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SUBARU LEGACY 1996 Complete Factory Service / Repair / Workshop Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 1996 Chassis Code: BD/BG (Second Generation) Codes Engine Code Common: EJ22, EJ25 Trim Levels: L, LS, GT, Outback (wagon variants) 👋...
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SUBARU LEGACY 1996 Complete Factory Service / Repair / Workshop ManualSUBARU LEGACY 1996 Complete Factory Service / Repair / Workshop ManualSUBARU LEGACY 1996 Complete Factory Service / Repair / Workshop ManualSUBARU LEGACY 1996 Complete Factory Service / Repair / Workshop Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy
Year:
1996
Chassis Code:
BD/BG (Second Generation)
Codes
Engine Code Common:
EJ22, EJ25
Trim Levels:
L, LS, GT, Outback (wagon variants)
👋 Introduction
Market Position
Segment:
Compact/Mid-size Sedan and Wagon, known for All-Wheel Drive capability.
Competitive Analysis
Competitors 1996:
Toyota Camry, Honda Accord, Mazda 626, Nissan Altima.
Key Features
Standard AWD:
Subaru's signature Symmetrical All-Wheel Drive system was standard on most models, a key differentiator.
Boxer Engine:
Horizontally-opposed (Boxer) engine design contributing to a lower center of gravity and improved handling.
Outback Variant:
Introduction of the Outback model, a more rugged, lifted wagon version, increasing its appeal to outdoor enthusiasts.
📋 Manual Details
Coverage Areas
Regions Covered:
North America, Europe, Japan (specifications may vary slightly)
Body Styles:
Sedan, Wagon (Outback)
Page Count
Estimated Page Count:
1500-2000+
Manual Type
Type:
Factory Service Manual / Workshop Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanicals (EJ22, EJ25 DOHC/SOHC), fuel system, ignition system, cooling system, lubrication, exhaust system.
Drivetrain:
All-Wheel Drive (AWD) system, clutch, differentials (front, rear, center viscous coupling), driveshafts.
Transmission:
4-speed automatic transmission (4EAT), 5-speed manual transmission (5MT).
Suspension Steering:
Front strut suspension, rear multi-link independent suspension, power steering system, steering column.
Brakes:
Front ventilated disc brakes, rear disc brakes (all-wheel disc optional), ABS system, parking brake.
Electrical:
12V electrical system, battery, alternator, starter motor, lighting, instruments, wiring diagrams, ECU, sensors.
Body Chassis:
Body panels, interior trim, glass, door mechanisms, chassis components, corrosion protection.
HVAC:
Heating, ventilation, and air conditioning (HVAC) system operation and repair.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, belt inspections and adjustments.
Engine Repair:
Engine disassembly, inspection, reassembly, piston/ring replacement, head gasket replacement, timing belt/chain service (if applicable).
Transmission Repair:
Automatic and manual transmission overhaul, clutch replacement, torque converter service.
Suspension Steering Repair:
Shock absorber/strut replacement, ball joint service, tie rod end replacement, power steering pump and rack repair.
Brake System Repair:
Brake pad/shoe replacement, rotor resurfacing/replacement, caliper overhaul, bleeding brake lines, ABS component testing.
Electrical Diagnostics:
Troubleshooting using wiring diagrams, component testing, sensor diagnostics, ECU relearn procedures.
Bodywork Refinishing:
Minor body panel repair, door and latch adjustments, glass installation, interior component removal/installation.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, fault code interpretation.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to full engine and transmission overhauls, including detailed diagnostic procedures and specifications.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (typically, depending on PDF creation)
Print Quality
Printability:
Printable
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine 1 Displacement:
2.2 Liters (2212 cc)
Engine 1 Type:
EJ22, SOHC, 16-valve, horizontally-opposed 4-cylinder
Engine 1 Horsepower:
135 hp @ 5600 rpm
Engine 1 Torque:
140 lb-ft @ 4400 rpm
Optional Engine
Engine 2 Displacement:
2.5 Liters (2457 cc)
Engine 2 Type:
EJ25D, DOHC, 16-valve, horizontally-opposed 4-cylinder
Engine 2 Horsepower:
165 hp @ 6000 rpm
Engine 2 Torque:
162 lb-ft @ 4000 rpm
Performance
Compression Ratio Ej22:
9.5:1
Compression Ratio Ej25D:
9.7:1
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPFI)
Recommended Fuel:
87 Octane Unleaded Gasoline
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (5MT)
Optional
Type:
4-speed Electronic Automatic Transmission (4EAT) with AWD coupling.
Features
AWD Engagement:
Full-time Symmetrical All-Wheel Drive with viscous coupling center differential (manual), electronically controlled clutch (automatic).
Fluid Specifications
Manual Transmission Fluid:
API GL-5, SAE 75W-90 Gear Oil
Automatic Transmission Fluid:
Subaru ATF-HP or Dexron III compatible
📐 Dimensions
Exterior
Length Sedan:
185.2 inches (4704 mm)
Width Sedan:
68.5 inches (1740 mm)
Height Sedan:
55.7 inches (1415 mm)
Wheelbase:
104.3 inches (2649 mm)
Weights
Curb Weight Approx:
3000-3300 lbs (1360-1497 kg) depending on trim and drivetrain
Cargo
Cargo Volume Sedan:
Approx. 15.5 cu ft
Cargo Volume Wagon:
Approx. 37.0 cu ft (seats up)
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
4/5 stars (typical for AWD vehicles of the era)
Active Features
ABS:
Anti-lock Braking System (ABS) available on higher trims or as an option.
Passive Features
Airbags:
Driver and front passenger airbags.
Seatbelts:
Front and rear seat belts, pre-tensioners for front belts.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player. Speaker configurations varied by trim.
Climate Control:
Manual climate control with A/C. Automatic climate control not standard on most models.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
Power Windows Locks:
Available power windows and door locks on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 - 5,000 miles or 6 months, whichever comes first (check manual for specific recommendations based on driving conditions).
Engine Oil Filter:
Subaru Part #: 15208AA100 (example, verify with VIN)
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on inspection.
Spark Plug Replacement:
Every 30,000 - 60,000 miles (typically copper plugs)
Coolant Flush:
Every 30,000 - 60,000 miles or 2-4 years.
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 5W-30, 5W-40, or 10W-30 (check manual for climate/driving conditions).
Coolant Type:
Subaru Genuine Coolant or equivalent ethylene glycol-based coolant, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 3
Known Issues
Head Gaskets:
The EJ25D DOHC engine is known for potential head gasket failures, often requiring replacement with updated gaskets.
Oil Leaks:
Valve cover gaskets and oil pan gaskets can develop leaks over time.
Cv Axle Boots:
Outer CV joint boots can degrade and tear, leading to lubricant loss and potential joint failure.
Radiator Fan Control:
In some cases, radiator fan control modules can fail.
📚 Vehicle History
Brand Heritage
Subaru Philosophy:
Focus on reliability, safety, and go-anywhere capability with its AWD system and boxer engines.
Model Evolution
Second Gen Introduction:
The 1995 model year saw the introduction of the second generation (BD/BG), featuring a significant redesign and updated powertrains.
Production
Manufacturing Location:
Japan
Generation Years:
1990-1994 (First Gen), 1995-1999 (Second Gen)
🏆 Awards & Recognition
Recognitions
Outback Launch:
The Outback variant redefined the crossover utility vehicle (CUV) segment, though awards specifically for the '96 model are less prominent than later iterations.
Ratings
Consumer Reports:
Generally rated as having average to above-average reliability for its class, particularly the powertrain.
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