Subaru Legacy 2004-2005 Repair Service Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Product Name: Subaru Legacy 2004-2005 Repair Service Manual Product Type: Repair Service Manual Generation Generation Code: BP/BL Generation Years: 2004-2009 Codes Chassis...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy

Product Name:

Subaru Legacy 2004-2005 Repair Service Manual

Product Type:

Repair Service Manual

Generation

Generation Code:

BP/BL

Generation Years:

2004-2009

Codes

Chassis Code:

BP (Wagon), BL (Sedan)

👋 Introduction

Market Position

Vehicle Class:

Mid-size Sedan and Wagon

Competitive Segment:

Direct competitor to vehicles like Toyota Camry, Honda Accord, Mazda6, Nissan Altima.

Subaru Niche:

Known for standard Symmetrical All-Wheel Drive, Boxer engines, and a reputation for reliability and safety.

Competitive Analysis

Differentiation:

Standard AWD provided a significant advantage in traction and all-weather capability compared to most competitors in its class.

Engine Offerings:

Offered a range of Boxer engines, including naturally aspirated and turbocharged variants, appealing to performance-oriented buyers.

Key Features

Standard AWD:

Symmetrical All-Wheel Drive was a hallmark feature of the Legacy, enhancing grip and stability.

Boxer Engine Layout:

Low center of gravity from horizontally opposed 'Boxer' engines contributed to better handling dynamics.

Safety Focus:

Subaru's commitment to safety, often receiving high marks in crash tests.

Available Performance Variants:

The GT and GT Limited trims offered turbocharged power and sport-tuned suspension for enthusiast appeal.

📋 Manual Details

Coverage Areas

Model Years Covered:

2004, 2005

Engine Variants Covered:

2.5L Naturally Aspirated (EJ253), 2.5L Turbocharged (EJ255 - GT models), 3.0L H6 Naturally Aspirated (EZ30D)

Transmission Types Covered:

5-speed Manual, 4-speed Automatic, 5-speed Automatic (5EAT)

Trim Levels Covered:

All available trim levels including 2.5i, GT, GT Limited, Outback (if applicable to the generation covered by manual)

Page Count

Estimated Page Count:

1500-2500+ (typical for comprehensive service manuals)

Manual Type

Manual Type:

Factory Service Manual (FSM)

Target Audience:

Professional Technicians, Experienced DIYers

Language

Language:

English

Format

Format:

PDF Download

Searchable Text:

Yes (assumed for PDF service manuals)

Printable:

Yes (assumed for PDF service manuals)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed disassembly, assembly, overhaul, and component testing for EJ253, EJ255, EZ30D engines. Includes timing belt replacement, valve adjustments, piston ring installation, cylinder head reconditioning.

Engine Electrical:

Ignition system, fuel injection system (EFI), sensors (MAF, MAP, O2, Crank/Cam), ignition coils, starter motor, alternator, battery, wiring diagrams.

Transmission Manual:

Disassembly, assembly, inspection, and repair of 5-speed manual transmission. Includes clutch operation, gear synchros, shift forks, output shaft, bearings.

Transmission Automatic:

Troubleshooting, repair, and overhaul of 4-speed and 5EAT automatic transmissions. Includes valve body diagnostics, torque converter, transmission control module (TCM) operation, fluid types and capacities.

Drivetrain:

All-Wheel Drive (AWD) system, front and rear differentials, driveshafts, CV joints, wheel bearings, propeller shaft.

Suspension:

Front and rear suspension components, struts, shocks, coil springs, control arms, ball joints, bushings, anti-roll bars, alignment specifications.

Steering:

Power steering system (hydraulic), steering rack, tie rods, steering column, steering angle sensor, alignment procedures.

Brakes:

Front and rear disc brake systems, ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), brake fluid specifications, bleeding procedures, rotor and pad replacement, caliper repair.

Electrical System Body:

Lighting system (headlights, taillights, interior), power windows, power locks, mirrors, wipers, horn, central locking, keyless entry, immobilizer system.

HVAC:

Heating, Ventilation, and Air Conditioning system. Includes refrigerant types, charging procedures, blower motor, evaporator, condenser, compressor, cabin air filter replacement.

Body Exterior:

Body panel removal and installation (fenders, bumpers, doors, hood, trunk), glass replacement, seals, exterior trim.

Body Interior:

Dashboard removal, seat removal and installation, interior trim panels, headliner, carpeting, airbag system safety precautions.

Safety Systems:

Airbag system (SRS), seatbelt pre-tensioners, pre-collision systems (if equipped), safety sensor locations and testing.

Diagnostics:

OBD-II (On-Board Diagnostics II) system, diagnostic trouble codes (DTCs), diagnostic scan tool usage, live data interpretation, component testing procedures.

Procedures Included

Routine Maintenance:

Oil and filter change, air filter replacement, cabin air filter replacement, spark plug replacement, fluid checks and top-offs.

Major Maintenance:

Timing belt replacement (EJ engines), coolant flush and replacement, brake fluid flush, transmission fluid change, differential fluid change.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues across all vehicle systems, symptom-based troubleshooting guides.

Repair And Overhaul:

Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation.

Component Testing:

Electrical component testing using multimeters, resistance checks, voltage checks, continuity tests.

Calibration And Adjustment:

Wheel alignment procedures, idle speed adjustment (if applicable), headlight aim adjustment.

Technical Depth

Depth Of Coverage:

Comprehensive, detailed, and thorough. Covers everything from basic maintenance to complete engine and transmission rebuilds.

Diagnostic Capability:

Advanced diagnostic procedures for electrical and mechanical systems, including interpretation of sensor data and fault codes.

Rebuild Instructions:

Detailed instructions for rebuilding major components like engines, transmissions, and differentials.

Specification Accuracy:

Highly accurate torque specifications, clearances, fluid capacities, and electrical resistance values.

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Print Quality

Image Resolution:

High-resolution images, diagrams, and schematics suitable for clear viewing and printing.

Binding Type

Binding Method:

N/A (Digital Download - printable pages)

Paper Type

Recommended Paper Type:

N/A (Digital Download - printable pages)

⚙️ Engine Specifications

Primary Engine

Engine Code Base:

EJ253

Engine Type Base:

2.5L SOHC Naturally Aspirated Boxer-4

Displacement Base:

2457 cc

Bore X Stroke Base:

99.5 mm x 79.0 mm

Compression Ratio Base:

9.7:1

Horsepower Base:

165 hp @ 5600 rpm

Torque Base:

166 lb-ft @ 4000 rpm

Performance Engine

Engine Code Gt:

EJ255

Engine Type Gt:

2.5L DOHC Turbocharged Boxer-4

Displacement Gt:

2457 cc

Compression Ratio Gt:

8.4:1

Horsepower Gt:

250 hp @ 6000 rpm

Torque Gt:

250 lb-ft @ 3600 rpm

H6 Engine

Engine Code H6:

EZ30D

Engine Type H6:

3.0L DOHC Naturally Aspirated Boxer-6

Displacement H6:

2999 cc

Compression Ratio H6:

10.7:1

Horsepower H6:

245 hp @ 6600 rpm

Torque H6:

217 lb-ft @ 4200 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane recommended, 91+ for GT models for optimal performance)

Fuel Tank Capacity:

65 Liters (17.2 Gallons)

Engine Management

Engine Control Unit (ECU) with various sensors for closed-loop operation.

Turbocharger Specs:

IHI VF40 (GT models), Wastegate-controlled, intercooled.

🔧 Transmission

Standard

Standard Transmission Type:

5-Speed Manual Transmission

Optional

Optional Transmission Type 1:

4-Speed Automatic Transmission

Optional Transmission Type 2:

5-Speed 'Sportshift' Automatic Transmission (5EAT)

Features

AWD System Integration:

All transmissions are paired with Subaru's Symmetrical All-Wheel Drive system.

Manual Gear Ratios:

Specific gear ratios for each gear are detailed in the manual (e.g., 1st: 3.454, 2nd: 1.842, 3rd: 1.370, 4th: 1.060, 5th: 0.788, Reverse: 3.333).

Automatic Transmission Modes:

5EAT models feature a sequential manual shift mode ('Sportshift').

Fluid Specs

Manual Transmission Fluid:

API GL-5 SAE 75W-90 Hypoid Gear Oil.

Automatic Transmission Fluid:

Subaru ATF-HP (High Performance) or equivalent DEXRON III compatible fluid. Capacity approx. 6.5-7.5 quarts for change with filter.

Center Differential Fluid:

Subaru Differential Fluid-5 (or GL-5 equivalent).

Rear Differential Fluid:

Subaru Differential Fluid-5 (or GL-5 equivalent).

📐 Dimensions

Exterior

Sedan Length:

Approx. 4760 mm (187.4 in)

Wagon Length:

Approx. 4755 mm (187.2 in)

Width:

Approx. 1770 mm (69.7 in)

Height:

Approx. 1430 mm (56.3 in) (Sedan), Approx. 1470 mm (57.9 in) (Wagon)

Wheelbase:

Approx. 2670 mm (105.1 in)

Ground Clearance:

Approx. 150 mm (5.9 in)

Interior

Passenger Volume:

Approx. 97.4 cu ft (Sedan), Approx. 101.4 cu ft (Wagon)

Cargo

Trunk Volume Sedan:

Approx. 14.7 cu ft

Cargo Volume Wagon:

Approx. 30.0 cu ft (behind rear seats), Approx. 67.6 cu ft (with rear seats folded)

Weights

Curb Weight Base:

Approx. 1490 kg (3285 lbs)

Curb Weight Gt Sedan:

Approx. 1580 kg (3483 lbs)

Gross Vehicle Weight Rating:

Typically around 1950-2050 kg (4300-4500 lbs)

Towing Capacity:

Not officially specified or recommended by Subaru for most trims.

Wheel Bolt Pattern:

5x100 mm

Wheel Size Standard:

16 or 17 inches

Wheel Size Gt:

17 or 18 inches

Tire Size Example:

205/55R16 (base), 215/45R17 (GT)

🛡️ Safety Features

Ratings

NHTSA Frontal Driver:

5 Stars (2004-2006 models)

NHTSA Frontal Passenger:

5 Stars (2004-2006 models)

NHTSA Side Driver:

5 Stars (2004-2006 models)

NHTSA Side Passenger:

5 Stars (2004-2006 models)

NHTSA Side Rear Occupant:

5 Stars (2004-2006 models)

IIHS Moderate Overlap Frontal:

Good (2005 models)

IIHS Side Impact:

Good (2005 models)

Active Features

Standard Anti-lock Braking System

Standard Electronic Brake-force Distribution

Traction Control:

Available (often standard on higher trims or with certain transmissions)

Stability Control:

Available (Vehicle Dynamics Control - VDC)

Passive Features

Airbags:

Front dual-stage airbags, front side-impact airbags, front and rear side-curtain airbags (availability varies by trim).

Seatbelts:

3-point height-adjustable front seatbelts with pretensioners and load limiters, 3-point rear seatbelts.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system.

Rollover Protection:

Reinforced chassis structure designed to resist roof crush.

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM stereo with CD player. Premium audio systems with subwoofer and amplifier were available on higher trims. SiriusXM satellite radio integration.

Navigation:

Optional factory GPS navigation system available on select models and trims.

Climate Control:

Manual climate control standard, optional automatic climate control with dual-zone capability on higher trims.

Driver Assistance

Cruise Control:

Standard cruise control.

Remote Keyless Entry:

Available on most trims.

Security System:

Factory alarm system and immobilizer.

Tire Pressure Monitoring:

Optional on some models.

Connectivity

Auxiliary Input:

Optional auxiliary audio input jack (often on premium audio systems).

Bluetooth:

Not a standard feature on most models from this era. Aftermarket solutions common.

Usb Port:

Not standard. Usually added via aftermarket integration for infotainment systems.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles (6,000 km) or 6 months, or 7,500 miles (12,000 km) / 12 months with synthetic oil, under normal driving conditions. Severe conditions may require more frequent changes.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months, or more often in dusty conditions.

Cabin Air Filter Replacement:

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

Spark Plug Replacement:

Every 60,000 miles (96,000 km) for platinum/iridium plugs (e.g., NGK).

Timing Belt Replacement:

Every 105,000 miles (168,000 km) or 7 years for EJ engines (critical preventative maintenance item).

Coolant Replacement:

Every 30,000 miles (48,000 km) or 24 months for the initial service, then every 60,000 miles (96,000 km) or 48 months thereafter.

Brake Fluid Replacement:

Every 30,000 miles (48,000 km) or 24 months.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 Synthetic (preferred) or 5W-30 Conventional. Check owner's manual for exact specification.

Engine Oil Capacity:

4.5 US Quarts (4.3 Liters) with filter for 2.5L, 5.0 US Quarts (4.7 Liters) with filter for 3.0L H6.

Coolant Type:

Subaru Super Coolant (Blue) or equivalent silicate-free, long-life coolant. Never use green conventional coolant.

Power Steering Fluid:

Subaru Power Steering Fluid or Dexron III ATF.

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Head Gaskets:

While not as prevalent as in earlier generations, some EJ25 engines can still experience head gasket issues, especially if overheated. The manual will detail inspection and replacement procedures.

Oil Leaks:

Common areas for oil leaks include valve cover gaskets and crankshaft seals. The manual covers seal replacement.

Evaporative Emissions System:

Issues with the EVAP system, such as a faulty purge valve or charcoal canister, can trigger check engine lights. The manual details EVAP system diagnostics.

Automatic Transmission Issues:

Some 5EAT transmissions have been known to develop issues with torque converters or valve bodies. Proper maintenance and fluid changes are crucial. The manual provides diagnostic guidance.

Wheel Bearing Wear:

Premature wear of wheel bearings can occur, especially with aggressive driving or in areas with road salt. The manual details bearing replacement.

Ac System Leaks:

O-rings and seals in the AC system can degrade over time, leading to refrigerant leaks. The manual outlines AC system servicing.

Clutch Wear:

Standard wear item for manual transmission vehicles. The manual provides clutch replacement procedures and specifications.

Brake Component Wear:

Rotors and pads are wear items, with replacement intervals depending on driving style. The manual covers brake system inspection and replacement.

Cv Axle Boots:

Torn CV axle boots can lead to joint failure. The manual details CV axle replacement.

📚 Vehicle History

Brand Heritage

Subaru Origin:

Founded in 1953, originally Fuji Heavy Industries. Known for its automotive division specializing in horizontally opposed 'Boxer' engines and Symmetrical All-Wheel Drive.

Legacy Brand Introduction:

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

Model Evolution

Generation Introduction:

The fourth generation (BP/BL) Legacy was introduced for the 2005 model year, with the 2004 model year being the final year of the third generation (BD/BG/BK).

Design Philosophy Gen4:

Featured a more aerodynamic and refined exterior design compared to its predecessor. Increased wheelbase and track width improved handling and interior space.

Engine Updates Gen4:

Introduction of the 3.0L EZ30D H6 engine for premium trims and continued use of updated EJ25 variants.

Production

Manufacturing Location:

Ota City, Gunma Prefecture, Japan

Production Period:

2003-2009 (for the BP/BL generation)

Sales Performance:

Competed effectively in the mid-size segment, with AWD appeal driving sales, especially in regions with challenging weather.

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

The 2005 Subaru Legacy received an 'Excellent' rating in frontal offset crash tests by the IIHS, often earning 'Top Safety Pick' status.

NHTSA Ratings:

Consistently achieved 5-star ratings from the National Highway Traffic Safety Administration (NHTSA) for frontal and side-impact crashworthiness.

Consumer Reports Reliability:

Consumer Reports often rated Subaru models, including the Legacy, favorably for reliability and owner satisfaction, though specific model year ratings can vary.

Motor Trend Car Of The Year Nominee:

While not winning, the Legacy generation was often a contender or praised in reviews by automotive publications for its AWD and performance variants.

Klюд Safety Award:

Subaru's commitment to safety is often recognized by various organizations, including the Insurance Institute for Highway Safety (IIHS).