2004 SUBARU LEGACY Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 2004 Codes Chassis Code: BP/BL Engine Codes Covered: EJ253, EJ204 👋 Introduction Market Position Vehicle Segment: Mid-size sedan and wagon, known...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy

Year:

Codes

Chassis Code:

BP/BL

Engine Codes Covered:

EJ253, EJ204

👋 Introduction

Market Position

Vehicle Segment:

Mid-size sedan and wagon, known for its standard All-Wheel Drive and Subaru's reputation for reliability and safety.

Competitive Analysis

Key Competitors:

Toyota Camry, Honda Accord, Nissan Altima, Mazda6, Ford Fusion.

Key Features

Standard AWD:

The hallmark of the Subaru Legacy, providing enhanced traction and stability in various driving conditions.

Boxer Engine:

Subaru's signature horizontally opposed engine design contributes to a lower center of gravity and smoother operation.

Practicality:

Available as both a sedan and a versatile wagon, offering practicality for families and individuals.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive service and repair for all major systems and components.

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Internal combustion engine (2.5L Naturally Aspirated, 2.0L Naturally Aspirated), including disassembly, assembly, diagnostics, and repair.

Fuel System:

Fuel delivery, fuel injection system (MPI), fuel pump, fuel filter, evaporative emissions control system.

Cooling System:

Radiator, thermostat, water pump, coolant hoses, cooling fan, temperature sensors.

Ignition System:

Spark plugs, ignition coils, ignition control module, timing.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, oxygen sensors.

Transmission Automatic:

4-speed automatic transmission (4EAT), torque converter, valve body, transmission control module (TCM), fluid and filter service.

Transmission Manual:

5-speed manual transmission, clutch system, flywheel, transmission fluid service.

Drivetrain:

Symmetrical All-Wheel Drive (AWD) system, front and rear differentials, driveshafts, CV joints, transfer case.

Suspension:

Front and rear suspension components, struts, shock absorbers, control arms, bushings, coil springs, anti-roll bars.

Steering:

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

Brakes:

Front and rear disc brakes, brake calipers, brake pads, brake rotors, brake fluid, ABS system, parking brake.

Electrical System:

12V battery, alternator, starter motor, wiring diagrams, fuse box, relays, lighting system.

Engine Control System:

ECU (Engine Control Unit), sensors (MAP, MAF, O2, TPS, ECT, CKP, CMP), actuators, diagnostic trouble codes (DTCs).

Body And Interior:

Body panels, doors, hood, trunk, bumpers, interior trim, seats, airbags.

HVAC:

Heating, Ventilation, and Air Conditioning system, A/C compressor, condenser, evaporator, refrigerant, climate control unit.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, tire rotation.

Diagnostics:

Troubleshooting guides, symptom-based diagnostics, diagnostic trouble code (DTC) interpretation, electrical system diagnostics.

Repair:

Component removal and installation, rebuild procedures, component adjustment, calibration.

Engine Overhaul:

Complete engine disassembly, inspection, machining, and reassembly procedures.

Transmission Service:

Automatic and manual transmission fluid and filter replacement, internal component service, torque converter replacement.

Brake Service:

Brake pad and rotor replacement, brake caliper service, brake fluid bleeding, ABS component testing.

Suspension Repair:

Strut and shock absorber replacement, bushing replacement, alignment specifications.

Electrical Component Replacement:

Alternator, starter, battery, sensors, actuators, ECUs, ECUs.

Airbag System Service:

Airbag module replacement, SRS system diagnostics.

HVAC System Repair:

A/C system recharge, component replacement, leak detection.

Technical Depth

Depth Of Coverage:

Expert-level, covering everything from basic maintenance to complete engine and transmission rebuilds.

Diagnostic Tools:

Includes information on diagnostic codes (DTCs) and procedures for using OBD-II scanners.

Technical Data:

Provides specific torque specifications, clearances, fluid capacities, and electrical values.

Schematics:

Includes detailed wiring diagrams for all electrical systems.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Searchable text for quick information retrieval.

Printability:

Printable pages for workshop use.

Print Quality

Image Resolution:

High-resolution images and illustrations.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Quality:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Name 1:

2.5L Flat-4 Naturally Aspirated

Engine Code 1:

EJ253

Displacement 1:

2.5 liters (2498 cc)

Configuration 1:

Horizontally Opposed (Boxer), SOHC, 16 valves

Horsepower 1:

165-175 hp @ 5600-6000 rpm (depending on market/tune)

Torque 1:

160-166 lb-ft @ 4000 rpm (depending on market/tune)

Secondary Engine

Engine Name 2:

2.0L Flat-4 Naturally Aspirated

Engine Code 2:

EJ204

Displacement 2:

2.0 liters (1994 cc)

Configuration 2:

Horizontally Opposed (Boxer), DOHC, 16 valves

Horsepower 2:

137 hp @ 6000 rpm

Torque 2:

127 lb-ft @ 4200 rpm

Fuel System

Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Fuel Type:

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

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual Transmission

Optional

Optional Transmission:

4-speed Automatic Transmission (4EAT) with Traction Control

Features

AWD System:

Symmetrical All-Wheel Drive (AWD) with viscous center differential (manual) or electronically controlled multi-plate clutch (automatic).

📐 Dimensions

Exterior

Sedan Length:

Approx. 187.4 inches

Wagon Length:

Approx. 190.2 inches

Width:

Approx. 68.1 inches

Height:

Approx. 56.1 inches (Sedan), 57.7 inches (Wagon)

Wheelbase:

Approx. 104.0 inches

Cargo

Sedan Trunk Volume:

Approx. 14.4 cubic feet

Wagon Cargo Volume:

Approx. 39.7 cubic feet (seats up), 71.4 cubic feet (seats down)

Weights

Curb Weight:

Approx. 3100-3400 lbs (depending on trim and transmission)

Towing Capacity:

Not Recommended (typically)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

NHTSA Front Impact Passenger:

NHTSA Side Impact Driver:

NHTSA Side Impact Rear Passenger:

IIHS Offset Front:

IIHS Side Impact:

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Available Traction Control System (TCS) on automatic models

Passive Features

Airbags:

Front driver and passenger airbags, available front side-impact airbags.

Seatbelts:

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

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system

💡 Technology Features

Infotainment

Audio System:

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

Climate Control:

Manual climate control standard, with optional automatic climate control on higher trims.

Driver Assistance

Cruise Control:

Standard cruise control.

All Wheel Drive:

Subaru's Symmetrical All-Wheel Drive system is standard across all trims.

Connectivity

Auxiliary Input:

Optional auxiliary audio input jack available on some models.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 3 months (severe driving) / 7,500 miles or 6 months (normal driving).

Air Filter Replacement:

Every 15,000 miles or 12 months.

Cabin Air Filter Replacement:

Every 15,000 miles or 12 months.

Spark Plug Replacement:

Every 60,000 miles (Iridium type).

Timing Belt Replacement:

Every 105,000 miles or 7 years (for EJ253). The EJ204 is a timing chain engine.

Fluid Specifications

Engine Oil Type:

SAE 5W-30, API SN or higher certified.

Engine Oil Capacity:

Approx. 4.8 US quarts (4.5 liters) with filter change.

Coolant Type:

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

Transmission Fluid Automatic:

Subaru ATF-HP (High Performance) or equivalent.

Transmission Fluid Manual:

GL-4 or GL-5 gear oil, SAE 75W-90.

Brake Fluid Type:

DOT 3 or DOT 4.

Power Steering Fluid Type:

Subaru Automatic Transmission Fluid (ATF) or Dexron III compatible.

Known Issues

Head Gaskets:

While less common on the EJ253 compared to earlier EJ25 engines, head gasket leaks can still occur, especially with high mileage or improper maintenance.

Wheel Bearings:

Front wheel bearings can be a wear item and may require replacement.

Cv Joints:

The constant velocity (CV) joints, particularly the front ones, can wear out over time, leading to clicking noises during turns.

Automatic Transmission Issues:

The 4EAT can sometimes experience harsh shifting or solenoid issues. Regular fluid changes are critical.

📚 Vehicle History

Brand Heritage

Subaru History:

Subaru, a division of Fuji Heavy Industries, has a long history in aviation and automotive manufacturing, known for its commitment to All-Wheel Drive technology and boxer engines.

Model Evolution

Legacy Generation:

Third Generation (BP/BL), 2004-2009. This generation introduced a more rounded and aerodynamic design, increased interior space, and refined powertrains.

Production

Manufacturing Location:

Ota City, Gunma Prefecture, Japan

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

The 2004 Subaru Legacy received good ratings from the IIHS for its crashworthiness, contributing to its reputation for safety.

NHTSA Overall Safety:

Achieved strong overall safety ratings from NHTSA in frontal and side impact tests.