🏷️ Basic Information

Make:

Subaru

Model:

Legacy

Year:

1996

Chassis Code:

BD/BG

Engine Code Primary:

EJ22 (2.2L SOHC)

Engine Code Optional 1:

EJ25D (2.5L DOHC)

Engine Code Optional 2:

EJ20 (2.0L Turbocharged - JDM/Europe)

Transmission Code Primary:

4EAT (4-speed Automatic)

Transmission Code Optional:

MT5 (5-speed Manual)

👋 Introduction

Vehicle Segment:

Mid-size sedan and wagon, known for its standard All-Wheel Drive and robust engineering.

Key Competitors:

Toyota Camry, Honda Accord, Ford Taurus, Mazda 626, Nissan Altima.

Standard AWD:

Symmetrical All-Wheel Drive was a defining feature, offering superior traction and stability in various weather conditions.

Body Styles:

Available as a 4-door sedan and a 5-door wagon (Outback Sport in North America).

Engine Options Na:

Primarily offered with the 2.2L EJ22 SOHC engine, with a more powerful 2.5L EJ25D DOHC engine available on higher trims.

Diy Support:

Empowers owners to perform complex repairs and routine maintenance, saving significant costs.

Professional Reference:

Serves as an indispensable resource for professional mechanics, providing factory-accurate data.

📋 Manual Details

Manual Type:

Factory Service Repair Manual (FSM)

Language:

English

Format:

Downloadable PDF

Completeness:

Complete official factory documentation

Print Capability:

Printable in its entirety or selected pages

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, inspection, and reassembly procedures for EJ22, EJ25D, and EJ20 engines. Includes cylinder head, pistons, crankshaft, camshafts, timing belts, lubrication system, cooling system.

Fuel System:

Fuel injection system (MPI), fuel pump, fuel injectors, fuel pressure regulator, fuel tank, evaporative emissions control (EVAP).

Ignition System:

Ignition coils, spark plugs, ignition timing, crank angle sensor, camshaft position sensor.

Transmission Manual:

Clutch system, transmission gear sets, shift forks, synchronizers, hydraulic controls, lubrication.

Transmission Automatic:

4EAT system, valve body, torque converter, planetary gear sets, hydraulic control unit (HCU), solenoids, fluid cooler.

Drivetrain AWD:

Symmetrical All-Wheel Drive system, front and rear differentials, viscous coupling unit (VCU), propeller shaft, half-shafts.

Suspension:

Front MacPherson struts, rear multi-link suspension, control arms, ball joints, bushings, sway bars, springs, shock absorbers.

Steering:

Power steering system, steering rack and pinion, power steering pump, steering column.

Brakes:

Front disc brakes (ventilated), rear disc brakes, ABS (Anti-lock Braking System) components, brake lines, master cylinder, brake booster.

Electrical System:

Battery, alternator, starter motor, wiring harnesses, fuses, relays, lighting system (headlights, taillights, interior), horn.

Engine Management:

ECU (Engine Control Unit) diagnostics, sensors (MAF, MAP, O2, coolant temp, throttle position), actuators (idle air control valve).

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, A/C compressor, condenser, evaporator, blower motor, climate controls.

Body And Frame:

Body panel removal and installation, structural components, door mechanisms, window regulators, exterior trim.

Interior:

Dashboard removal, seat removal, interior trim panels, upholstery.

Scheduled Maintenance:

Detailed instructions for all scheduled maintenance items, including oil changes, filter replacements, spark plug changes, timing belt replacement intervals.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting guides, common problem identification and resolution for various systems.

Repair Procedures:

Step-by-step repair instructions for virtually all mechanical and electrical components, including engine rebuilds, transmission overhauls, brake caliper replacement, etc.

Diagnostic Codes:

OBD-I (On-Board Diagnostics) code definitions and diagnostic procedures for the 1996 model year.

Specifications And Tolerances:

Precise measurements, torque specifications, clearances, and tolerances for all critical engine, drivetrain, suspension, and brake components.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems, including engine control, lighting, audio, power accessories, and ABS.

Special Tools:

Identification and usage instructions for any Subaru-specific or specialized tools required for certain procedures.

Assembly And Disassembly:

Detailed instructions for the proper removal, disassembly, cleaning, inspection, repair, and reassembly of all major vehicle components.

Depth Level:

Comprehensive, from basic fluid changes and inspections to complete engine and transmission overhauls and advanced electrical diagnostics.

Target Audience:

Professional technicians, DIY enthusiasts, and Subaru owners seeking in-depth repair and maintenance knowledge.

📊 Manual Specifications

Digital Format:

PDF (Portable Document Format)

Searchability:

Likely text-searchable (depending on PDF creation quality), allowing for quick information retrieval.

Print Resolution:

Optimized for clear printing of diagrams, schematics, and text.

Digital Format Implication:

N/A (Digital Format)

Digital Format Implication:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Name 1:

EJ22

Displacement 1:

2.2 Liters (2211 cc)

Configuration 1:

Horizontally Opposed (Boxer), SOHC (Single Overhead Camshaft), 16 Valves

Bore X Stroke 1:

96.0 mm x 75.0 mm

Compression Ratio 1:

9.5:1

Horsepower 1:

135 hp @ 5600 rpm (approx.)

Torque 1:

138 lb-ft @ 4400 rpm (approx.)

Engine Name 2:

EJ25D

Displacement 2:

2.5 Liters (2457 cc)

Configuration 2:

Horizontally Opposed (Boxer), DOHC (Double Overhead Camshaft), 16 Valves

Bore X Stroke 2:

99.5 mm x 79.0 mm

Compression Ratio 2:

9.5:1

Horsepower 2:

165 hp @ 5600 rpm (approx.)

Torque 2:

162 lb-ft @ 4000 rpm (approx.)

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline (87 octane or higher recommended)

Emissions Control:

Catalytic converter, oxygen sensors, EVAP system

🔧 Transmission

Transmission Type:

4-speed Electronically Controlled Automatic Transmission (4EAT)

AWD System Integration:

Electronically controlled AWD system integrated with transmission

Transmission Type Manual:

5-speed Manual Transmission (MT5)

AWD System Integration Manual:

Full-time Symmetrical All-Wheel Drive with viscous coupling center differential

Automatic Modes:

Sport mode, Snow mode (on select 4EAT models)

Automatic Fluid Type:

Subaru ATF HP (or equivalent) - Capacity approx. 7.5 quarts (7.1 liters) for fluid change

Manual Fluid Type:

GL-5 75W-90 Synthetic Gear Oil (approx. 2.4 quarts / 2.3 liters)

📐 Dimensions

Wheelbase:

104.3 inches (2649 mm)

Length:

187.2 inches (4755 mm) (Sedan)

Width:

69.1 inches (1755 mm)

Height:

55.1 inches (1400 mm) (Sedan)

Ground Clearance:

5.7 inches (145 mm) (approx.)

Passenger Volume:

Approx. 97 cubic feet (2748 liters)

Trunk Volume:

Approx. 15 cubic feet (425 liters) (Sedan)

Curb Weight:

3100 - 3400 lbs (1406 - 1542 kg) (Varies by trim and transmission)

Gross Vehicle Weight Rating:

Approx. 4300 lbs (1950 kg)

🛡️ Safety Features

NHTSA Front Impact Driver:

4 Stars (1996 models)

NHTSA Front Impact Passenger:

4 Stars (1996 models)

IIHS Side Impact:

Acceptable (for models tested)

ABS:

Standard on most models, 4-wheel disc brakes with ABS available

Traction Control:

Not typically available for 1996 models

Airbags:

Driver and front passenger airbags standard

Seatbelts:

Front and rear 3-point seatbelts, front pretensioners

Body Structure:

Reinforced body structure for improved crashworthiness

💡 Technology Features

Audio System:

Factory-installed AM/FM stereo with cassette player, optional CD player. Basic speaker configurations.

Climate Control:

Manual or automatic climate control systems depending on trim level.

Cruise Control:

Standard or optional depending on trim level.

Phone Integration:

No factory integrated Bluetooth or smartphone connectivity for this era.

Headlights:

Composite halogen headlights.

🔧 Maintenance

Engine Oil Change:

Every 3,750 miles or 3 months (whichever comes first) for normal service; 3,000 miles or 3 months for severe service.

Engine Oil Filter Replacement:

Replace with every oil change.

Air Filter Replacement:

Inspect every 15,000 miles, replace as needed. Replace every 30,000 miles.

Spark Plug Replacement:

Replace every 30,000 miles (platinum tipped).

Timing Belt Replacement:

Replace every 60,000 miles or 4 years. Critical on EJ engines to prevent catastrophic damage.

Coolant Replacement:

Replace every 30,000 miles or 2 years (using Subaru Super Coolant or equivalent)

Transmission Fluid Change Auto:

Inspect every 15,000 miles, change every 30,000 miles or as needed, especially under severe use.

Transmission Fluid Change Manual:

Inspect every 30,000 miles, change as recommended (often around 60,000 miles).

Engine Oil Viscosity:

10W-30 (preferred), 5W-30 or 5W-40 may be used based on climate.

Engine Oil API Spec:

API Service SG or SH, SH/CD or SH/CF

Coolant:

Subaru Super Coolant (Blue) or equivalent ethylene glycol based coolant with corrosion inhibitors.

Power Steering Fluid:

Dexron II or equivalent ATF

Brake Fluid:

DOT 3

Ej25D Head Gaskets:

The EJ25D engine is known for premature head gasket failures, often manifesting as coolant leaks or internal coolant passage contamination. The manual will detail proper inspection and replacement procedures, torque sequences, and gasket types.

Timing Belt Tensioner:

Failure of the timing belt tensioner can lead to belt slippage and engine damage. Regular replacement is crucial. The manual will outline replacement procedures and tensioner specifications.

Automatic Transmission AWD Clutch Pack:

Wear in the AWD clutch pack within the 4EAT can lead to reduced AWD performance or engagement issues. Fluid changes and proper maintenance are key. The manual will cover diagnostic checks and internal repairs.

Oil Leaks:

Common areas for oil leaks include valve cover gaskets, oil pan gaskets, and front crankshaft seals. The manual provides detailed instructions for seal replacement.

Evaporative Emissions System:

Issues with the EVAP system, such as canister purge valve or vent solenoid failures, can cause Check Engine Lights. The manual details diagnostic procedures for these components.

📚 Vehicle History

Subaru Specialization:

Subaru is historically known for its horizontally-opposed 'boxer' engines and its standard Symmetrical All-Wheel Drive systems, emphasizing safety and capability.

Second Generation:

The 1996 Legacy represents the second generation (second facelift), introduced for the 1995 model year.

Styling Changes:

The 1995 facelift brought updated exterior styling, including revised headlights, grille, bumpers, and a slightly wider track.

Engine Introduction:

The 2.5L DOHC EJ25D engine was introduced for this generation, offering a performance upgrade.

Production Years:

Second Generation: 1995-1999

Manufacturing Location:

Japan (various plants)

🏆 Awards & Recognition

Motor Trend Car Of The Year:

Subaru Legacy was named Motor Trend Car of the Year for 1990, setting a high standard for the brand.

Consumer Reports:

Consumer Reports often rated Subaru vehicles highly for reliability and owner satisfaction during this period, particularly models with the EJ22 engine.

Iso Certification:

Subaru's manufacturing facilities adhere to strict quality control standards, often including ISO certifications for production processes.