SUBARU LEGACY 1996 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 1996 Codes Chassis Code: BD/BG/BK Generation Generation Name: Second Generation (Second Facelift) 👋 Introduction Market Position Segment: Mid-size Sedan/Wagon Competitors: Toyota...

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标签: 1996 Car Cars LEGACY Misc Subaru

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy

Year:

Codes

Chassis Code:

BD/BG/BK

Generation

Generation Name:

Second Generation (Second Facelift)

👋 Introduction

Market Position

Segment:

Mid-size Sedan/Wagon

Competitors:

Toyota Camry, Honda Accord, Ford Taurus, Nissan Maxima

Competitive Analysis

Key Selling Points:

Standard Symmetrical All-Wheel Drive, boxer engine layout, reliable reputation, durable construction

Key Features

All Wheel Drive:

Standard Symmetrical All-Wheel Drive system offering superior traction and stability in various conditions.

Engine Layout:

Horizontally opposed (Boxer) engine for a lower center of gravity and improved handling.

Body Styles:

Offered in Sedan and Wagon body styles.

Trim Levels:

Available in various trim levels like RS, LS, GT, Outback (wagon variant).

📋 Manual Details

Coverage Areas

Primary Markets Covered:

North America, Europe, Japan

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul, cylinder head, block, crankshaft, pistons, connecting rods, timing belt, oil pump, lubrication system, cooling system

Engine Performance:

Fuel injection system, ignition system, emission control systems (catalytic converter, EGR, PCV), engine diagnostics, performance tuning

Transmission Manual:

Clutch system, gearbox overhaul, gear selection, synchronizers, bearings

Transmission Automatic:

Automatic transmission overhaul, hydraulic control systems, torque converter, valve body, shift control

Drivetrain:

All-Wheel Drive (AWD) system, viscous coupling, differentials (front and rear), driveshafts, CV joints, axle shafts

Suspension:

Front and rear suspension components, struts, shock absorbers, springs, control arms, ball joints, bushings, sway bars

Steering:

Power steering system, steering rack, tie rods, steering column, wheel alignment specifications

Brakes:

Front and rear brake systems, disc brakes, drum brakes, hydraulic lines, master cylinder, brake booster, ABS system (if equipped), parking brake

Electrical System:

Battery, charging system (alternator, starter), lighting systems, wiring diagrams, fuses, relays, ignition switch

Body And Chassis:

Body panel removal and installation, interior trim, exterior trim, glass, doors, hood, trunk, chassis diagnostics, rust prevention

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, climate controls

Diagnostics Troubleshooting:

Diagnostic Trouble Codes (DTCs), OBD-I (On-Board Diagnostics) system, troubleshooting flowcharts, common fault diagnosis

Procedures Included

Maintenance Routines:

Oil change, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid flush, power steering fluid flush

Repair Procedures:

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

Troubleshooting Guide:

Systematic approach to identifying and resolving common and uncommon vehicle issues, symptom-based diagnosis

Wiring Diagrams:

Detailed electrical wiring diagrams for all vehicle systems, component locations, connector pinouts

Diagnostic Procedures:

Procedures for using diagnostic tools, reading sensor data, testing electrical components, checking fuel pressure, ignition timing adjustments

Technical Depth

Depth:

Comprehensive from basic scheduled maintenance to complete engine and transmission rebuilds, including advanced diagnostics and component-level repair.

📊 Manual Specifications

File Format

File Type:

Searchability:

Fully searchable text for quick information retrieval

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity

Printable:

Printable pages for workshop use

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Quality:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

Engine Description 1:

2.2L SOHC 16-valve Boxer-4

Displacement 1:

2211 cc

Bore Stroke 1:

97.0 mm x 75.0 mm

Compression Ratio 1:

9.5:1

Horsepower 1:

135 hp @ 5600 rpm

Torque 1:

140 lb-ft @ 4400 rpm

Fuel Induction 1:

Multi-port Fuel Injection (MPI)

Ignition System 1:

Distributorless Ignition System (DIS) / Direct Ignition (DI)

Engine Code 2

Engine Code 2:

EJ25D

Engine Description 2

Engine Description 2:

2.5L DOHC 16-valve Boxer-4 (Optional on some models, more common in later years but may be present)

Displacement 2

Displacement 2:

2457 cc

Performance 2

Horsepower 2:

165 hp @ 5600 rpm

Torque 2:

155 lb-ft @ 4000 rpm

Fuel System

Fuel Type Requirement:

Unleaded gasoline, 87 octane (minimum)

Fuel Tank Capacity:

15.9 US gallons (60 liters)

🔧 Transmission

Standard

Standard Transmission:

5-Speed Manual

Optional

Optional Transmission:

4-Speed Automatic (with lock-up torque converter)

Features

AWD Integration:

Integrated with standard Symmetrical All-Wheel Drive system.

Fluid Specifications

Manual Transmission Fluid:

API GL-4, SAE 75W-90

Automatic Transmission Fluid:

Subaru ATF HP (or equivalent)

📐 Dimensions

Exterior Sedan

Length Sedan:

183.1 in (4650 mm)

Width Sedan:

67.7 in (1720 mm)

Height Sedan:

56.1 in (1425 mm)

Exterior Wagon

Length Wagon:

185.4 in (4710 mm)

Width Wagon:

67.7 in (1720 mm)

Height Wagon:

57.5 in (1460 mm) (standard), 60.0 in (1525 mm) (Outback)

Wheelbase

Wheelbase:

104.3 in (2650 mm)

Weights

Curb Weight Manual:

Approx. 3100-3300 lbs (1400-1500 kg)

Curb Weight Automatic:

Approx. 3200-3400 lbs (1450-1550 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 4300 lbs (1950 kg)

Cargo

Cargo Volume Sedan:

Approx. 14.1 cu ft (399 liters)

Cargo Volume Wagon:

Approx. 37.5 cu ft (1062 liters) (rear seats up)

Cargo Volume Wagon Seats Folded:

Approx. 70.0 cu ft (1982 liters) (rear seats folded)

🛡️ Safety Features

Ratings

NHTSA Driver Front Impact Rating:

Not rated or unavailable for this model year.

NHTSA Passenger Front Impact Rating:

Not rated or unavailable for this model year.

Active Features

Anti-lock Braking System (ABS) available on select trims.

Passive Features

Airbags:

Driver and passenger front airbags.

Seatbelts:

Three-point front and rear seatbelts. Pretensioners for front seatbelts.

Child Seat Anchors:

LATCH/ISOFIX not standard on this model year, but provisions for child seats may exist.

Construction

Body Structure:

Reinforced body structure with crumple zones.

💡 Technology Features

Infotainment

Audio System:

Factory fitted AM/FM stereo with cassette player. Optional CD player available on higher trims. Speaker configurations vary by trim.

Climate Control:

Manual climate control with A/C standard on most models. Automatic climate control was an option.

Driver Assistance

Cruise Control:

Standard on most trims.

Connectivity

Auxiliary Inputs:

No factory auxiliary inputs or Bluetooth connectivity. Aftermarket solutions available.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles (6,000 km) or 3 months, whichever comes first. Use synthetic oil for extended intervals.

Air Filter Replacement Interval:

Every 15,000 miles (24,000 km) or 12 months.

Fuel Filter Replacement Interval:

Every 30,000 miles (48,000 km).

Spark Plug Replacement Interval:

Every 30,000 miles (48,000 km) for standard plugs, or 60,000 miles (96,000 km) for platinum/iridium plugs (check specific plug type).

Timing Belt Replacement Interval:

Every 60,000 miles (96,000 km) or 5 years, critical to prevent catastrophic engine damage.

Coolant Flush Interval:

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

Brake Fluid Flush Interval:

Every 24,000 miles (38,000 km) or 2 years.

Fluid Specifications

Engine Oil Specification:

API SG or SH, SAE 5W-30 (preferred), 10W-30, or 10W-40 depending on climate.

Engine Oil Capacity Ej22:

4.5 US quarts (4.3 liters) with filter change.

Coolant Specification:

Subaru Super Coolant (blue) or equivalent ethylene glycol based coolant, 50/50 mix with distilled water.

Power Steering Fluid:

Subaru power steering fluid or Dexron II/III ATF.

Known Issues

Head Gaskets:

While less prevalent than in later EJ series engines, early EJ25D engines (if present) were known for head gasket failures. The EJ22 is generally more robust.

Suspension Bushings:

Wear and tear on suspension bushings and ball joints is common with age and mileage.

Oil Leaks:

Rear main seal and valve cover gasket leaks can occur over time.

Catalytic Converter:

Can become clogged or fail over time, especially with poor maintenance.

Maintenance Schedule Summary

Basic Checks:

Tire pressure, fluid levels, belts, hoses, lights should be checked regularly (monthly).

📚 Vehicle History

Brand Heritage

Subaru Philosophy:

Subaru is known for its emphasis on safety, durability, and its unique Symmetrical All-Wheel Drive system.

Model Evolution

Second Generation Intro:

The second generation Legacy (BD/BG/BK) was introduced for the 1995 model year, evolving from the first generation. The 1996 model represents a continuation of this generation, with minor updates.

Second Generation Facelift:

The second generation received a significant facelift for the 1997 model year, meaning the 1996 model is the pre-facelift version of the second generation.

Outback Variant:

The Outback variant, a lifted and more rugged version of the Legacy wagon, gained popularity during this generation.

Production

Production Locations:

Primarily manufactured in Japan.

Production Years Second Gen:

1995-1999

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

Subaru Legacy models, particularly the Outback variants, have been recognized by Car and Driver in their '10Best' lists in various years, acknowledging their practicality and capability.

Ratings

Ieda Safety Award:

Subaru often received high safety ratings from organizations like the Insurance Institute for Highway Safety (IIHS) for its durable construction.