Subaru Legacy 1999 All Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 1999 Codes Chassis Code: BD/BG/BK (second generation) 👋 Introduction Market Position Vehicle Segment: Mid-size sedan/wagon (often referred to as compact or...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy

Year:

Codes

Chassis Code:

BD/BG/BK (second generation)

👋 Introduction

Market Position

Vehicle Segment:

Mid-size sedan/wagon (often referred to as compact or intermediate depending on the market classification at the time).

Target Audience:

Families and individuals seeking reliable, all-wheel-drive capable transportation with a focus on practicality and safety.

Competitive Analysis

Key Competitors:

Toyota Camry, Honda Accord, Ford Taurus, Nissan Altima, Mitsubishi Galant.

Unique Selling Proposition:

Standard Symmetrical All-Wheel Drive (AWD) across most trims, offering superior traction and stability, particularly in adverse weather conditions.

Key Features

Standard AWD:

The defining feature, providing enhanced grip and confidence.

Horizontally Opposed Engine:

Subaru's signature Boxer engine layout, contributing to a lower center of gravity and improved handling.

Available Body Styles:

Offered as both a four-door sedan and a five-door wagon (often referred to as the Outback Sport or similar nomenclature in some markets).

📋 Manual Details

Coverage Areas

Coverage Summary:

Comprehensive service and repair for all 1999 Subaru Legacy models, including engine, transmission, drivetrain, suspension, steering, brakes, electrical systems, body, and HVAC.

Page Count

Estimated Pages:

1500-2000+

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed instructions for disassembly, inspection, repair, and reassembly of all engine components, including cylinder heads, pistons, crankshaft, camshafts, timing belt/chain, oil pump, and cooling system.

Engine Electrical:

Wiring diagrams, ECU diagnostics, ignition system troubleshooting, fuel injection system analysis, sensor testing, starter, alternator, and battery service.

Transmission Manual:

Service procedures for clutch inspection and replacement, gearbox disassembly, gear inspection, synchronizer repair, and transmission fluid service.

Transmission Automatic:

Troubleshooting, diagnostic procedures, fluid and filter replacement, valve body service, torque converter inspection, and transmission overhaul procedures.

Drivetrain:

Front and rear differential service, axle shaft inspection and replacement, driveshaft balancing, and universal joint service.

Suspension:

Front strut and shock absorber replacement, control arm bushing inspection, ball joint testing, sway bar link service, and rear multi-link suspension analysis.

Steering:

Power steering system diagnosis, pump and rack and pinion service, steering column repair, and tie rod end replacement.

Brakes:

Disc brake component replacement (pads, rotors), drum brake service, hydraulic system bleeding, ABS system diagnostics and component replacement, parking brake adjustment.

Body And Chassis:

Body panel alignment, door and latch service, glass replacement, interior trim removal and installation, structural component inspection.

HVAC:

Air conditioning system diagnosis, refrigerant handling, compressor replacement, evaporator and condenser service, heater core replacement, blower motor troubleshooting.

Fuel System:

Fuel pump testing, injector cleaning and replacement, fuel filter replacement, fuel tank service, evaporative emissions control system (EVAP).

Exhaust System:

Muffler and catalytic converter replacement, exhaust pipe inspection, oxygen sensor replacement.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, fluid level checks and top-offs, tire rotation.

Troubleshooting:

Systematic diagnostic procedures for common problems, including drivability issues, starting problems, and electrical faults.

Repair And Rebuild:

Detailed step-by-step instructions for component removal, repair, and installation, including major component overhauls.

Diagnostics:

Includes information on using OBD-II scan tools, interpreting diagnostic trouble codes (DTCs), and performing specific diagnostic tests on various systems.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems, essential for diagnosing electrical faults.

Technical Depth

Depth:

Advanced diagnostic and repair procedures, suitable for professional mechanics and experienced DIY enthusiasts. Covers full vehicle disassembly and reassembly.

📊 Manual Specifications

File Format

File Type:

Searchability:

Fully searchable text content for quick information retrieval.

Printability:

Printable pages for convenient workshop use.

Print Quality

Image Resolution:

High-resolution diagrams and illustrations for clarity.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

EJ22E

Engine Description 1:

2.2 Liter, 16-Valve SOHC Boxer-4 Engine

Displacement 1:

2212 cc (135 cubic inches)

Bore X Stroke 1:

96.0 mm x 75.0 mm

Compression Ratio 1:

9.5:1

Horsepower 1:

135 hp @ 5600 rpm

Torque 1:

136 lb-ft @ 4400 rpm

Alternative Engine

Engine Code 2:

EJ25D (Phase II DOHC)

Engine Description 2:

2.5 Liter, 16-Valve DOHC Boxer-4 Engine (found in higher trims and GT models)

Displacement 2:

2457 cc (150 cubic inches)

Bore X Stroke 2:

99.5 mm x 79.0 mm

Compression Ratio 2:

9.7:1

Horsepower 2:

165 hp @ 5600 rpm

Torque 2:

166 lb-ft @ 4000 rpm

Performance

Fuel Type:

Unleaded gasoline

Fuel System

Injection Type:

Multi-point fuel injection (MPFI)

Fuel Octane Rating:

87 Octane (minimum recommended, 91 for optimal performance with EJ25D)

Engine Cooling

Cooling System Type:

Liquid-cooled

Coolant Type:

Ethylene glycol based coolant (e.g., Subaru Super Coolant or equivalent)

Coolant Capacity:

Approx. 6.9 Liters (7.3 US Quarts)

Engine Oil

Oil Type Ej22E:

SAE 10W-30 or 10W-40 API SG/SH or SJ

Oil Capacity Ej22E W Filter:

4.5 Liters (4.8 US Quarts)

Oil Type Ej25D:

SAE 5W-30 API SG/SH or SJ (recommended for optimal performance and cold starts)

Oil Capacity Ej25D W Filter:

4.5 Liters (4.8 US Quarts)

Ignition System

Spark Plugs Ej22E:

NGK BKR6E or equivalent

Spark Plug Gap Ej22E:

1.0 - 1.1 mm (0.039 - 0.043 in)

Spark Plugs Ej25D:

NGK BKR6E or equivalent

Spark Plug Gap Ej25D:

1.0 - 1.1 mm (0.039 - 0.043 in)

Timing Belt

Timing Belt Replacement Interval:

Every 90,000 miles or 72 months, whichever comes first (critical maintenance item).

Timing Belt Tensioner:

Replacement of tensioner and idler pulleys recommended during timing belt service.

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual Transmission

Transmission Fluid Manual:

SAE 75W-90 API GL-5 (or GL-4 for some earlier models, consult manual)

Transmission Fluid Capacity Manual:

Approx. 2.3 Liters (2.4 US Quarts)

Optional

Transmission Type Optional:

4-Speed Automatic Transmission (4EAT)

Transmission Fluid Automatic:

Subaru ATF-HP (or Dexron III/Mercon compatible)

Transmission Fluid Capacity Automatic Drain Fill:

Approx. 3.5 Liters (3.7 US Quarts)

Transmission Fluid Capacity Automatic Total With Converter:

Approx. 8.0 Liters (8.5 US Quarts)

Features

Drivetrain AWD:

Full-time Symmetrical All-Wheel Drive with viscous coupling center differential (for manual transmission) and electronic control (for automatic transmission).

Differential Fluid Front Rear:

SAE 75W-90 API GL-5

Differential Fluid Capacity Front:

Approx. 0.8 Liters (0.8 US Quarts)

Differential Fluid Capacity Rear:

Approx. 0.8 Liters (0.8 US Quarts)

📐 Dimensions

Exterior

Length Sedan:

Approx. 4660 mm (183.5 in)

Length Wagon:

Approx. 4680 mm (184.3 in)

Width:

Approx. 1730 mm (68.1 in)

Height Sedan:

Approx. 1400 mm (55.1 in)

Height Wagon:

Approx. 1475 mm (58.1 in)

Wheelbase:

Approx. 2630 mm (103.5 in)

Ground Clearance:

Approx. 150 mm (5.9 in) for standard models, higher for Outback/Outback Sport variants.

Cargo

Cargo Volume Sedan:

N/A (specific figures not readily available, typical for segment)

Cargo Volume Wagon:

Approx. 0.9 cubic meters (31.7 cu ft) behind rear seats

Weights

Curb Weight Min:

Approx. 1350 kg (2976 lbs)

Curb Weight Max:

Approx. 1550 kg (3417 lbs)

Gross Vehicle Weight Rating Gvwr:

Varies by model and trim, typically around 1950-2050 kg (4300-4520 lbs)

Towing Capacity:

Not specified for most models; light trailer towing may be possible but not recommended without specific accessory and consultation.

Wheels Tires

Wheelbase Bolt Pattern:

5 x 100 mm

Wheel Size Standard:

15-inch alloy or steel wheels

Wheel Size Optional:

16-inch alloy wheels

Tire Size Standard:

P205/60R15

Tire Size Optional:

P205/55R16

Tire Pressure Front Rear Psi:

Typically 30-32 PSI (refer to door jamb sticker)

🛡️ Safety Features

Ratings

NHTSA Crash Test Ratings 1999:

Frontal crash test results for 1999 models generally indicated good to acceptable protection for occupants.

IIHS Ratings:

Insurance Institute for Highway Safety (IIHS) ratings for this generation typically showed good performance in frontal offset tests.

Active Features

Anti-lock Braking System (ABS) standard on most trims, optional on some base models.

Traction Control:

Traction control system (TCS) was optional on some automatic transmission models.

Passive Features

Airbags Front:

Driver and passenger front airbags.

Airbags Side:

Side airbags were not widely available or standard on this model year.

Seatbelts:

Three-point seatbelts for all seating positions, front seatbelt pretensioners.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system was not standard on this model year; typically relied on seatbelt systems for child seat installation.

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM stereo with cassette player and optional CD player. Speaker configurations varied by trim level.

Display:

Basic analog gauges for speed, RPM, fuel, and temperature. No digital displays or touchscreens.

Driver Assistance

Cruise Control:

Standard on most trims, providing highway driving convenience.

Headlights:

Halogen headlights, typically with manual aim adjustment. Fog lights were optional on some trims.

Connectivity

Phone Integration:

No factory Bluetooth or smartphone integration. Aftermarket solutions are available.

Climate Control

Manual HVAC:

Manual temperature and fan speed controls, recirculate function.

Automatic Climate Control:

Automatic climate control was not available on this model year.

🔧 Maintenance

Service Intervals

Oil And Filter Change:

Every 3,750 miles or 3 months (severe service) / 7,500 miles or 6 months (normal service), check manual for specific conditions.

Air Filter Replacement:

Every 15,000 miles or 12 months.

Cabin Air Filter Replacement:

Not typically equipped on this model year.

Fuel Filter Replacement:

Every 30,000 miles or 24 months.

Spark Plug Replacement:

Every 60,000 miles (copper plugs) or 100,000 miles (platinum plugs if equipped).

Timing Belt Service:

Critical: Every 90,000 miles or 72 months. Includes tensioner and idler pulleys.

Brake Fluid Flush:

Every 30,000 miles or 24 months.

Coolant Flush:

Every 30,000 miles or 24 months (using Subaru Super Coolant or equivalent).

Transmission Fluid Change Manual:

Every 30,000 miles or 24 months.

Transmission Fluid Change Automatic:

Every 30,000 miles or 24 months (more frequent under severe use).

Fluid Specifications

Power Steering Fluid:

ATF DEXRON III or Subaru compatible fluid.

Brake Fluid Type:

DOT 3

Known Issues

Head Gasket Failure Ej25D:

The EJ25D engine (2.5L DOHC) is known for potential head gasket failures. The manual will detail inspection and replacement procedures.

Automatic Transmission Issues:

Some instances of valve body issues or premature wear in the 4EAT automatic transmission can occur, especially with neglected fluid changes.

Timing Belt Tensioner Failure:

Failure of the timing belt tensioner or idler pulleys can lead to belt failure and catastrophic engine damage. Replacement during belt service is crucial.

Catalytic Converter Failure:

Can occur due to rich fuel mixture or oil consumption, leading to reduced engine performance and check engine lights.

Susceptibility To Rust:

Like many vehicles of this era, rust can be an issue, particularly in the rocker panels, wheel arches, and rear subframe. The manual covers body repair sections.

📚 Vehicle History

Brand Heritage

Subaru History:

Subaru, a division of Fuji Heavy Industries, has a long history in aerospace and automotive manufacturing, known for its unique engineering philosophies like the Boxer engine and Symmetrical All-Wheel Drive.

Model Evolution

Legacy Generation 2:

The 1999 model is part of Subaru's second generation (1995-1999) Legacy, which saw significant styling updates and platform refinements over the first generation.

Outback Variant:

The Outback, a more rugged, lifted version of the Legacy wagon, became a distinct model line during this generation, originating from the Legacy wagon platform.

Facelift:

The 1998 model year received a significant facelift, including redesigned front and rear fascias, interior updates, and improved safety features, which carried through to the 1999 model.

Production

Production Location:

Primary manufacturing location was Gunma, Japan.

Sales Performance:

The second-generation Legacy was a key model in establishing Subaru's market presence in North America, with AWD being a significant draw.

🏆 Awards & Recognition

Recognitions

Overall Reputation:

The Subaru Legacy of this era is generally regarded as a reliable and durable vehicle, particularly praised for its AWD system and longevity when properly maintained.

Ratings

Consumer Reports:

Historically, Subaru models have received favorable ratings from consumer organizations for reliability and owner satisfaction, though specific 1999 Legacy ratings would need archival access.

Certifications

Emissions Standards:

Meets EPA and California Air Resources Board (CARB) emissions standards for the model year.