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Subaru Legacy 2003 Workshop Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 2003 Trim Levels Covered: L, GT, Outback Codes Chassis Code General: BH/BE Series 👋 Introduction Market Position Market Segment: Mid-size sedan...
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Subaru Legacy 2003 Workshop Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy
Year:
2003
Trim Levels Covered:
L, GT, Outback
Codes
Chassis Code General:
BH/BE Series
👋 Introduction
Market Position
Market Segment:
Mid-size sedan and wagon, often positioned as an all-wheel-drive (AWD) focused alternative to front-wheel-drive (FWD) competitors.
Competitive Analysis
Key Competitors 2003:
Toyota Camry, Honda Accord, Mazda 6, Nissan Altima, Ford Mondeo/Fusion.
Key Features
Subaru Brand Differentiator:
Symmetrical All-Wheel Drive (standard on most trims), horizontally opposed (Boxer) engines, reputation for safety and durability.
2003 Legacy Highlights:
Introduction of the 4th generation platform (BP/BL), revised styling, improved interior, continued emphasis on AWD and safety.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive workshop and service information
Page Count
Estimated Page Count:
2000+
Manual Type
Manual Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, torque specifications, cylinder head, block, pistons, connecting rods, crankshaft, camshafts, timing belt/chain systems, lubrication, cooling system, intake manifold, exhaust manifold.
Engine Management And Emissions:
Fuel injection system (MPI), ignition system, sensors (O2, MAF, TPS, CKP, CMP), actuators, ECM/PCM diagnosis, evaporative emission control (EVAP), catalytic converter, emission control systems.
Transmission Manual:
Clutch system, gearbox assembly, disassembly, gear ratios, shift mechanisms, torque specifications, internal components, maintenance.
Transmission Automatic:
Torque converter, transmission control unit (TCU), valve body, hydraulic circuits, gear sets, clutch packs, seals, internal components, diagnostic trouble codes (DTCs), fluid specifications, maintenance.
Drivetrain And Axles:
Front and rear differentials, driveshafts, CV joints, wheel bearings, AWD system operation, maintenance, and repair.
Suspension:
Front and rear suspension components (struts, shocks, control arms, ball joints, bushings), alignment specifications, troubleshooting, repair procedures.
Steering:
Power steering system (pump, rack and pinion, hoses), steering column, linkage, diagnosis, fluid specifications, repair.
Brakes:
Front and rear brake systems (discs, calipers, pads, lines, master cylinder, ABS), parking brake, hydraulic system bleeding, specifications, maintenance, repair.
Body And Frame:
Body panel removal/installation, structural components, door mechanisms, glass, bumpers, trim, rust prevention, repair techniques.
Electrical System Components:
Battery, alternator, starter motor, ignition switch, lighting (headlights, taillights, interior), horn, wipers, washer system.
Electrical System Wiring:
Wiring diagrams for all vehicle systems, connector pinouts, fuse box diagrams, relay locations, troubleshooting electrical faults.
Comfort And Convenience:
HVAC system (heating, ventilation, air conditioning), power windows, power locks, mirrors, seats, sunroof, keyless entry, remote start (if applicable).
Safety Systems:
Airbag system (SRS), seat belts, ABS system, traction control (if equipped), cruise control.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, coolant flushes, brake fluid changes, transmission fluid changes, differential fluid changes, fuel filter replacement.
Diagnostic Procedures:
Troubleshooting guides for common symptoms, diagnostic trouble code (DTC) interpretation, electrical system diagnostics, engine performance diagnosis.
Repair And Replacement:
Detailed step-by-step instructions for component removal, installation, and repair across all major vehicle systems.
Rebuilding Procedures:
Engine rebuilding, transmission rebuilding, differential rebuilding, and other major component overhauls.
Electrical Troubleshooting:
Schematic interpretation, circuit testing, component testing, diagnosis of wiring harness issues.
Special Tools And Equipment:
Identification of required special tools for specific procedures.
Torque Specifications:
Precise torque values for all critical fasteners.
Technical Depth
Depth Of Coverage:
Factory-level diagnostic and repair information, suitable for professional technicians and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
File Format:
Portable Document Format (PDF)
Print Quality
Print Quality Recommendation:
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding Type For Printed:
N/A (Digital Download)
Paper Type
Paper Type For Printed:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code 2 5I:
EJ253 (Naturally Aspirated)
Engine Displacement 2 5I:
2.5 Liters (2457 cc)
Engine Configuration 2 5I:
Horizontally Opposed (Boxer), 4-cylinder
Horsepower 2 5I:
165 hp @ 5600 rpm
Torque 2 5I:
166 lb-ft @ 4000 rpm
Gt Engine
Engine Code Gt:
EJ255 (Turbocharged)
Engine Displacement Gt:
2.5 Liters (2457 cc)
Engine Configuration Gt:
Horizontally Opposed (Boxer), 4-cylinder, Turbocharged
Horsepower Gt:
210 hp @ 5600 rpm
Torque Gt:
235 lb-ft @ 3600 rpm
Performance
Redline Rpm Typical:
6200 RPM
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline, 87 octane (91 recommended for GT model)
Engine Management
ECU Type:
Denso or Hitachi ECU
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission (5MT)
Optional
Transmission Type Optional:
4-speed Automatic Transmission (4AT) with Sportshift
Features
AWD System Type:
Symmetrical All-Wheel Drive (standard on all trims for 2003)
AWD System Details Manual:
Viscous coupling center differential (VCD) with a 50/50 front/rear torque split.
AWD System Details Automatic:
Active All-Wheel Drive system with an electronically controlled hydraulic transfer clutch, adjusting torque bias based on acceleration and wheel slip.
📐 Dimensions
Exterior
Wheelbase Sedan:
101.4 inches
Wheelbase Outback:
101.6 inches
Length Sedan:
186.8 inches
Length Outback:
188.8 inches
Width:
69.7 inches
Height Sedan:
56.1 inches
Height Outback:
59.3 inches
Ground Clearance Sedan:
5.9 inches
Ground Clearance Outback:
7.0 inches
Weights
Curb Weight Base Model Approx:
3100 - 3300 lbs
Gross Vehicle Weight Rating Approx:
4350 - 4550 lbs
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5 Stars
NHTSA Front Impact Passenger:
5 Stars
NHTSA Side Impact Front Seat:
4 Stars
NHTSA Side Impact Rear Seat:
4 Stars
IIHS Frontal Offset Rating:
Good
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Traction Control System (TCS) available on some trims, standard on GT
Passive Features
Airbags Front:
Dual front SRS airbags
Airbags Side:
Optional front side-impact airbags, optional front and rear side-curtain airbags (on some models)
Seatbelts:
3-point seatbelts for all seating positions, pretensioners and load limiters for front seats.
💡 Technology Features
Infotainment
Audio System Options:
Factory AM/FM/CD player, optional premium audio systems with multiple speakers and amplifier.
Display Screen:
Basic digital clock/display, no central infotainment screen on most trims.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
All Wheel Drive:
Advanced Symmetrical AWD system providing enhanced traction and stability in various conditions.
Connectivity
Auxiliary Input:
N/A (typically) - older model without standard auxiliary input.
Keyless Entry:
Available keyless entry and remote alarm system on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval Typical:
Every 3,750 miles or 6 months (severe driving) / 7,500 miles or 12 months (normal driving), consult manual for specifics.
Timing Belt Replacement:
105,000 miles or 105 months for EJ25 engines.
Coolant Flush Interval:
Every 30,000 miles or 30 months.
Fluid Specifications
Engine Oil Type 2 5I:
SAE 5W-30 (API SG or higher, ILSAC GF-2 or higher)
Engine Oil Type Gt:
SAE 5W-30 or 5W-40 (API SG or higher, ILSAC GF-2 or higher), synthetic oil recommended for turbo.
Engine Oil Capacity 2 5I:
4.8 quarts (with filter)
Engine Oil Capacity Gt:
4.8 quarts (with filter)
Transmission Fluid Type Manual:
API GL-5, SAE 75W-90 gear oil
Transmission Fluid Type Automatic:
Subaru ATF HP (or Dexron III/Mercon compatible fluid)
Differential Fluid Type:
API GL-5, SAE 75W-90 gear oil
Coolant Type:
Subaru Super Coolant (blue) or equivalent ethylene glycol-based coolant
Known Issues
Head Gasket Leaks:
While not as prevalent as in earlier generations, EJ25 engines can still be prone to head gasket leaks, especially if maintenance is neglected. Manual covers diagnosis and replacement.
Turbo Failure Gt:
Turbocharger issues can arise on GT models due to heat and oil degradation. Manual provides turbo system diagnostics and repair.
Cv Joint Wear:
Front CV joints can wear over time, especially in AWD vehicles. Manual covers inspection and replacement.
Exhaust Manifold Cracks:
Exhaust manifold cracks can occur due to heat cycles. Manual details inspection and replacement procedures.
📚 Vehicle History
Brand Heritage
Subaru Heritage:
Fuji Heavy Industries (now Subaru Corporation) has a long history in aviation engineering, influencing their focus on symmetrical designs and AWD systems.
Model Evolution
Legacy First Generation:
Launched in 1989 as a mid-size competitor, establishing the AWD platform.
Legacy Second Generation:
1995-1999 (BD/BG), refined design and AWD.
Legacy Third Generation:
2000-2004 (BE/BH), introducing the Outback variant as a distinct model, significant redesign.
Production
Production Location:
Subaru's main manufacturing plant in Gunma, Japan.
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick History:
Subaru Legacy models from this era often received good safety ratings, contributing to the brand's reputation.
Ratings
Consumer Reports Reliability:
Variable reliability history, but specific year and model performance can be detailed in the manual for repair insights.
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