🏷️ Basic Information

Make:

Subaru

Model:

Legacy

Year:

1991

Chassis Code:

BC/BF/BJ

👋 Introduction

Vehicle Segment:

Mid-size Sedan/Wagon

Usp:

Standard All-Wheel Drive (AWD), reputation for reliability and durability

Competitors:

Toyota Camry, Honda Accord, Mazda 626, Nissan Stanza

Powertrain Emphasis:

Horizontally-opposed (Boxer) engine, Symmetrical All-Wheel Drive

Design Philosophy:

Functional, symmetrical engineering for stability and traction

Benefit For Technicians:

Provides factory-level accuracy for efficient diagnostics and repairs.

Benefit For Enthusiasts:

Empowers owners with the knowledge to perform complex maintenance and repairs, saving money and understanding their vehicle deeply.

📋 Manual Details

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

PDF Download

Page Count:

Estimated 1000+ pages (typical for factory service manuals of this era)

📖 Manual Coverage

Engine:

Complete engine overhaul, tuning, fuel injection, ignition system, cooling system, lubrication system

Transmission:

Manual (5-speed), Automatic (4-speed) overhaul, adjustment, and repair; clutch system

Drivetrain:

All-Wheel Drive (AWD) system, differentials, driveshafts, CV joints

Suspension:

Front MacPherson struts, Rear independent suspension, shock absorbers, springs, bushings, alignment procedures

Brakes:

Front ventilated discs, Rear discs/drums (model dependent), ABS (if equipped), hydraulic system, parking brake

Steering:

Power steering system, steering rack, tie rods, steering column

Electrical:

Wiring diagrams, charging system, starting system, lighting, gauges, instrumentation, power windows, door locks, ECU diagnostics

Bodywork:

Body panel repair, interior trim, glass replacement, corrosion prevention

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, spark plug replacement, belt adjustments

Troubleshooting:

Diagnostic procedures, common problems and their solutions, DTC (Diagnostic Trouble Code) interpretation (for applicable systems)

Repair:

Step-by-step repair instructions for all major vehicle systems, component removal and installation

Diagnostics:

Engine diagnostics, electrical system troubleshooting, component testing

Specifications:

Torque specifications, fluid capacities, tolerances, wear limits

Depth Level:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds)

Target Audience:

Professional Technicians, experienced DIY enthusiasts

📊 Manual Specifications

File Type:

Digital PDF

Searchable:

Yes (typically, depending on scan quality)

Printable:

Yes

Resolution:

High-resolution scans ensuring clarity of diagrams and text

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Code 1:

EJ22

Engine Type 1:

Naturally Aspirated, SOHC Boxer-4

Displacement 1:

2.2 Liters (2212 cc)

Bore X Stroke 1:

92.0 mm x 83.0 mm

Compression Ratio 1:

9.5:1

Horsepower 1:

110 hp @ 5000 rpm

Torque 1:

137 lb-ft @ 4000 rpm

Fuel System 1:

Multi-point Fuel Injection (MPI)

Engine Code 2:

EJ22T (Turbocharged)

Engine Type 2:

Turbocharged, SOHC Boxer-4

Horsepower 2:

165 hp @ 5600 rpm

Torque 2:

181 lb-ft @ 3200 rpm

Fuel System 2:

Multi-point Fuel Injection (MPI) with Turbocharger

Recommended Fuel:

Unleaded Regular (87 Octane), Premium for Turbo models is recommended

🔧 Transmission

Transmission Type Std:

5-speed Manual

Drivetrain Std:

Symmetrical All-Wheel Drive (AWD)

Transmission Type Opt:

4-speed Automatic

Drivetrain Opt:

Full-time All-Wheel Drive (AWD) with Lockable Center Differential

Clutch Type:

Dry, Single Plate

Transmission Fluid Manual:

API GL-4, SAE 75W-90 Gear Oil

Transmission Fluid Automatic:

Subaru ATF-HP or equivalent DEXRON-III/MERCON

📐 Dimensions

Wheelbase:

101.4 inches (2575 mm)

Length:

178.1 inches (4525 mm)

Width:

67.1 inches (1705 mm)

Height:

55.3 inches (1405 mm) (Sedan) / 58.1 inches (1475 mm) (Wagon)

Curb Weight Min:

Approx. 2760 lbs (1250 kg) (2.2L Manual Sedan)

Curb Weight Max:

Approx. 3100 lbs (1406 kg) (2.2L Turbo Automatic Wagon)

Gross Vehicle Weight Rating:

Varies by model and configuration

Towing Capacity:

Not specified by manufacturer for this model year

🛡️ Safety Features

NHTSA Frontal Impact:

Not rated by NHTSA in 1991

IIHS Crash Tests:

Not tested by IIHS in 1991

ABS:

Optional on some models

AWD System:

Standard Symmetrical All-Wheel Drive

Airbags:

Driver-side airbag standard on most models

Seatbelts:

3-point front seatbelts, 2-point rear seatbelts (later models may have 3-point rear)

Crumple Zones:

Designed with front and rear crumple zones

💡 Technology Features

Audio System:

Factory AM/FM Cassette player, optional CD player on higher trims

Speakers:

Typically 4 to 6 speakers depending on trim level

Cruise Control:

Optional

Connectivity Features:

None from factory (pre-internet era)

🔧 Maintenance

Oil Change Interval:

Every 3,000 - 5,000 miles (5,000 - 8,000 km) or 6 months, whichever comes first

Air Filter Replacement:

Every 15,000 - 30,000 miles (24,000 - 48,000 km)

Spark Plug Replacement:

Every 30,000 miles (48,000 km)

Timing Belt Replacement:

Every 60,000 miles (96,000 km) or 4 years (critical for interference engines)

Coolant Flush:

Every 2 years or 30,000 miles (48,000 km)

Engine Oil Capacity:

4.7 US quarts (4.4 liters) with filter (EJ22)

Engine Oil Viscosity:

10W-30 or 10W-40 recommended for most climates

Coolant Type:

Ethylene Glycol based coolant, 50/50 mix with distilled water

Brake Fluid:

DOT 3

Power Steering Fluid:

ATF DEXRON-II or equivalent

Head Gaskets:

While not as prevalent as later generations, some EJ series engines can develop head gasket leaks.

Crankshaft Position Sensor:

Early models may experience CPS failure leading to no-start or stalling.

Idler Pulley Bearing:

The idler pulley bearing on the timing belt can fail prematurely, requiring replacement to avoid catastrophic engine damage.

Rust Corrosion:

Like many vehicles of this era, body panels, especially around wheel wells and rocker panels, can be susceptible to rust.

Oil Filter Example:

Subaru Part Number: 15208AA031 (or aftermarket equivalent like Fram PH7317, Wix 51515)

Air Filter Example:

Subaru Part Number: 16546AA020 (or aftermarket equivalent like Fram CA8529)

Spark Plug Example:

NGK BKR6E (or equivalent)

Timing Belt Example:

Subaru Part Number: 13028AA070 (or aftermarket equivalent kit)

📚 Vehicle History

Manufacturer Origin:

Japan

Founding Year:

1953

First Generation Start:

1989

First Generation End:

1994

Chassis Codes Gen1:

BC (Sedan), BF (Wagon), BJ (Hardtop Coupe)

Facelift Timing:

Minor styling updates occurred throughout the generation, particularly for 1992 and 1993 models.

Manufacturing Plant:

Ota, Gunma, Japan

Production Run 1991:

Significant production volume as it was a core model for Subaru in North America and other markets.

🏆 Awards & Recognition

Historical Accolades:

Subaru's reputation for AWD and durability was building during this era, though specific model awards for the '91 Legacy are less prominent than later generations. Often lauded for its handling and all-weather capability.