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Subaru Legacy Outback Complete Workshop Service Repair Manual 1992 1993 1994 1995 1996 1997 1998 1999

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Outback Generation Generation Code: BD/BG Codes Chassis Codes: BD2, BD3, BD4, BD5, BD9, BG2, BG3, BG4, BG5, BG9, BHC Engine Codes: EJ22,...
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UGS: 494178
Subaru Legacy Outback Complete Workshop Service Repair Manual 1992 1993 1994 1995 1996 1997 1998 1999
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy Outback
Generation
Generation Code:
BD/BG
Codes
Chassis Codes:
BD2, BD3, BD4, BD5, BD9, BG2, BG3, BG4, BG5, BG9, BHC
Engine Codes:
EJ22, EJ25D, EJ251, EJ252, EJ20
👋 Introduction
Market Position
Vehicle Segment:
Mid-size Crossover SUV / Station Wagon, known for its AWD capability and practical utility.
Competitive Analysis
Key Competitors:
Toyota Camry/Scepter Wagon, Honda Accord Wagon, Mitsubishi Galant Wagon, Mazda 626 Wagon.
Key Features
All Wheel Drive:
Standard Symmetrical All-Wheel Drive system provided superior traction and stability in varying weather conditions, a key differentiator.
Practicality:
Offered a raised ride height and versatile cargo space, making it a popular choice for families and outdoor enthusiasts.
Safety Emphasis:
Subaru's reputation for safety, with a focus on robust construction and Boxer engine design contributing to a low center of gravity.
📋 Manual Details
Coverage Areas
Model Years Covered:
1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Page Count
Estimated Page Count:
Over 1500
Manual Type
Manual Type:
Complete Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed coverage of EJ22, EJ25D, EJ251, EJ252 naturally aspirated and turbocharged engines, including disassembly, assembly, diagnosis, and repair of all components.
Transmission:
Comprehensive coverage of 4-speed automatic (4EAT) and 5-speed manual transmissions, including removal, installation, internal component repair, and fluid specifications.
Drivetrain:
Detailed information on front-wheel drive and Subaru's legendary Symmetrical All-Wheel Drive system, including differential service, CV joints, driveshafts, and transfer case.
Suspension:
In-depth coverage of front and rear suspension systems, including struts, coil springs, control arms, bushings, sway bars, and alignment procedures.
Brakes:
Complete brake system diagnosis and repair, including front/rear disc brakes, ABS system components, hydraulic lines, master cylinder, and brake bleeding procedures.
Steering:
Power steering system service, including rack and pinion, power steering pump, hoses, and fluid specifications.
Electrical:
Extensive electrical system coverage, including wiring diagrams for all major systems, starter, alternator, battery, lighting, ignition system, and fuse/relay locations.
Climate Control:
Air conditioning and heating system diagnosis and repair, including refrigerant handling, compressor, evaporator, heater core, and blower motor.
Body And Interior:
Body panel removal/installation, door mechanisms, glass replacement, interior trim, seat removal, and basic body repair techniques.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, air filter service, and general inspection procedures.
Troubleshooting:
Detailed diagnostic flowcharts and symptom-based troubleshooting guides for engine performance, electrical faults, and mechanical issues.
Major Repairs:
Engine rebuild procedures, transmission overhaul, head gasket replacement, clutch replacement, and suspension component replacement.
Component Replacement:
Step-by-step instructions for replacing common wear items and major components such as fuel pumps, alternators, radiators, water pumps, and brake calipers.
Specifications And Tolerances:
Precise torque specifications for all fasteners, engine clearances, bearing preloads, and other critical dimensional data.
Technical Depth
Diagnostic Capabilities:
Covers on-board diagnostics (OBD-I and early OBD-II), including reading trouble codes and interpreting sensor data.
Repair Complexity:
Suitable for both DIY enthusiasts with moderate mechanical skills and professional technicians, providing clear, concise instructions for all levels of repair.
System Diagrams:
Includes detailed schematics and diagrams for electrical systems, vacuum routing, and fluid pathways.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution scans, ensuring clarity of text, diagrams, and photographs.
Binding Type
Binding Type:
Digital Download (N/A for physical)
Paper Type
Paper Type:
Digital Download (N/A for physical)
⚙️ Engine Specifications
Primary Engine
Ej22E:
2.2L SOHC EJ22E Boxer-4, naturally aspirated. Power: Approx. 110 hp @ 5000 rpm. Torque: Approx. 137 lb-ft @ 4000 rpm.
Ej25D:
2.5L DOHC EJ25D Boxer-4, naturally aspirated. Power: Approx. 165 hp @ 5600 rpm. Torque: Approx. 155 lb-ft @ 4000 rpm. (Later models).
Performance
Compression Ratio:
8.5:1 (EJ22E), 9.5:1 (EJ25D)
Bore X Stroke:
92.0 mm x 80.0 mm (EJ22E), 99.5 mm x 79.0 mm (EJ25D)
Fuel System
Fuel Injection:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (87 octane recommended, 91 octane for turbo models if applicable)
🔧 Transmission
Standard
Transmission Options:
5-speed manual transmission (standard on most trims) and 4-speed Electronically Controlled Automatic Transmission (4EAT, optional).
Optional
AWD Coupling:
Symmetrical All-Wheel Drive with viscous coupling center differential (manual) or electronically controlled clutch pack (automatic).
Features
Gear Ratios Manual:
Specific gear ratios vary by model year and engine, typically ranging from ~3.45:1 in first gear to ~0.82:1 in fifth gear.
Gear Ratios Automatic:
Typically a 3.6:1 first gear, 2.0:1 second gear, 1.4:1 third gear, and 0.7:1 overdrive.
Transmission Fluid:
Manual: Subaru Extra-S Gear Oil API GL-5 75W-90. Automatic: Subaru ATF-HP (High Performance) or Dexron II/III equivalent.
📐 Dimensions
Exterior
Wheelbase:
Approx. 104.3 inches (2649 mm)
Length:
Approx. 187.4 inches (4760 mm)
Width:
Approx. 69.1 inches (1755 mm)
Height:
Approx. 60.2 inches (1529 mm) (non-Outback), Approx. 62.0 inches (1575 mm) (Outback)
Cargo
Cargo Volume:
Approx. 30.7 cu ft (with rear seats up), Approx. 68.6 cu ft (with rear seats folded).
Weights
Curb Weight:
Approx. 3,100 - 3,400 lbs (1406 - 1542 kg), varies by trim and drivetrain.
Towing Capacity:
Rated for up to 2,000 lbs (907 kg) when properly equipped with trailer brake.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4-star rating (driver), 3-star rating (passenger) for 1996-1999 models (may vary slightly by year and specific test).
Active Features
Antilock Brakes:
Available on most models, particularly later years and higher trims.
Passive Features
Airbags:
Driver and passenger front airbags standard on most models from mid-90s onwards.
Seatbelts:
Three-point front and rear seatbelts, pretensioners on front seatbelts.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette or CD players, often with 4 or 6 speakers. Aftermarket head unit installation is common.
Driver Assistance
Cruise Control:
Standard on most higher trims, electronic cruise control system.
Connectivity
Power Accessories:
Power windows, power door locks, and power mirrors were available on various trims.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000 - 5,000 miles (4,800 - 8,000 km) or 6 months, depending on driving conditions (consult manual for specific recommendation).
Engine Oil Filter:
Replace with every oil change. Common part numbers: Subaru 15208AA031, Wix 51500.
Air Filter:
Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km). Common part numbers: Subaru 16546AA020, Wix 42315.
Spark Plugs:
Replace every 30,000 - 60,000 miles (48,000 - 96,000 km), depending on plug type. Use NGK platinum or iridium plugs.
Timing Belt:
Crucial: Replace every 60,000 - 90,000 miles (96,000 - 145,000 km) or 5-7 years. Includes idler pulleys and tensioner. Subaru part number for kit: 13069AA003 (check compatibility).
Fluid Specifications
Engine Oil:
10W-30 or 5W-30 API SG, SH, or SJ rated. Capacity: 4.8 US quarts (4.5 L) with filter (EJ22E), 4.8 US quarts (4.5 L) with filter (EJ25D).
Coolant:
Subaru Super Coolant (blue) or a 50/50 mix of ethylene glycol-based antifreeze and distilled water. Capacity: Approx. 7.0 US quarts (6.6 L).
Known Issues
Head Gaskets:
A well-documented issue, particularly with the EJ25D engine, prone to coolant leaks. Early detection and repair are critical.
Oil Leaks:
Valve cover gaskets and oil pan gaskets can degrade over time, leading to minor to moderate oil leaks.
Suspension Wear:
Worn strut mounts, ball joints, and control arm bushings are common due to age and mileage.
📚 Vehicle History
Brand Heritage
Subaru Core Values:
Subaru's commitment to AWD, reliability, and safety innovation has been a hallmark since its inception.
Model Evolution
First Generation Outback:
The Outback was introduced in 1995 as a variant of the Subaru Legacy, distinguished by its raised suspension, body cladding, and unique interior accents, creating the crossover SUV segment.
Updates During Generation:
Key updates included the introduction of the 2.5L DOHC EJ25D engine in 1996, offering increased power, and minor styling refreshes and feature additions throughout the years.
Production
Manufacturing Location:
Japan (Gunma Prefecture)
Production Years For This Generation:
1990-1999 (Legacy), 1995-1999 (Outback variant)
🏆 Awards & Recognition
Recognitions
Motor Trend Car Of The Year:
Subaru Legacy was a contender for MotorTrend Car of the Year in its early years, showcasing its competitive positioning.
Ratings
IIHS Top Safety Pick:
Subaru vehicles, including the Legacy Outback, consistently received good ratings from the Insurance Institute for Highway Safety (IIHS) for their crashworthiness.
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