Subaru Legacy 2004-2005 Workshop Service Manual Repair

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Years Covered: 2004-2005 Generation Generation: Fourth Generation (BL/BP) Codes Chassis Codes: BL (Sedan), BP (Wagon) 👋 Introduction Market Position Segment: Mid-size Sedan/Wagon...

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Type: Car

Vendor:

Sku: 384412

Tags: 2004 2005 Car Cars Legacy Misc Subaru

Product variants

Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy

Years Covered:

2004-2005

Generation

Generation:

Fourth Generation (BL/BP)

Codes

Chassis Codes:

BL (Sedan), BP (Wagon)

👋 Introduction

Market Position

Segment:

Mid-size Sedan/Wagon

Key Selling Points:

Symmetrical AWD standard, boxer engine, upscale interior, refined ride quality

Competitive Analysis

Competitors:

Toyota Camry, Honda Accord, Mazda6, Nissan Altima

Key Features

Standard AWD:

Standard Symmetrical All-Wheel Drive across all models and trims.

Engine Options:

Choice of reliable 2.5L flat-four or potent 3.0L flat-six engines.

Performance Variant:

GT models offered enhanced performance with turbocharged engines and sport-tuned suspension.

Manual Purpose

Target Audience:

Professional technicians and experienced DIY enthusiasts

📋 Manual Details

Coverage Areas

Coverage Areas:

Complete workshop service and repair

Page Count

Estimated Page Count:

Over 2000 pages (typical for comprehensive workshop manuals)

Manual Type

Manual Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

2.5L EJ25 SOHC/DOHC Naturally Aspirated and Turbocharged (GT models), 3.0L EZ30 DOHC H6 Naturally Aspirated

Transmission:

5-speed Manual, 4-speed Automatic, 5-speed Automatic (5EAT on GT models)

Drivetrain:

Symmetrical All-Wheel Drive (AWD) system, differentials, driveshafts, hubs

Suspension:

Front MacPherson struts, Rear multi-link, springs, dampers, bushings, alignment specifications

Brakes:

Front and rear disc brakes, ABS, EBD, brake system bleeding, component replacement

Steering:

Power assisted rack and pinion, steering column, wheel alignment

Electrical:

Battery, charging system, ignition, lighting, starter, fuses, relays, wiring diagrams, instrument cluster

Climate Control:

HVAC system, A/C compressor, refrigerant, heater core, blower motor, controls

Fuel System:

Fuel tank, pump, injectors, fuel pressure, evaporative emission control (EVAP)

Exhaust System:

Catalytic converter, mufflers, exhaust manifold, oxygen sensors

Body And Interior:

Body panels, doors, windows, seats, trim, sound deadening, airbags

Diagnostics:

OBD-II diagnostic trouble codes (DTCs), diagnostic procedures, scan tool usage

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement

Repair:

Engine component overhaul, transmission overhaul, brake caliper replacement, suspension component replacement, exhaust system repair

Troubleshooting:

Step-by-step diagnostic guides for common and uncommon issues, symptom-based troubleshooting

Disassembly And Assembly:

Detailed instructions for removing and reinstalling all major components and sub-assemblies

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems

Technical Depth

Depth:

Comprehensive, from basic maintenance to full engine and transmission rebuilds, including advanced diagnostics and torque specifications

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content

Print Quality

Print Quality:

High resolution, suitable for printing individual pages or sections

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

EJ253 (2.5L SOHC)

Displacement 1:

2457 cc

Horsepower 1:

165 hp @ 5600 rpm

Torque 1:

166 lb-ft @ 4000 rpm

Engine Code 2:

EJ255 (2.5L DOHC Turbocharged)

Displacement 2:

2457 cc

Horsepower 2:

250 hp @ 5600 rpm (GT models)

Torque 2:

250 lb-ft @ 3600 rpm (GT models)

Engine Code 3:

EZ30D (3.0L DOHC H6)

Displacement 3:

3000 cc

Horsepower 3:

245 hp @ 6600 rpm

Torque 3:

217 lb-ft @ 4200 rpm

Performance

Compression Ratio Ej25:

10.7:1

Compression Ratio Ej25 Turbo:

8.4:1

Compression Ratio Ez30:

10.7:1

Bore X Stroke Ej25:

99.5 mm x 79.0 mm

Bore X Stroke Ez30:

89.2 mm x 77.0 mm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline, 87 octane (91 octane recommended for GT models)

Evap System:

EVAP canister system

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual (TY754)

Optional

Optional Transmission 1:

4-speed Automatic (43024AE070)

Optional Transmission 2:

5-speed Automatic (5EAT - TZ1B7MC1AA) on GT models

Features

AWD System:

Symmetrical AWD with viscous coupling center differential (manual) or electronically controlled multi-plate transfer clutch (automatic/5EAT)

Gear Ratios 5Mt Ej25:

3.167 / 1.882 / 1.290 / 0.971 / 0.731 (example, verify with manual)

Gear Ratios 4At Ej25:

2.78 / 1.54 / 1.0 / 0.72 (example, verify with manual)

Transmission Fluid Type Manual:

Subaru Extra Gear Oil API GL-5 75W-90 (or equivalent)

Transmission Fluid Type Auto:

Subaru ATF HP (High Performance)

📐 Dimensions

Exterior

Wheelbase:

104.0 inches (2640 mm)

Length Sedan:

187.4 inches (4760 mm)

Length Wagon:

188.0 inches (4775 mm)

Width:

69.7 inches (1770 mm)

Height Sedan:

57.1 inches (1450 mm)

Height Wagon:

56.7 inches (1440 mm)

Ground Clearance:

5.9 inches (150 mm)

Weights

Curb Weight 2.5I Mt:

3362 lbs (1525 kg)

Curb Weight 2.5Gt 5Eat:

3572 lbs (1620 kg)

Curb Weight 3.0R 5Eat:

3593 lbs (1630 kg)

Wheel Bolt Pattern:

5 x 100 mm

Wheel Size Standard:

16 or 17 inches

Wheel Size Gt:

17 or 18 inches

Tire Size Standard:

205/55R16 or 215/45R17

Tire Size Gt:

215/45R18 or 215/50R17

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5 Stars (2004, 2005 models)

NHTSA Front Impact Passenger:

5 Stars (2004, 2005 models)

NHTSA Side Impact Front Seat:

5 Stars (2004, 2005 models)

NHTSA Side Impact Rear Seat:

5 Stars (2004, 2005 models)

IIHS Front Crash Rating:

IIHS Side Impact Rating:

IIHS Rear Impact Rating:

Active Features

Standard Anti-lock Braking System (ABS)

Standard Electronic Brake-force Distribution (EBD)

Traction Control:

Available Traction Control System (TCS)

Stability Control:

Available Vehicle Dynamics Control (VDC)

Passive Features

Airbags:

Front dual-stage airbags, front side-impact airbags, side curtain airbags (optional on some models)

Seatbelts:

3-point front and rear seatbelts, pretensioners, load limiters

Child Seats:

LATCH (Lower Anchors and Tethers for Children) system

💡 Technology Features

Infotainment

Audio System:

Available AM/FM/CD stereo systems with optional premium audio, subwoofer, and steering wheel audio controls.

Navigation:

Optional factory navigation system available on higher trims.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Connectivity

Auxiliary Input:

Some models may feature an auxiliary audio input jack.

Keyless Entry:

Available keyless entry and remote start systems.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles (6,000 km) or 6 months (severe use), or 7,500 miles (12,000 km) or 12 months (normal use) - check manual for specific conditions

Engine Oil Filter Replacement:

With every oil change

Engine Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months

Cabin Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months

Spark Plug Replacement Ej25:

105,000 miles (169,000 km) for iridium spark plugs

Transmission Fluid Change Manual:

Every 45,000 miles (72,000 km) or 45 months (severe use), or 75,000 miles (120,000 km) or 75 months (normal use) - check manual

Transmission Fluid Change Auto:

Every 30,000 miles (48,000 km) or 30 months (severe use), or 60,000 miles (96,000 km) or 60 months (normal use) - check manual

Coolant Flush:

Every 30,000 miles (48,000 km) or 30 months

Brake Fluid Flush:

Every 30,000 miles (48,000 km) or 30 months

Fluid Specifications

Engine Oil Type:

SAE 5W-30, API SJ or higher (synthetic recommended)

Engine Oil Capacity Ej25:

4.8 US quarts (4.6 L) with filter

Engine Oil Capacity Ez30:

6.1 US quarts (5.8 L) with filter

Coolant Type:

Subaru Super Coolant (blue, P/N KEL10320000)

Power Steering Fluid:

Subaru Genuine ATF HP (or equivalent)

Known Issues

Head Gaskets:

While not as prevalent as in earlier generations, internal coolant leaks related to head gaskets can occur, especially on the EJ25 engine. The manual will detail inspection and replacement procedures.

Turbo Lag Gt Models:

Some owners report turbo lag on GT models; the manual provides diagnostics for the turbocharger system.

Automatic Transmission Hesitation:

Occasional reports of transmission hesitation or rough shifting, particularly with the 4-speed automatic. Manual details solenoid and fluid checks.

Oil Consumption:

Some EJ25 engines may exhibit higher-than-average oil consumption; the manual covers engine health checks.

Suspension Wear:

Worn suspension bushings and ball joints can lead to noise and handling issues over time. Manual includes replacement and alignment specs.

📚 Vehicle History

Brand Heritage

Subaru Heritage:

Founded in 1953, Subaru is known for its horizontally-opposed (boxer) engines and Symmetrical All-Wheel Drive systems.

Model Evolution

Legacy Introduction:

The Subaru Legacy was introduced in 1989 as a replacement for the Subaru Leone. The 2004-2005 models represent the fourth generation (BL/BP).

Fourth Generation Design:

This generation featured a significant redesign with a more European-influenced styling, increased dimensions, and improved interior quality compared to its predecessor.

Production

Production Years:

2004-2005

Manufacturing Plant:

Ota City, Gunma, Japan

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

While specific 'Top Safety Pick' designation for these exact years can vary in interpretation, the 2004-2005 Legacy consistently received high safety ratings from IIHS and NHTSA.

Car And Driver 10Best:

While not consistently on the 10Best list during these specific years, the Legacy platform has been recognized by automotive publications for its performance and AWD capabilities.

Ratings

Consumer Reports:

Consumer Reports generally rated the 2004-2005 Legacy with average to above-average reliability, particularly for the drivetrain and AWD system.