Subaru Legacy 1996 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 1996 Generation Code: BD/BG/BK Codes Platform Code: Subaru ALL-Wheel Drive (AWD) 👋 Introduction Market Position Vehicle Segment: Mid-size sedan/wagon, known for...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy

Year:

Generation Code:

BD/BG/BK

Codes

Platform Code:

Subaru ALL-Wheel Drive (AWD)

👋 Introduction

Market Position

Vehicle Segment:

Mid-size sedan/wagon, known for AWD capability and reliability

Competitive Analysis

Key Competitors:

Toyota Camry, Honda Accord, Nissan Altima, Mitsubishi Galant

Key Features

Standard AWD:

Subaru's hallmark Symmetrical All-Wheel Drive system provided exceptional traction and stability.

Engine Options:

Reliable horizontally-opposed 'Boxer' engines known for their low center of gravity.

Body Styles:

Available as a 4-door sedan and a 5-door wagon (Outback model).

Reliability:

Generally considered a reliable vehicle with proper maintenance.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive repair, overhaul, diagnostics, and maintenance

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnosis, repair, and overhaul for EJ22E, EJ25D, and EJ22T engines

Transmission:

Manual (M/T) and Automatic (A/T) transmission repair, overhaul, and fluid service

Drivetrain:

All-Wheel Drive (AWD) system maintenance and repair, including differentials and driveshafts

Suspension:

Front and rear suspension diagnosis, component replacement, and alignment procedures

Brakes:

Brake system service, including disc and drum brake overhaul, hydraulic system bleeding, and ABS troubleshooting

Steering:

Power steering system diagnosis and repair, steering column and linkage servicing

Electrical:

Complete electrical system schematics, wiring diagrams, component testing, diagnosis of charging, starting, lighting, and accessory systems

Body And Interior:

Body panel repair, interior trim removal and installation, glass replacement, HVAC system diagnosis and repair

Cooling System:

Radiator, water pump, thermostat, and cooling fan servicing

Fuel System:

Fuel pump, injectors, fuel filter replacement, and fuel system pressure testing

Exhaust System:

Exhaust manifold, catalytic converter, muffler, and pipe replacement

Climate Control:

HVAC system diagnosis, refrigerant handling, component replacement

Safety Systems:

Airbag system diagnosis and repair, seat belt servicing

Procedures Included

Routine Maintenance:

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

Troubleshooting:

Diagnostic flowcharts and procedures for common and uncommon issues across all major systems

Engine Repair:

Engine rebuild procedures, cylinder head service, piston and ring replacement, crankshaft and bearing service

Transmission Overhaul:

Complete disassembly and reassembly instructions for both manual and automatic transmissions

Brake Replacement:

Pads, rotors, calipers, and brake line replacement procedures

Electrical Diagnostics:

Component testing using multimeters and oscilloscopes, wiring harness repair

Body Repair:

Dent removal, panel straightening, rust repair, welding procedures

Interior Restoration:

Dashboard removal, seat repair, carpet replacement

Cooling System Flushing:

Procedures for draining, flushing, and refilling the cooling system

Timing Belt Replacement:

Detailed steps for timing belt and tensioner replacement, crucial for EJ series engines

Clutch Replacement:

Step-by-step guide for manual transmission clutch assembly replacement

Wheel Alignment:

Specifications and procedures for front and rear wheel alignment

Technical Depth

Depth Level:

Expert level, covering complete engine and transmission rebuilds, advanced diagnostics, and electrical troubleshooting

Diagnostic Tools:

Information on specific diagnostic codes (OBD-I/OBD-II for applicable systems) and required tools

Torque Specifications:

Comprehensive list of all critical torque specifications for engine, chassis, and driveline components

Special Tools:

Identification and usage of Subaru-specific or recommended special tools for certain procedures

📊 Manual Specifications

File Format

File Type:

Searchable PDF

PDF Quality:

High-resolution scans of original factory documentation

Printable:

Yes, printable pages

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Quality:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

EJ22E

Engine Type 1:

2.2L SOHC 16-valve Flat-4 (Boxer)

Horsepower 1:

135 hp @ 5600 rpm

Torque 1:

140 lb-ft @ 4400 rpm

Bore X Stroke 1:

96.9 mm x 75.0 mm

Compression Ratio 1:

9.5:1

Fuel Delivery 1:

Multi-port Fuel Injection (MPI)

Optional Engine

Engine Code 2:

EJ25D

Engine Type 2:

2.5L DOHC 16-valve Flat-4 (Boxer)

Horsepower 2:

165 hp @ 6000 rpm

Torque 2:

162 lb-ft @ 4000 rpm

Bore X Stroke 2:

99.5 mm x 79.0 mm

Compression Ratio 2:

9.7:1

Fuel Delivery 2:

Multi-port Fuel Injection (MPI)

Turbocharged Engine

Engine Code 3:

EJ22T (GT Turbo)

Engine Type 3:

2.2L SOHC 16-valve Turbocharged Flat-4 (Boxer)

Horsepower 3:

190 hp @ 5600 rpm

Torque 3:

200 lb-ft @ 4000 rpm

Boost Pressure 3:

Approx. 7.0 psi

Performance

0-60 Mph Ej22:

Approx. 9.5 - 10.5 seconds

0-60 Mph Ej25:

Approx. 8.0 - 9.0 seconds

0-60 Mph Ej22T:

Approx. 7.0 - 8.0 seconds

Fuel System

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

15.9 US gallons

Fuel Economy Ej22:

Est. 20 MPG city / 26 MPG highway

Fuel Economy Ej25:

Est. 19 MPG city / 25 MPG highway

🔧 Transmission

Standard

Transmission Type Ej22 Ej25:

5-speed Manual Transmission (M/T)

Transmission Type Ej22T:

5-speed Manual Transmission (M/T) standard on GT models

Optional

Transmission Type Ej22 Ej25:

4-speed Automatic Transmission (A/T)

Transmission Type Ej22T:

4-speed Automatic Transmission (A/T) optional on GT models

Features

AWD System:

Symmetrical All-Wheel Drive with viscous coupling center differential (M/T) or electronically controlled multi-plate clutch (A/T)

Clutch Type Mt:

Dry single plate, hydraulically actuated

Atf Specification Auto:

Subaru ATF-HP or equivalent

Gear Ratios Mt:

Refer to manual for specific ratios per model/trim.

Gear Ratios At:

Refer to manual for specific ratios per model/trim.

📐 Dimensions

Exterior

Length Sedan:

181.1 inches

Length Wagon:

186.0 inches

Width:

69.1 inches

Height Sedan:

56.5 inches

Height Wagon:

58.7 inches

Wheelbase:

104.0 inches

Ground Clearance:

Approx. 6.0 inches

Wheel Size:

15-inch or 16-inch alloy or steel wheels

Tire Size Standard:

P205/60R15

Tire Size Optional Gt:

P205/55R16

Bolt Pattern:

5 x 100 mm

Weights

Curb Weight Sedan Ej22 Mt:

Approx. 3130 lbs

Curb Weight Wagon Ej25 At:

Approx. 3390 lbs

Gross Vehicle Weight Rating:

Refer to vehicle VIN plate

Cargo

Cargo Volume Sedan:

Approx. 14.1 cu ft

Cargo Volume Wagon:

Approx. 35.1 cu ft (rear seats up), 66.6 cu ft (rear seats folded)

🛡️ Safety Features

Ratings

NHTSA Driver Side Frontal:

4-star (1996 model year, though ratings may vary)

NHTSA Passenger Side Frontal:

4-star (1996 model year, though ratings may vary)

Active Features

Anti Lock Brakes:

Optional ABS on many models

Traction Control:

Not typically available on this generation

Passive Features

Airbags:

Driver and passenger front airbags standard

Seatbelts:

3-point front and rear seatbelts

Crumple Zones:

Designed with front and rear crumple zones

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM cassette player, optional CD player. Basic speaker setup.

Display:

Minimal display for radio and clock; no integrated navigation or infotainment screens.

Driver Assistance

Cruise Control:

Available on most models.

Traction Control:

Generally not equipped with electronic traction control systems.

Connectivity

Auxiliary Inputs:

No factory auxiliary or USB inputs.

Bluetooth:

Not available.

Vehicle Systems

ECU Type:

Engine Control Unit (ECU) manages fuel injection, ignition timing, and other engine parameters.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 3 months (severe service) / 7,500 miles or 6 months (normal service)

Engine Oil Type:

API SG or SH, SAE 5W-30 or 10W-30 (refer to owner's manual for specific conditions)

Oil Filter Part Number:

Subaru: 15208AA031 or equivalent (e.g., Wix 51516, Fram PH8300)

Timing Belt Replacement Interval:

Every 60,000 - 100,000 miles or 5-7 years (crucial interval for EJ engines)

Transmission Fluid Change Interval Auto:

Every 30,000 miles or 2 years (severe service) / 60,000 miles or 4 years (normal service)

Transmission Fluid Change Interval Manual:

Every 60,000 miles or 4 years

Coolant Flush Interval:

Every 30,000 miles or 2 years

Spark Plug Replacement Interval:

Every 60,000 miles (platinum-tipped)

Fluid Specifications

Coolant Type:

Subaru Super Coolant (Blue) or equivalent ethylene glycol based coolant

Brake Fluid Type:

DOT 3 or DOT 4

Power Steering Fluid Type:

Subaru Automatic Transmission Fluid (ATF) or Dexron II/III compatible fluid

Known Issues

Head Gasket Leaks:

While not as prevalent as later generations, some EJ25D engines can be prone to head gasket leaks due to coolant flow design. Early detection and proper sealant are key.

Automatic Transmission Issues:

Older automatic transmissions may exhibit delayed shifting or slipping if not properly maintained; regular fluid changes are critical.

Suspension Wear:

Bushings and ball joints can wear over time, leading to clunking noises and poor handling.

Exhaust Manifold Cracks:

Subaru exhaust manifolds, particularly the cast iron ones, can be prone to cracking due to heat cycles, leading to exhaust leaks.

Idle Control Valve Issues:

The Idle Air Control (IAC) valve can become dirty or faulty, leading to rough idling or stalling.

Rear Main Seal Leaks:

Rear main crankshaft seal leaks can occur, often requiring transmission removal to replace.

📚 Vehicle History

Brand Heritage

Subaru Specialty:

Subaru Corporation, a Japanese manufacturer, has a long history of producing vehicles with horizontally-opposed engines and all-wheel drive.

Model Evolution

Legacy Introduction:

The Subaru Legacy was introduced globally in 1989 as a replacement for the Subaru Leone.

Second Generation:

The 1996 model year represents the second generation (BD/BG/BK) of the Subaru Legacy, which was produced from 1993 to 1999.

Outback Variant:

The Outback variant, a lifted and more rugged version of the Legacy wagon, was introduced in 1995 and gained popularity for its off-road capabilities.

Production

Manufacturing Location:

Japan (Subaru's main manufacturing facilities)

Production Years Gen2:

1993-1999

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

While not specific to 1996, the Legacy platform has historically been recognized by automotive publications for its engineering and capability.

Ratings

Consumer Reports Reliability:

Consumer Reports ratings for this era varied, but generally Subaru maintained a reputation for solid engineering.