2004 SUBARU LEGACY Service Repair Manual - DIY Factory Service / Workshop Repair / Maintenance Manual - 04 LEGACY * (109 MB)

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 2004 Generation Generation Designation: BP/BL Codes Chassis Code: BP (Wagon), BL (Sedan) 👋 Introduction Market Position Segment: Mid-size Sedan and Wagon...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy

Year:

Generation

Generation Designation:

BP/BL

Codes

Chassis Code:

BP (Wagon), BL (Sedan)

👋 Introduction

Market Position

Segment:

Mid-size Sedan and Wagon

Key Selling Points:

Symmetrical All-Wheel Drive, boxer engine, safety, practicality

Competitive Analysis

Primary Competitors:

Toyota Camry, Honda Accord, Mazda6, Nissan Altima

Key Features

Drivetrain Standard:

Symmetrical All-Wheel Drive (AWD)

Engine Layout:

Horizontally-opposed (Boxer)

Body Styles:

4-door Sedan, 5-door Wagon

📋 Manual Details

Coverage Areas

Primary Coverage:

North America

Secondary Coverage:

Global specifications may vary slightly

Page Count

Estimated Page Count:

1500-2000+ (Typical for comprehensive factory service manuals)

Manual Type

Manual Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, valve train, timing system (belts/chains), lubrication system, cooling system

Engine Performance:

Fuel injection, ignition system, emissions control (EGR, catalytic converter), intake and exhaust systems, turbocharging (if applicable)

Transmission Manual:

Clutch operation, gear shifting mechanism, internal components, maintenance, and repair

Transmission Automatic:

Torque converter, planetary gear sets, valve body, hydraulic system, electronic controls, maintenance, and repair

Drivetrain:

Front and rear differentials, driveshafts, CV joints, AWD system operation and maintenance

Suspension:

Front struts/coilovers, rear multi-link suspension, control arms, bushings, springs, shock absorbers, sway bars

Steering:

Power steering system (hydraulic), steering rack, steering column, tie rods

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System), brake hydraulics, parking brake

Electrical System:

Battery, alternator, starter, wiring diagrams, fuses, relays, lighting system, horns

Body And Chassis:

Body panels, doors, hoods, trunk, glass, interior trim, structural components, corrosion protection

HVAC:

Heating, ventilation, and air conditioning systems, refrigerant service

Safety Systems:

Airbag system (SRS), seat belts, child seat anchors (ISOFIX)

Diagnostics:

OBD-II (On-Board Diagnostics), diagnostic trouble codes (DTCs), troubleshooting procedures

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks, tire rotations, brake inspections, belt inspections

Engine Repair:

Engine overhaul, head gasket replacement, timing belt/chain replacement, piston ring replacement, bearing replacement

Transmission Repair:

Clutch replacement, transmission fluid and filter changes, torque converter replacement, internal transmission component repair

Brake Service:

Brake pad and rotor replacement, caliper service, brake fluid flush and bleed, ABS component testing

Suspension And Steering Repair:

Strut/shock replacement, control arm bushing replacement, ball joint replacement, tie rod end replacement, power steering pump and rack replacement

Electrical Diagnostics And Repair:

Wiring harness repair, sensor testing, actuator diagnosis, starter and alternator testing and replacement

Bodywork And Trim:

Door panel removal, exterior trim replacement, glass replacement, bumper repair/replacement

HVAC Service:

Evaporator and condenser replacement, blower motor replacement, refrigerant recharge

Safety System Service:

Airbag module replacement, seat belt replacement, seat belt pretensioner replacement

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting guides

Technical Depth

Depth Of Coverage:

Comprehensive (covers basic maintenance to full engine and transmission rebuilds)

Diagnostic Tools:

Specifies use of Subaru Select Monitor (SSM) or equivalent diagnostic scan tools

Special Tools:

Lists required Subaru special tools with part numbers for specific procedures

Torque Specifications:

Detailed torque values for all fasteners

Clearances And Tolerances:

Engine bearing clearances, piston ring gap, valve lash specifications

Wiring Diagrams:

Detailed color-coded electrical schematics for all systems

Illustrations And Diagrams:

High-quality diagrams, exploded views, and step-by-step illustrations

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Searchability:

Text-searchable PDF for easy information retrieval

Print Quality

Print Feature:

Printable pages (individual or complete manual)

Binding Type

Binding Type Digital:

N/A (Digital format)

Paper Type

Paper Type Digital:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

EJ253 (2.5L SOHC Non-Turbo), EJ255 (2.5L DOHC Turbo - GT models)

Engine Displacement:

2.5 Liters (2457 cc)

Engine Configuration:

Flat-4 (Boxer)

Valvetrain:

SOHC (Single Overhead Camshaft) for 2.5i, DOHC (Double Overhead Camshaft) with AVCS for GT models

Performance

Horsepower 2.5I:

165 hp @ 5600 rpm

Torque 2.5I:

170 lb-ft @ 4000 rpm

Horsepower 2.5Gt:

250 hp @ 5600 rpm (approx.)

Torque 2.5Gt:

250 lb-ft @ 3600 rpm (approx.)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

Fuel Requirement Gt:

Premium Unleaded (91 octane or higher recommended)

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual Transmission

Optional

Transmission Type:

4-Speed Automatic Transmission with Sportshift

Features

AWD System:

Symmetrical All-Wheel Drive with viscous center coupling

Automatic Transmission Mode:

Includes adaptive shift control

📐 Dimensions

Exterior

Length Sedan:

187.6 inches (4765 mm)

Length Wagon:

189.1 inches (4803 mm)

Width:

69.1 inches (1755 mm)

Height Sedan:

57.9 inches (1470 mm)

Height Wagon:

58.1 inches (1475 mm)

Wheelbase:

104.0 inches (2640 mm)

Weights

Curb Weight Starting:

3340 lbs (approx. for 2.5i Manual Sedan)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5-Star

NHTSA Front Impact Passenger:

5-Star

IIHS Front Offset Crash Rating:

Active Features

Standard (4-wheel disc ABS)

Traction Control:

Available on some trims

Electronic Stability Control:

Available on some trims

Passive Features

Airbags:

Front airbags, front side-impact airbags

Seatbelts:

Three-point seatbelts in all positions, front seat pretensioners

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD player, optional premium audio system with subwoofer and amplifier.

Climate Control:

Manual or automatic climate control (available on higher trims).

Driver Assistance

Cruise Control:

Standard

Connectivity

Auxiliary Input:

Optional on some models.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 6 months, whichever comes first (severe driving conditions) or 7,500 miles or 12 months (normal driving conditions).

Engine Oil Filter Replacement:

Replace at every oil change.

Engine Air Filter Replacement:

Inspect every 15,000 miles; replace as needed. Replace every 30,000 miles if operating in dusty conditions.

Cabin Air Filter Replacement:

Replace annually or every 15,000 miles.

Transmission Fluid Change Manual:

Check periodically; replacement interval typically 60,000-100,000 miles, consult manual.

Transmission Fluid Change Automatic:

Check periodically; replace fluid and filter every 30,000-60,000 miles, consult manual.

Coolant Replacement:

Replace every 30,000 miles or 24 months. Subaru Super Coolant is recommended.

Spark Plug Replacement:

Replace every 60,000 miles for iridium spark plugs (standard on many models).

Fluid Specifications

Engine Oil Type:

SAE 5W-30 API Service SG, SH, SJ, SL, SM or ILSAC GF-2, GF-3, GF-4

Engine Oil Capacity:

4.8 US quarts (4.5 Liters) with filter (approx.)

Coolant Type:

Subaru Super Coolant (Blue) or equivalent ethylene glycol based antifreeze

Automatic Transmission Fluid Type:

Subaru ATF-HP (High Performance)

Manual Transmission Fluid Type:

Subaru 75W-90 GL-5 Gear Oil

Power Steering Fluid Type:

Subaru Genuine Power Steering Fluid or Dexron III/Mercon compatible fluid

Known Issues

Head Gasket Leaks:

While more common on earlier EJ25 engines (pre-2005), some models may still experience head gasket issues. The 2004 model year is on the cusp of this potential issue.

Catalytic Converter Failure:

Can occur due to age, mileage, or engine issues leading to rich fuel mixture.

Suspension Component Wear:

Bushings, ball joints, and tie rod ends can wear over time, leading to noise and steering issues.

📚 Vehicle History

Brand Heritage

Brand Focus:

Subaru is known for its Symmetrical All-Wheel Drive systems and horizontally-opposed Boxer engines, emphasizing safety and capability.

Model Evolution

Generation Introduction:

The BP/BL generation of the Subaru Legacy was introduced for the 2005 model year, meaning the 2004 model year represents the final year of the previous generation (BD/BG/BK).

Previous Generation:

The 2004 Legacy belongs to the third generation (BD/BG/BK, 1999-2004), which saw a significant redesign for the 2000 model year.

Production

Assembly Location:

Lafayette, Indiana, USA (Subaru of Indiana Automotive, Inc. - SIA)

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

The 2004 Legacy often received good safety ratings from IIHS for its structural integrity.

Ratings

Consumer Reports Reliability:

Reliability ratings varied for this generation; consult specific year reports for detailed analysis.