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Subaru Legacy 1996 All Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 1996 Codes Chassis Code: BD/BG/BK Series 👋 Introduction Market Position Positioning: Subaru's mid-size offering, known for its standard All-Wheel Drive (AWD)...
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Subaru Legacy 1996 All Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy
Year:
1996
Codes
Chassis Code:
BD/BG/BK Series
👋 Introduction
Market Position
Positioning:
Subaru's mid-size offering, known for its standard All-Wheel Drive (AWD) system and durable engineering. Competed against models like the Toyota Camry, Honda Accord, and Mitsubishi Galant.
Competitive Analysis
Key Differentiators:
Standard AWD, boxer engine layout offering a low center of gravity, robust build quality, and a reputation for longevity.
Key Features
Model Highlights:
Emphasis on practicality, all-weather capability, and reliability. The 1996 model represents the second generation (second facelift) of the Subaru Legacy.
📋 Manual Details
Coverage Areas
Engine Types:
2.2L EJ22 SOHC, 2.5L EJ25 DOHC
Drivetrain:
All-Wheel Drive (AWD)
Body Styles:
Sedan, Wagon
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Downloadable Digital Format (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, pistons, crankshaft, camshafts, timing belt, lubrication system, cooling system, fuel injection, emissions control.
Engine Performance:
Ignition system, detonation control, idle speed control, turbocharger (if applicable on specific trims, though not standard for '96 US models).
Transmission:
Manual transmission (5-speed), Automatic transmission (4-speed), clutch system, transfer case, AWD system components.
Brakes:
Front disc brakes (ventilated), Rear disc brakes (solid), Anti-lock Braking System (ABS), parking brake, brake hydraulics.
Suspension Steering:
Front struts, rear struts, control arms, sway bars, power steering system, steering rack.
Electrical Electronics:
Battery, alternator, starter motor, lighting system, wiring diagrams, fuses and relays, instrument cluster, power windows, power locks, climate control system, audio system.
Body Chassis:
Body panel removal and installation, interior trim, door mechanisms, glass, seals, chassis components, rust prevention.
HVAC:
Air conditioning system, heater core, blower motor, refrigerant system.
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, timing belt replacement, brake pad replacement, tune-ups.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, OBD-I diagnostic codes (relevant for 1996 models) and troubleshooting procedures.
Repair Rebuild:
Engine overhaul, transmission overhaul, brake system repair, suspension component replacement, electrical component repair.
Installation:
Component installation and replacement (e.g., alternator, starter, fuel pump).
Technical Depth
Depth:
Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring schematics.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Searchable text for quick information retrieval
Print Quality
Printability:
Printable for hard copy reference
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine 1 Code:
EJ22
Engine 1 Type:
2.2 Liter SOHC (Single Overhead Cam) Boxer-4
Engine 1 Displacement:
2212 cc (134.9 cu. in.)
Engine 1 Bore X Stroke:
96.9 mm x 75.0 mm (3.81 in x 2.95 in)
Engine 1 Compression Ratio:
9.5:1
Engine 1 Horsepower Est:
135 hp @ 5600 rpm
Engine 1 Torque Est:
138 lb-ft @ 4400 rpm
Secondary Engine
Engine 2 Code:
EJ25
Engine 2 Type:
2.5 Liter DOHC (Dual Overhead Cam) Boxer-4
Engine 2 Displacement:
2457 cc (149.9 cu. in.)
Engine 2 Bore X Stroke:
99.5 mm x 79.0 mm (3.92 in x 3.11 in)
Engine 2 Compression Ratio:
9.7:1
Engine 2 Horsepower Est:
165 hp @ 5600 rpm
Engine 2 Torque Est:
162 lb-ft @ 4000 rpm
Fuel System
Injection Type:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Cooling System
Coolant Type:
Subaru Super Coolant (or equivalent silicate-free, long-life coolant)
🔧 Transmission
Standard
Type:
5-Speed Manual Transmission
Optional
Type:
4-Speed Electronically Controlled Automatic Transmission
Features
Drivetrain:
Symmetrical All-Wheel Drive (AWD) standard on all models.
Fluid Specifications
Manual Transmission Fluid:
API GL-5, SAE 75W-90 (or as specified in manual)
Automatic Transmission Fluid:
Subaru ATF-HP (or Dexron III/Mercon equivalent, consult manual for exact specs)
Fluid Capacity Manual
Capacity Liters:
2.6 L (2.7 US qt)
Fluid Capacity Automatic
Capacity Liters:
3.5 L (3.7 US qt) (Pan Drop)
📐 Dimensions
Exterior Sedan
Length Mm:
4661 mm (183.5 in)
Width Mm:
1700 mm (66.9 in)
Height Mm:
1405 mm (55.3 in)
Exterior Wagon
Length Mm:
4656 mm (183.3 in)
Width Mm:
1700 mm (66.9 in)
Height Mm:
1486 mm (58.5 in)
Wheelbase Mm
Wheelbase:
2634 mm (103.7 in)
Weights
Curb Weight Kg:
1380 - 1470 kg (approx. 3042 - 3241 lbs)
Gross Vehicle Weight Rating Kg:
1830 kg (approx. 4034 lbs)
Cargo Wagon
Cargo Volume Liters:
Approx. 1030 Liters (with rear seats up)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4 Stars (for 1996 model year, specific testing may vary)
NHTSA Front Impact Passenger:
4 Stars (for 1996 model year, specific testing may vary)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Passive Features
Airbags:
Driver and Passenger Frontal Airbags
Seatbelts:
3-point front and rear seatbelts, pretensioners for front seats
💡 Technology Features
Infotainment
Audio System:
Factory radio with cassette player, optional CD player. Basic speaker system.
Driver Assistance
Cruise Control:
Optional on some trims
Connectivity
Original Connectivity:
Limited to analog systems; no modern Bluetooth or USB connectivity.
🔧 Maintenance
Service Intervals General
Oil Filter Change:
Every 7,500 miles (12,000 km) or 6 months
Engine Oil Change:
Every 7,500 miles (12,000 km) or 6 months (using synthetic oil, consult manual for conventional oil intervals)
Timing Belt Replacement:
Every 105,000 miles (168,000 km) or 7 years (critical interval)
Spark Plugs:
Inspect at 30,000 miles (48,000 km), replace as needed (or at higher intervals depending on type)
Coolant Flush:
Every 30,000 miles (48,000 km) or 2 years
Fluid Specifications
Engine Oil:
API SG or SH, ILSAC GF-2, SAE 5W-30 or 10W-30 (Consult manual for specific temperature ranges)
Coolant:
Subaru Super Coolant (or equivalent silicate-free, long-life coolant), 50/50 mix with distilled water
Brake Fluid:
DOT 3 (or DOT 4 if specified)
Fluid Capacities
Engine Oil Liters:
4.5 L (4.8 US qt) with filter (EJ22), 4.7 L (5.0 US qt) with filter (EJ25)
Coolant Liters:
7.6 L (8.0 US qt) (approx.)
Known Issues
Head Gaskets:
While less common on the EJ22, EJ25 DOHC engines (especially early ones) can be prone to head gasket failures due to coolant leaks. The manual will provide specific procedures for diagnosis and replacement.
Automatic Transmission:
Some reports of torque converter shudder or delayed engagement on higher mileage vehicles. Manual will detail diagnostic checks.
Timing Belt:
Timely replacement is crucial. Failure can lead to severe engine damage. Manual provides replacement intervals and procedures.
📚 Vehicle History
Brand Heritage
Heritage:
Subaru, a division of Subaru Corporation (formerly Fuji Heavy Industries), has a long history in aviation and automotive manufacturing, pioneering the use of boxer engines and All-Wheel Drive in passenger vehicles.
Model Evolution
Second Generation Phase:
The 1996 Legacy is part of the second generation (BD/BG/BK), produced from 1993 to 1999. This model year represents the second significant facelift of the second generation, featuring updated styling and technology.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
All Wheel Drive Reputation:
Subaru's Symmetrical All-Wheel Drive system received accolades for its effectiveness in various weather conditions, enhancing safety and traction.
Ratings
Consumer Reports Rankings:
Generally rated well for reliability and performance, particularly praised for its AWD capability. Specific ratings vary by model year and trim.
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