs Top Safety Pick:
The Subaru Legacy often received high safety ratings from organizations like the IIHS and NHTSA during this period, contributing to its reputation for safety.
Ratings
Consumer Reports Reliability:
Consumer Reports generally rated Subaru models, including the Legacy, as having average to above-average reliability, though specific model years and components could vary.
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