🏷️ Basic Information

Make:

Subaru

Model:

Legacy

Model Years Covered:

2004, 2005

Chassis Codes:

BP (Wagon), BL (Sedan)

Subaru Product Code:

Likely a specific service manual identification code, not explicitly provided but implied by the product description

👋 Introduction

Vehicle Segment:

Mid-size sedan and wagon, known for its All-Wheel Drive capability and practicality.

Brand Perception:

Subaru is recognized for its engineering, particularly its horizontally opposed ('boxer') engines and standard AWD, appealing to buyers seeking traction and reliability.

Key Competitors:

Toyota Camry, Honda Accord, Nissan Altima, Mazda6, Ford Fusion.

Differentiators:

Standard Symmetrical All-Wheel Drive across most trims, Boxer engine for a lower center of gravity, reputation for durability and safety.

Manual Value Proposition:

Empowers owners to perform maintenance and repairs, saving money and ensuring quality work, crucial for enthusiasts and budget-conscious owners of a well-engineered vehicle.

📋 Manual Details

Coverage Type:

Comprehensive Service and Repair

Market Scope:

North America (implied by typical product sales channels)

Estimated Page Count:

1500+ pages (typical for a complete factory service manual of this era and scope)

Manual Format:

Digital Download

Manual Category:

Factory Service Manual (FSM) / Workshop Manual

Language:

English

Digital Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Detailed overhaul and repair procedures for all engine variants, including timing belt replacement, piston and ring service, cylinder head repair, and crankshaft/connecting rod procedures.

Engine Management And Emissions:

Diagnostics, testing, and repair of fuel injection systems (MPI), ignition systems, exhaust systems, evaporative emission control (EVAP), and OBD-II diagnostics.

Transmission Manual:

Disassembly, inspection, repair, and reassembly of 5-speed and 6-speed manual transmissions, including clutch operation and driveline components.

Transmission Automatic:

Diagnosis, fluid service, and repair procedures for the 4-speed automatic transmission, including torque converter, valve body, and internal component servicing.

All Wheel Drive System:

Information on the Active All-Wheel Drive (AWD) system, including front and rear differentials, viscous coupling, and related driveline components.

Suspension:

Front and rear suspension component diagnosis, replacement, and alignment procedures for MacPherson struts and multi-link rear suspension.

Steering:

Power steering system diagnosis, component replacement (pump, rack and pinion), and troubleshooting.

Brakes:

Disc brake systems (front and rear), ABS (Anti-lock Braking System) operation, diagnosis, and component replacement (pads, rotors, calipers, master cylinder, brake lines).

Electrical System:

Complete wiring diagrams, component testing, charging system (alternator, battery), starting system, lighting, and accessory circuits.

HVAC:

Air conditioning system operation, refrigerant service, blower motor, climate control module diagnosis, and heater core replacement.

Body And Interior:

Body panel removal and installation, door mechanisms, interior trim, seat removal, glass replacement, and structural repair information.

Restraint Systems:

Airbag system diagnostics, SRS (Supplemental Restraint System) component testing, and safety precautions.

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, and coolant service.

Troubleshooting Guides:

Step-by-step diagnostic procedures for common and complex issues across all vehicle systems, often linked to DTC (Diagnostic Trouble Codes).

Component Replacement:

Detailed instructions for removing, installing, and adjusting virtually every mechanical and electrical component on the vehicle.

Torque Specifications:

Precise torque values for all fasteners, critical for proper assembly and preventing component damage.

Diagnostic Procedures:

Systematic approaches to diagnosing faults using test equipment, visual inspections, and logical deduction.

Wiring Diagrams:

Complete and detailed wiring schematics for all electrical circuits, essential for electrical diagnostics and repair.

Depth Of Coverage:

Factory-level repair and diagnostic information, suitable for professional technicians and advanced DIY enthusiasts.

Diagnostic Tools:

Information on necessary diagnostic tools, scan tools, and specialized equipment required for certain procedures.

Rebuild Procedures:

Includes detailed instructions for the complete disassembly, inspection, and reassembly of major components like engines and transmissions.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable, allowing for quick information retrieval.

Digital Resolution:

High resolution, suitable for printing individual pages or sections.

Binding:

Not applicable for digital download; user can print and bind as desired.

Paper Recommendation:

N/A (digital format); users may prefer sturdy paper for printed copies.

⚙️ Engine Specifications

Engine Codes:

EJ251 (2.5L SOHC), EJ253 (2.5L SOHC), EJ255 (2.5L DOHC Turbocharged for GT models), EJ205 (2.0L DOHC Turbocharged for GT models in some markets, less common in US 2004-2005)

Displacement:

2.5 Liters (2457 cc) for naturally aspirated models; 2.0L or 2.5L for turbocharged GT models.

Horsepower:

Approx. 165-170 HP for naturally aspirated 2.5L; Approx. 210-227 HP for turbocharged GT models.

Torque:

Approx. 166-170 lb-ft for naturally aspirated 2.5L; Approx. 235-250 lb-ft for turbocharged GT models.

Fuel Delivery:

Sequential Multi-Point Fuel Injection (MPI).

Fuel Type:

Unleaded gasoline (87 octane minimum for naturally aspirated, 91+ octane recommended for turbo models).

Configuration:

Horizontally Opposed (Boxer) 4-Cylinder.

Valve Train:

SOHC (Single Overhead Camshaft) for most 2.5L engines; DOHC (Double Overhead Camshaft) for turbo GT models.

🔧 Transmission

Standard Transmission:

5-speed Manual Transmission (part-time or full-time AWD depending on model/trim).

Optional Transmission:

4-speed Automatic Transmission with Lock-up Torque Converter (standard Symmetrical AWD).

AWD System:

Subaru's Symmetrical All-Wheel Drive system is standard on most Legacy models for this generation, providing enhanced traction and stability.

📐 Dimensions

Sedan Wheelbase:

Approx. 104.0 inches (2640 mm)

Wagon Wheelbase:

Approx. 104.0 inches (2640 mm)

Sedan Length:

Approx. 187.2 inches (4755 mm)

Wagon Length:

Approx. 188.2 inches (4780 mm)

Width:

Approx. 68.1 inches (1730 mm)

Height:

Approx. 56.1 inches (1425 mm) (Sedan) / 57.7 inches (1465 mm) (Wagon)

Sedan Trunk Volume:

Approx. 13.0 cubic feet

Wagon Cargo Volume:

Approx. 30.1 cubic feet (seats up) / 65.3 cubic feet (seats down)

Curb Weight:

Approx. 3,200 - 3,500 lbs (depending on trim and transmission)

Gross Vehicle Weight Rating:

Varies by specific model and configuration, typically around 4,500 - 4,700 lbs.

🛡️ Safety Features

NHTSA Front Crash Test:

5-star rating (for models equipped with side airbags)

NHTSA Side Impact Rating:

5-star rating (for models equipped with side airbags)

IIHS Frontal Offset Rating:

Good (for models tested)

ABS:

Standard Anti-lock Braking System (ABS).

Traction Control:

Available Traction Control System (TCS).

AWD:

Standard Symmetrical All-Wheel Drive enhances active safety by improving grip.

Airbags:

Front airbags; available front side-impact airbags and side curtain airbags (depending on trim).

Seatbelts:

Three-point seatbelts for all occupants, pretensioners and force limiters for front seats.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Audio System:

Factory AM/FM/CD player with available premium audio systems, some with multi-disc changers. Aux input typically not standard.

Navigation:

Optional factory navigation system available on higher trims.

Cruise Control:

Standard cruise control.

Climate Control:

Manual or automatic climate control systems depending on trim level.

Phone Integration:

Limited to aftermarket Bluetooth adapters; no integrated Bluetooth or smartphone mirroring as standard.

Keyless Entry:

Available keyless entry and remote start.

Power Accessories:

Power windows, power door locks, power mirrors standard on most trims.

🔧 Maintenance

Oil Change Interval:

Every 3,750 miles or 6 months for severe driving conditions, or 7,500 miles or 12 months for normal conditions (check manual for specific recommendation based on engine oil type).

Timing Belt Replacement:

At 105,000 miles or 105 months for 2.5L SOHC engines. Crucial preventative maintenance to avoid catastrophic engine damage.

Spark Plug Replacement:

Typically around 60,000-105,000 miles, depending on the spark plug type (platinum or iridium).

Coolant Flush:

Every 30,000 miles or 30 months for the first service, then every 15,000 miles or 15 months thereafter (using Subaru Super Coolant).

Engine Oil Type:

SAE 5W-30 or 5W-40 API certified (check manual for exact specification and viscosity based on climate).

Transmission Fluid Manual:

API GL-5 SAE 75W-90 gear oil for manual transmissions and differentials.

Transmission Fluid Automatic:

Subaru ATF HP (High Performance) Automatic Transmission Fluid. Requires regular changes, especially under severe use.

Coolant Type:

Subaru Super Coolant (blue color) or equivalent silicate-free, long-life coolant.

Head Gaskets:

While less prevalent in this generation compared to earlier models, EJ series engines can still be susceptible to head gasket failure, especially turbocharged variants pushed hard. The manual will detail diagnostic and replacement procedures.

Wheel Bearings:

Front and rear wheel bearings can wear out over time, especially with AWD and potential road salt exposure. Manual provides replacement instructions.

Oxygen Sensors:

Oxygen sensors (O2 sensors) can degrade, affecting fuel economy and emissions. The manual covers testing and replacement.

Catalytic Converter:

Can become clogged over time, impacting performance. Manual details diagnosis and replacement.

📚 Vehicle History

Subaru History:

Subaru, the automotive division of Fuji Heavy Industries, has a long history of innovation, particularly in the areas of all-wheel drive and horizontally opposed engines, established in 1958.

Legacy Introduction:

The Subaru Legacy was introduced globally in 1989 as a successor to the Subaru Leone. The 2004-2005 models represent the fourth generation (BP/BL) of the Legacy, which debuted for the 2005 model year in North America.

Fourth Generation Changes:

This generation marked a significant styling evolution, increased dimensions, improved interior quality, and refinements to the powertrain and AWD system. It was also the first generation to feature the turbocharged GT models in the US market, known for their performance.

Manufacturing Locations:

Primarily manufactured in Japan (Ota City, Gunma Prefecture) and also in Lafayette, Indiana, USA for the North American market.

Production Years For Gen:

2003-2009 (global production for BL/BP generation)

🏆 Awards & Recognition

IIHS Top Safety Pick:

The 2004-2005 Subaru Legacy often received high safety ratings from IIHS and NHTSA, contributing to its reputation as a safe vehicle.

Consumer Reports Reliability:

Consumer Reports typically rated Subarus well for reliability and owner satisfaction during this period, though specific model year ratings can vary. This manual helps maintain that reliability.

California Emissions Certification:

Vehicles sold in California and certain other states are PZEV (Partial Zero Emission Vehicle) or ULEV (Ultra-Low Emission Vehicle) certified, with specific emissions system details covered in the manual.