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Subaru Legacy 1996 Service Repair Workshop Manual

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$16.99
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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 1996 👋 Introduction Market Position Vehicle Class: Mid-size Sedan and Wagon (also available as a Coupe) Segment Competitors: Toyota Camry, Honda...
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Subaru Legacy 1996 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy
Year:
1996
👋 Introduction
Market Position
Vehicle Class:
Mid-size Sedan and Wagon (also available as a Coupe)
Segment Competitors:
Toyota Camry, Honda Accord, Nissan Altima, Mazda Millenia
Competitive Analysis
Subaru Differentiation:
Standard Symmetrical All-Wheel Drive (AWD) on most models, horizontally opposed 'boxer' engines, robust build quality.
Key Features
Engine Configuration:
Horizontally-opposed 'Boxer' engines.
Drivetrain Standard:
Symmetrical All-Wheel Drive (AWD) for most trims, FWD for some base models.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Service and Repair Instructions
Intended Audience:
Professional Mechanics and DIY Enthusiasts
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
Detailed coverage of all engine types and components, including disassembly, assembly, diagnosis, and repair.
Transmission:
Comprehensive information on both manual and automatic transmissions, including operation, maintenance, and repair procedures.
Drivetrain:
Covers front-wheel drive (FWD) and Subaru's Symmetrical All-Wheel Drive (AWD) systems, including differentials, axles, and driveshafts.
Suspension:
Detailed instructions for front and rear suspension components, including struts, shocks, control arms, and alignment procedures.
Steering:
Service and repair procedures for the power steering system, steering column, and rack and pinion assembly.
Brakes:
Complete coverage of hydraulic brake systems, including ABS, brake calipers, rotors, pads, lines, and bleeding procedures.
Electrical:
Extensive information on the vehicle's electrical system, including wiring diagrams, component locations, testing procedures, and diagnostics.
Body:
Body panel removal and installation, collision repair guidance, interior trim, and exterior component servicing.
HVAC:
Service and repair for the heating, ventilation, and air conditioning system, including component testing and refrigerant handling.
Fuel:
Detailed coverage of the fuel delivery system, including fuel pump, injectors, fuel lines, and evaporative emission control (EVAP) system.
Cooling:
Information on the engine cooling system, including radiator, thermostat, water pump, and cooling fans.
Exhaust:
Service and troubleshooting for the exhaust system, including catalytic converter, mufflers, and emission controls.
Procedures Included
Maintenance:
Routine maintenance procedures such as oil changes, filter replacements, spark plug service, and belt inspections.
Troubleshooting:
Systematic diagnostic charts and symptom-based troubleshooting guides for common and complex issues.
Repair:
Step-by-step repair instructions for virtually all components and systems of the vehicle.
Disassembly Assembly:
Detailed instructions for removing, inspecting, and reinstalling components during repair or overhaul.
Specifications:
Torque specifications, clearances, fluid capacities, and other critical data required for proper repair.
Technical Depth
Depth:
Comprehensive from basic maintenance to full engine and transmission rebuilds, including in-depth electrical diagnostics.
📊 Manual Specifications
File Format
Digital Format Details:
Likely a searchable PDF document, optimized for clear display and printing of individual pages.
Print Quality
Print Recommendation:
High-resolution digital format suitable for printing high-quality diagrams and text.
Binding Type
Physical Binding:
N/A (Digital Format)
Paper Type
Physical Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
EJ22, EJ25
Engine Type:
Naturally Aspirated Flat-4 (Boxer)
Displacement Ej22:
2.2 Liters (2211 cc)
Displacement Ej25:
2.5 Liters (2457 cc)
Performance
Horsepower Ej22:
135 hp @ 5600 rpm (approx.)
Torque Ej22:
140 lb-ft @ 4400 rpm (approx.)
Horsepower Ej25:
165 hp @ 5600 rpm (approx.)
Torque Ej25:
170 lb-ft @ 4000 rpm (approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Ignition System:
Distributorless Ignition System (DIS) with Coil-on-Plug (COP) on some EJ25 models.
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Transmission (5MT)
Optional
Transmission Type:
4-Speed Automatic Transmission (4EAT)
Features
AWD Coupling:
Viscous coupling center differential for AWD models.
Automatic Shift Control:
Electronically controlled for the 4EAT, often with a sport mode.
📐 Dimensions
Exterior
Length Sedan:
4620 mm (181.9 in)
Width:
1730 mm (68.1 in)
Height Sedan:
1415 mm (55.7 in)
Wheelbase:
2630 mm (103.5 in)
Wheelbase Wagon:
2520 mm (99.2 in)
Weights
Curb Weight:
1350 - 1500 kg (approx.)
Gross Vehicle Weight Rating:
Varies by trim and configuration
Towing Capacity:
Not typically recommended or specified by Subaru for passenger cars of this era.
🛡️ Safety Features
Ratings
NHTSA Frontal Crash:
Not specifically rated for 1996 models by NHTSA, but known for decent crashworthiness in its class.
Active Features
Traction Control:
Available on some higher trims, particularly with AWD.
ABS:
Standard on most trims, especially AWD models.
Passive Features
Airbags:
Driver and front passenger airbags standard.
Seatbelts:
Three-point front and rear seatbelts.
Rollover Protection:
Reinforced body structure typical of Subaru's safety design philosophy.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with cassette player. Optional CD player available on some trims.
Speaker Configuration:
Typically 4 or 6 speakers depending on trim level.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
Phone Integration:
No integrated Bluetooth or smartphone connectivity; aftermarket solutions would be required.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 - 7,500 miles (6,000 - 12,000 km) or 3-6 months, depending on driving conditions and oil type (refer to manual for specifics).
Engine Air Filter:
Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).
Spark Plugs:
Replace every 30,000 - 60,000 miles (48,000 - 96,000 km) depending on plug type (copper vs. platinum).
Timing Belt Ej25:
Critical replacement every 60,000 - 90,000 miles (96,000 - 144,000 km) or 5-7 years for EJ25 engines (interference engine). EJ22 may use a timing chain or belt, manual will specify.
Fluid Specifications
Engine Oil Type:
API SG/SH or higher, SAE 5W-30 or 10W-30 recommended (check manual for climate specific viscosity).
Engine Oil Capacity:
Approx. 4.5 quarts (4.3 L) with filter for EJ22/EJ25.
Coolant Type:
Ethylene Glycol based coolant, typically Subaru Super Coolant or equivalent (pink color).
Transmission Fluid Manual:
API GL-5, SAE 75W-90 (check manual for specific subaru fluid).
Transmission Fluid Automatic:
Subaru Genuine ATF HP or equivalentDexron-III/Mercon compatible fluid (check manual).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Head Gaskets:
While less prevalent on the EJ22, EJ25 engines are known for potential head gasket leaks as they age, especially when overheated. The manual will detail inspection and replacement procedures.
Oil Leaks:
Common areas include valve cover gaskets, oil pan gaskets, and front/rear crankshaft seals, particularly on higher mileage vehicles.
Cv Axle Boots:
Torn CV axle boots are a common wear item due to age and exposure, leading to joint damage if not addressed.
Rear Main Seal:
The rear main crankshaft seal can leak oil, often requiring transmission removal for replacement.
Ac Compressor:
AC compressors can fail on these models; the manual covers diagnosis and replacement.
📚 Vehicle History
Brand Heritage
Subaru Origins:
Founded in 1953, Fuji Heavy Industries (now Subaru Corporation) has a history in aircraft manufacturing, influencing its engineering approach.
Model Evolution
Legacy Introduction:
First generation (first model) introduced in 1989 as a replacement for the Subaru Loyale/DL/GL series.
Second Generation Start:
The 1996 model year marks the introduction of the second generation (BD/BG/BK platform) for the Subaru Legacy.
Platform Update:
The second generation brought updated styling, improved aerodynamics, and significant chassis refinements, including longer wheelbases for improved ride comfort.
Production
Manufacturing Location:
Mainly Gunma Plant, Japan.
Production Years 2Nd Gen:
1996-2004 (globally, with regional variations)
🏆 Awards & Recognition
Recognitions
Car And Driver Award:
The Subaru Legacy has historically been a frequent recipient of Car and Driver's '10Best' list, although specific model year awards for 1996 are not prominently cited, the general reputation for quality and AWD capability was strong.
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