SUBARU LEGACY 2005 Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 2005 Codes Chassis Code: BP/BL 👋 Introduction Market Position Segment: Mid-size Sedan/Wagon Usp: Symmetrical All-Wheel Drive standard, Boxer Engine, strong reputation...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy

Year:

Codes

Chassis Code:

BP/BL

👋 Introduction

Market Position

Segment:

Mid-size Sedan/Wagon

Symmetrical All-Wheel Drive standard, Boxer Engine, strong reputation for safety and durability

Competitive Analysis

Key Competitors:

Toyota Camry, Honda Accord, Nissan Altima, Mazda6

Key Features

Powertrain Offering:

Standard Symmetrical AWD across most trims

Safety Focus:

High safety ratings, available advanced safety features

Practicality:

Spacious interior, available wagon body style offers increased utility

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Service and Repair

Regional Variants:

North American Market (adjustments for other regions may apply)

Page Count

Estimated Pages:

2000+

Manual Type

Type:

Factory Service Manual (FSM)

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine Mechanical, Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System, Engine Control System (ECU/ECM)

Transmission Drivetrain:

Manual Transmission (MT), Automatic Transmission (AT), All-Wheel Drive (AWD) System, Differentials, Driveshafts, Axles

Suspension Steering:

Front Suspension, Rear Suspension, Steering System, Power Steering

Braking System:

Front Brakes, Rear Brakes, ABS (Anti-lock Braking System), Brake Booster, Parking Brake

Electrical Systems:

Battery, Charging System, Starting System, Lighting, Gauges, Instrumentation, Body Electrical, Powertrain Control Module (PCM), Chassis Control Module (CCM)

Body Chassis:

Body Panels, Doors, Hood, Trunk, Interior Trim, Chassis Structure, Frame

HVAC System:

Heating, Ventilation, Air Conditioning (HVAC) Controls and Components

Safety Features:

Airbag System, Seatbelts

Procedures Included

Maintenance Procedures:

Oil Change, Filter Replacement, Spark Plug Replacement, Coolant Flush, Brake Fluid Flush, Belt Inspection/Replacement

Diagnostic Procedures:

Troubleshooting Charts, Diagnostic Trouble Codes (DTCs) Interpretation, Symptom-based Diagnostics

Repair Procedures:

Component Removal and Installation, Engine Rebuild, Transmission Overhaul, Suspension Component Replacement, Electrical Component Repair

Adjustment Calibration:

Alignment Specifications, Clutch Adjustment, Parking Brake Adjustment

Wiring Diagrams:

Comprehensive Electrical Schematics for all Systems

Technical Depth

Depth:

Comprehensive (from basic fluid checks to complete engine/transmission rebuilds)

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable Text

Print Quality

Diagram Clarity:

High-resolution, clear diagrams and illustrations

Binding Type

Binding For Physical Copy:

N/A (Digital)

Paper Type

Paper Type For Physical Copy:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

EJ253

Engine Type 1:

2.5L Naturally Aspirated Boxer-4

Cylinders Pistons 1:

4 Cylinders, Horizontally Opposed (Boxer)

Valvetrain 1:

DOHC (Dual Overhead Camshafts), 16 Valves

Bore X Stroke 1:

99.5 mm x 79.0 mm

Compression Ratio 1:

9.5:1

Fuel Induction 1:

Multi-Point Fuel Injection (MPI)

Horsepower 1:

175 hp @ 6000 rpm

Torque 1:

169 lb-ft @ 4400 rpm

Engine Code 2

Engine Code 2:

EZ30D

Engine Type 2

Engine Type 2:

3.0L Naturally Aspirated Boxer-6 (Optional on GT/GT Limited trims)

Cylinders Pistons 2:

6 Cylinders, Horizontally Opposed (Boxer)

Valvetrain 2:

DOHC, 24 Valves

Bore X Stroke 2:

89.2 mm x 79.0 mm

Compression Ratio 2:

10.7:1

Fuel Induction 2:

Sequential Multi-Port Fuel Injection (S-MPI)

Horsepower 2:

250 hp @ 6600 rpm

Torque 2:

217 lb-ft @ 4200 rpm

Fuel System

Fuel Type Recommendation:

87 Octane Regular Unleaded Gasoline (91 Octane recommended for GT models with 3.0L engine)

🔧 Transmission

Standard

Standard Transmission Type:

5-Speed Manual Transmission (MT)

Optional

Optional Transmission Type:

4-Speed Automatic Transmission (AT) with Sportshift (Paddle Shifters on GT models)

Features

AWD System:

Symmetrical All-Wheel Drive (Active Torque Split AWD on MT, Variable Torque Distribution AWD on AT)

Differential Type:

Front: Open; Rear: Optional Limited-Slip Differential (LSD) on some performance trims, Open on standard trims

Fluid Specifications

Mt Fluid Type:

Subaru Extra-S (75W-90 GL-5) or equivalent

At Fluid Type:

Subaru ATF-HP (High Performance) or equivalent

📐 Dimensions

Exterior

Length:

Sedan: 187.4 in (4760 mm), Wagon: 188.2 in (4780 mm)

Width:

70.1 in (1780 mm)

Height:

Sedan: 56.1 in (1425 mm), Wagon: 59.1 in (1500 mm)

Wheelbase:

105.1 in (2670 mm)

Ground Clearance:

5.7 in (145 mm)

Weights

Curb Weight Sedan 2.5I Mt:

3320 lbs (1506 kg)

Curb Weight Wagon 2.5I At:

3520 lbs (1597 kg)

Curb Weight Gt Sedan 3.0 At:

3650 lbs (1656 kg)

Wheel Bolt Pattern:

5x100

Wheel Size Standard:

16-inch alloy

Wheel Size Optional:

17-inch alloy (GT, Outback Sport)

Tire Size Standard:

205/55R16

Tire Size Optional:

215/45R17

Cargo

Cargo Volume Sedan:

14.7 cu ft (416 L)

Cargo Volume Wagon:

30.0 cu ft (850 L) with rear seats up, 65.1 cu ft (1844 L) with rear seats folded

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5 Stars

NHTSA Front Impact Passenger:

5 Stars

NHTSA Side Impact Front Seat:

5 Stars

NHTSA Side Impact Rear Seat:

4 Stars

NHTSA Rollover Resistance:

4 Stars

IIHS Front Offset Crash Test:

IIHS Side Impact Crash Test:

Active Features

Standard Active Safety:

ABS, EBD (Electronic Brake-force Distribution), Brake Assist

Optional Active Safety:

Traction Control System (TCS), Vehicle Stability Control (VDC)

Passive Features

Standard Passive Safety:

Front Airbags, Side Curtain Airbags (optional/standard depending on trim), Front Seatbelt Pretensioners

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD player with 4 or 6 speakers. Optional premium audio system with subwoofer available on higher trims.

Navigation System:

Optional factory-installed GPS Navigation system available on select trims.

Driver Assistance

Cruise Control:

Standard cruise control.

Climate Control:

Manual air conditioning standard, optional automatic climate control.

Connectivity

Auxiliary Input:

Optional auxiliary input jack for external audio devices on some models/trims.

Usb Port:

N/A (No factory USB ports on this generation)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 3.75 months (severe driving) or 7,500 miles or 7.5 months (normal driving) with synthetic oil. Check manual for specific recommendations.

Air Filter Replacement:

Every 15,000 - 30,000 miles, or as needed based on conditions.

Cabin Air Filter Replacement:

Every 15,000 - 30,000 miles, or as needed.

Spark Plug Replacement Ej253:

Every 60,000 miles (Iridium type)

Spark Plug Replacement Ez30D:

Every 100,000 miles (Iridium type)

Coolant Flush:

Every 30,000 miles or 3 years.

Transmission Fluid Change At:

Every 30,000 miles or 3 years for normal use, 15,000 miles or 1.5 years for severe use.

Transmission Fluid Change Mt:

Every 45,000 miles or 4.5 years.

Brake Fluid Flush:

Every 30,000 miles or 3 years.

Timing Belt Replacement:

N/A (All 2005 Legacy models use timing chains)

Fluid Specifications

Engine Oil Capacity 2.5L:

4.5 US quarts (4.3 L) with filter (using SAE 5W-30 synthetic)

Engine Oil Capacity 3.0L:

5.5 US quarts (5.2 L) with filter (using SAE 5W-30 synthetic)

Coolant Type:

Subaru Super Coolant (Blue) or equivalent (50/50 mix with distilled water)

Power Steering Fluid:

Subaru PSF orDexron III ATF

Known Issues

Common Issues Engine 2.5I:

Head gasket leaks (less common than earlier generations but still possible), oil consumption, catalytic converter failure.

Common Issues Engine 3.0I:

Oil leaks from valve covers, occasional oil pressure sensor issues.

Common Issues Transmission:

Automatic transmission torque converter shudder (on older ATs, less prevalent here but worth noting), clutch wear on manuals.

Common Issues Suspension:

Worn sway bar bushings, rear differential mounts can crack.

Common Issues Electrical:

ABS sensor failures, window regulator issues, climate control module failures.

📚 Vehicle History

Brand Heritage

Subaru Heritage:

Founded in 1953 as Fuji Heavy Industries, known for pioneering Subaru boxer engines and Symmetrical All-Wheel Drive systems, particularly in rally racing and inclement weather regions.

Model Evolution

Legacy Introduction:

The Subaru Legacy was introduced in 1989 as a replacement for the Subaru Leone, offering a more refined and powerful alternative with standard AWD.

Fifth Generation:

The 2005 model year represents the introduction of the fourth generation (BP/BL) Subaru Legacy, a complete redesign.

Key Changes 2005:

All-new chassis, significantly updated styling, introduction of the 3.0L H6 EZ30D engine for GT models, refined interior, improved safety features.

Production

Production Plant:

Subaru of Indiana Automotive, Inc. (SIA) in Lafayette, Indiana, USA and Gunma Plant, Japan.

Production Years

Fourth Generation Years:

2005-2009

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

Likely received 'Top Safety Pick' awards from IIHS for this generation due to good crash test performance.

Consumers Reports Ratings:

Generally received average to above-average ratings for reliability and performance from consumer organizations.

Certifications

Emissions Standards:

Meets or exceeds all relevant US Federal and California EPA emissions standards for 2005 model year.