Subaru Legacy 2004 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 2004 👋 Introduction Market Position Vehicle Class: Mid-size sedan and wagon, known for its Symmetrical All-Wheel Drive system. Competitive Analysis Competitors...

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Type: Car

Vendor:

Sku: 475676

Tags: 2004 Car Cars Legacy Misc Subaru

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy

Year:

👋 Introduction

Market Position

Vehicle Class:

Mid-size sedan and wagon, known for its Symmetrical All-Wheel Drive system.

Competitive Analysis

Competitors 2004:

Toyota Camry, Honda Accord, Nissan Altima, Mazda6, Ford Fusion.

Key Features

Standard AWD:

Subaru's signature Symmetrical All-Wheel Drive system was standard on most Legacy models in 2004, offering enhanced traction and stability.

Boxer Engine Layout:

Flat-four (boxer) engine configuration, contributing to a lower center of gravity for improved handling.

Safety Focus:

Subaru's reputation for safety, often achieving good crash test ratings.

📋 Manual Details

Coverage Areas

Manual Type:

Full Service Repair Manual

Language:

English

Format:

Digital (assumed PDF for sale, often referred to as 'electronic' or 'downloadable')

Page Count

Page Count:

Estimated 2000+ pages (typical for a comprehensive factory service manual)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder heads, crankshaft, pistons, connecting rods, timing belt/chain, lubrication system, cooling system, fuel delivery system (mechanical components).

Engine Electrical:

Ignition system, starting system, charging system, engine control unit (ECU), sensors (e.g., crankshaft position, camshaft position, MAF, MAP, O2), actuators (e.g., fuel injectors, ignition coils).

Transmission Manual:

Clutch system, gearbox (internal components), gear shift mechanism, lubrication.

Transmission Automatic:

Torque converter, planetary gear sets, valve body, hydraulic control system, transmission control module (TCM), cooler, lubrication.

Drivetrain:

Front and rear differentials, driveshafts, CV joints, AWD system components (if applicable).

Suspension:

Front and rear suspension components (struts, shock absorbers, control arms, bushings, ball joints, sway bars), wheel bearings.

Steering:

Steering rack/gearbox, power steering pump, steering column, tie rods, power steering fluid.

Brakes:

Front and rear brake systems (discs, pads, calipers, rotors), hydraulic system (master cylinder, brake lines, ABS unit), parking brake.

Electrical Chassis:

Lighting system (headlights, taillights, interior lights), power windows, power locks, mirrors, wipers, horn, fuse box diagrams, relay locations.

HVAC:

Heating, ventilation, and air conditioning system components, refrigerant system, blower motor, controls.

Body Exterior:

Body panel removal/installation, door mechanisms, hood, trunk lid, bumpers, glass replacement.

Body Interior:

Dashboard removal, seat removal, trim panels, headliner, carpeting.

Diagnostics Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, electrical circuit diagrams.

Procedures Included

Routine Maintenance:

Oil change, filter replacements (oil, air, fuel, cabin), spark plug replacement, fluid checks and top-offs, tire rotation.

Component Removal Installation:

Detailed step-by-step instructions for removing and reinstalling virtually all major components covered in the 'systems_covered' section.

Rebuild Procedures:

Instructions for rebuilding engines, transmissions, differentials, and other complex mechanical assemblies.

Electrical Diagnostics:

Wiring diagrams, component testing procedures, circuit tracing, connector pinouts.

Tightening Specifications:

Torque specifications for critical fasteners across all systems.

Special Tools:

Identification and usage of specialized tools required for specific repair or maintenance tasks.

Technical Depth

Diagnostic Troubleshooting:

Comprehensive guides for diagnosing and resolving common and complex issues, often including flowcharts and symptom-based approaches.

Rebuild Information:

Detailed procedures for complete overhauls of major mechanical components like engines and transmissions, including specifications for wear limits and clearances.

Schematics Diagrams:

Inclusion of detailed electrical wiring diagrams, vacuum hose routing diagrams, and exploded views of assemblies.

📊 Manual Specifications

File Format

File Format:

PDF (typically searchable, printable)

Print Quality

Print Quality:

High-resolution scans ensuring clarity of text, diagrams, and images.

Binding Type

Binding Type:

Not Applicable (Digital Format)

Paper Type

Paper Type:

Not Applicable (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Naturally Aspirated Boxer 4-Cylinder

Engine Displacement 2.5I:

2.5 Liters (2457 cc)

Engine Codes 2.5I:

EJ253

Performance 2.5I

Horsepower 2.5I:

165-175 hp (depending on specific market/tune)

Torque 2.5I:

166-170 lb-ft

Optional Engine

Engine Type Gt:

Turbocharged Boxer 4-Cylinder

Engine Displacement Gt:

2.5 Liters (2457 cc)

Engine Codes Gt:

EJ255

Performance Gt

Horsepower Gt:

210-250 hp (depending on trim - GT, GT Limited, GT spec.B)

Torque Gt:

236-280 lb-ft

Fuel System

Fuel Injection:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Timing Belt Maintenance

Timing Belt Replacement Interval:

Every 105,000 miles or 105 months (critical for EJ series engines to prevent catastrophic failure).

🔧 Transmission

Standard Transmission

Transmission Type 2.5I:

5-Speed Manual

Optional Transmission 2.5I

Transmission Type 2.5I Auto:

4-Speed Automatic

Standard Transmission Gt

Transmission Type Gt:

5-Speed Manual (standard on GT trims)

Optional Transmission Gt

Transmission Type Gt Auto:

4-Speed Automatic (optional on GT, standard on GT Limited)

Special Transmission

Transmission Type Spec B:

6-Speed Manual (exclusive to Legacy GT spec.B)

Fluid Specifications

Automatic Transmission Fluid Type:

Subaru ATF-HP (or equivalent Dexron III/Mercon compatible fluid, check specific manual revision)

Manual Transmission Fluid Type:

API GL-5, SAE 75W-90 (specific Subaru recommendation may vary)

Features

AWD System Integration:

Integration with Symmetrical AWD, including viscous coupling center differential for manual and Subaru's Active Torque Split AWD for automatics.

📐 Dimensions

Exterior Sedan

Length Sedan:

Approximately 187.8 inches

Width Sedan:

Approximately 68.1 inches

Height Sedan:

Approximately 56.1 inches

Exterior Wagon

Length Wagon:

Approximately 188.2 inches

Width Wagon:

Approximately 68.1 inches

Height Wagon:

Approximately 58.7 inches

Wheelbase

Wheelbase:

Approximately 101.4 inches

Weights

Curb Weight Est:

3200 - 3600 lbs (varies by trim and drivetrain)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5-Star (2004 Model Year)

NHTSA Front Impact Passenger:

5-Star (2004 Model Year)

IIHS Front Offset Score:

Good (for models with improved side impact protection)

Active Features

Standard Anti-lock Braking System (ABS)

E Brake Force Distribution:

Electronic Brake-force Distribution (EBD)

Passive Features

Airbags Front:

Dual Frontal Airbags

Airbags Side:

Optional or Standard Side Curtain Airbags (depending on trim)

Seatbelts:

Front 3-point seatbelts with pre-tensioners and load limiters, Rear 3-point seatbelts.

💡 Technology Features

Infotainment

Audio System:

Factory CD player, optional AM/FM/CD changer, available premium audio systems (e.g., McIntosh on higher trims). Manual covers basic stereo system diagnostics and speaker replacement.

Driver Assistance

Cruise Control:

Standard cruise control on most models.

Connectivity

Keyless Entry:

Available keyless entry and alarm system.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 3 months (severe duty) or 7,500 miles or 6 months (normal duty) with synthetic oil. Consult owner's manual for specific recommendations.

Engine Air Filter Replacement:

Every 15,000 - 30,000 miles, or as needed based on driving conditions.

Cabin Air Filter Replacement:

Every 15,000 - 30,000 miles, or as needed.

Brake Fluid Flush:

Every 30,000 miles or 3 years.

Fluid Specifications

Engine Oil Type:

API SG or higher, SAE 5W-30 (synthetic recommended for improved performance and longevity). Check specific oil cap or owner's manual for exact specification.

Coolant Type:

Subaru Super Coolant (or equivalent silicate-free, extended-life ethylene glycol coolant). Mixing brands or types is not recommended.

Power Steering Fluid:

Subaru Genuine Power Steering Fluid or Dexron III/Mercon equivalent.

Known Issues

Head Gaskets:

While less prevalent in the 3rd generation compared to previous ones, head gasket leaks can still occur, especially on higher mileage vehicles. The manual will cover diagnosis and replacement procedures.

Oil Leaks:

Common areas for oil leaks include valve cover gaskets and oil pan gaskets. Manual provides procedures for inspection and sealing.

Wheel Bearings:

Front wheel bearings can wear out prematurely, leading to humming or grinding noises. Manual covers replacement.

Clutch Wear:

Manual transmission clutch wear is normal with use; manual details clutch inspection and replacement.

📚 Vehicle History

Brand Heritage

Subaru History:

Subaru, part of Fuji Heavy Industries, has a long history in aviation and automotive manufacturing, emphasizing AWD and Boxer engines since the early 1970s.

Model Evolution

Legacy Generation 2004:

This is the third generation (BP/BL chassis) Subaru Legacy, introduced for the 2004 model year. It represented a significant redesign with more refined styling and chassis improvements.

Production

Manufacturing Location:

Gunma Plant, Japan

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

While specific year-by-year awards can fluctuate, the 2004 Legacy generally performed well in safety tests, aligning with Subaru's consistent safety reputation.