🏷️ Basic Information

Make:

Subaru

Model:

Legacy

Year:

1996

Product Type:

Workshop Service Manual / Repair Manual

Target Audience:

Professional Technicians, Experienced DIY Mechanics

👋 Introduction

Segment:

Mid-size sedan/wagon, known for its standard All-Wheel Drive system and reputation for reliability and safety.

Competitors:

Toyota Camry, Honda Accord, Mazda 626, Nissan Altima, Ford Taurus.

Standard AWD:

Subaru's signature Symmetrical All-Wheel Drive system was a major differentiator, offering enhanced traction and stability in various weather conditions.

Boxer Engine:

Horizontally-opposed (Boxer) engine design for a lower center of gravity, improving handling characteristics.

Durability:

Reputation for robust construction and longevity.

📋 Manual Details

Engines Covered:

EJ22 (2.2L SOHC), EJ25D (2.5L DOHC)

Drivetrain Covered:

All-Wheel Drive (AWD), Front-Wheel Drive (FWD) (where applicable)

Body Styles Covered:

Sedan, Wagon

Countries Of Sale Covered:

North America, potentially global markets depending on specific regional configurations.

Estimated Page Count:

1500-2000+ pages (typical for a comprehensive workshop manual of this era)

Type:

Factory Authorized Workshop Service Manual

Language:

English

Format:

PDF Download

File Type:

PDF

Searchable:

Likely searchable text within the PDF, allowing for quick information retrieval.

Printable:

Designed to be printable, allowing users to print specific sections or the entire manual.

Resolution:

High resolution for clear viewing of diagrams and text.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

📖 Manual Coverage

Engine Mechanical:

Engine removal/installation, cylinder head, valve train, pistons, connecting rods, crankshaft, oil pump, timing belt/chain, seals, gaskets.

Engine Performance And Tuning:

Fuel injection system, ignition system, emissions control, engine diagnostics, performance specifications.

Transmission Manual:

Clutch, gearshift mechanism, internal transmission components, fluid specifications, repair procedures for 5-speed manual transmissions.

Transmission Automatic:

Torque converter, planetary gear sets, hydraulic control system, valve body, transmission control unit (TCU), fluid specifications, repair procedures for 4-speed automatic transmissions.

Drivetrain And Axles:

Front and rear differentials, driveshafts, CV joints, wheel bearings, AWD system components.

Suspension And Steering:

Front and rear suspension components (struts, shocks, springs, control arms, bushings), power steering system, steering rack, wheel alignment specifications.

Brakes:

Front and rear brake systems (discs/drums), calipers, wheel cylinders, master cylinder, brake booster, ABS system, parking brake, hydraulic lines, bleeding procedures.

Electrical System And Diagnostics:

Battery, charging system (alternator, regulator), starting system (starter motor), lighting systems, fuses, relays, wiring diagrams, diagnostic trouble codes (DTCs).

Climate Control:

HVAC system, air conditioning system, heater core, blower motor, refrigerant specifications, diagnosis and repair.

Body And Interior:

Body panel removal/installation, doors, windows, seats, dashboard, trim pieces, glass replacement, exterior trim.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, hangers, oxygen sensors.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel lines, injectors, evaporative emission control (EVAP).

Maintenance:

Routine service procedures, oil changes, filter replacements, spark plug replacement, fluid checks and changes, drive belt inspection/replacement.

Repair:

Detailed step-by-step repair instructions for all major vehicle systems, including component removal, disassembly, inspection, repair, and reassembly.

Troubleshooting:

Diagnostic procedures, common problems and their solutions, fault finding charts, symptom-based diagnostics.

Diagnostics:

OBD-II diagnostic procedures, sensor testing, ECU troubleshooting, wiring harness checks.

Torque Specifications:

Precise torque values for all critical fasteners throughout the vehicle.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems.

Depth:

Complete overhaul and rebuild procedures for engines, transmissions, differentials, and other major mechanical components.

Diagnostics Capability:

Advanced diagnostic procedures, including circuit testing, component resistance checks, and signal waveform analysis.

Special Tools:

Identification of specific tools required for various repair and maintenance tasks.

⚙️ Engine Specifications

Engine Code 1:

EJ22

Description 1:

2.2 Liter, 16-valve, SOHC (Single Overhead Camshaft) Boxer-4

Displacement 1:

2211 cc

Bore X Stroke 1:

96.0 mm x 77.0 mm

Compression Ratio 1:

9.0:1

Horsepower 1:

135 hp @ 5600 rpm

Torque 1:

140 lb-ft @ 4400 rpm

Fuel System 1:

Multi-Point Fuel Injection (MPFI)

Ignition System 1:

Electronic Ignition (Distributorless Ignition System - DIS on some later models, but likely distributor on early '96 models)

Cooling System 1:

Pressurized liquid cooling system.

Engine Code 2:

EJ25D

Description 2:

2.5 Liter, 16-valve, DOHC (Dual Overhead Camshaft) Boxer-4

Displacement 2:

2457 cc

Bore X Stroke 2:

99.5 mm x 79.0 mm

Compression Ratio 2:

9.5:1

Horsepower 2:

165 hp @ 5800 rpm

Torque 2:

162 lb-ft @ 4000 rpm

Fuel System 2:

Multi-Point Fuel Injection (MPFI)

Ignition System 2:

Electronic Ignition (Distributorless Ignition System - DIS)

Cooling System 2:

Pressurized liquid cooling system.

Timing Belt Replacement Interval Ej25D:

60,000 miles or 5 years (critical for EJ25D as it is an interference engine)

🔧 Transmission

Type Standard:

5-Speed Manual Transmission (5MT)

Drivetrain Standard:

Symmetrical All-Wheel Drive (AWD)

Type Optional:

4-Speed Electronically Controlled Automatic Transmission (4EAT)

Drivetrain Optional:

Full-Time All-Wheel Drive (AWD)

Subaru AWD System:

Manual: Viscous coupling center differential with a 50/50 torque split. Automatic: Electronically controlled multi-plate transfer clutch, typically with a 45/55 front/rear bias.

Manual Fluid Type:

GL-5 Gear Oil (e.g., Subaru Extra-S or equivalent 75W-90)

Automatic Fluid Type:

Subaru ATF HP or equivalent Dexron II/III compatible fluid.

📐 Dimensions

Wheelbase:

104.3 inches (2649 mm)

Length:

184.1 inches (4676 mm) (Sedan) / 185.2 inches (4704 mm) (Wagon)

Width:

69.7 inches (1770 mm)

Height:

57.1 inches (1450 mm) (Sedan) / 57.3 inches (1455 mm) (Wagon)

Wheel Bolt Pattern:

5 x 100 mm

Tire Size Standard:

195/70 R14, 205/55 R15 (depending on trim and options)

Curb Weight Approx:

3100-3300 lbs (1406-1497 kg) (depending on engine and transmission)

🛡️ Safety Features

NHTSA Driver Side Impact Rating:

Likely 4-star for frontal impact (based on contemporary testing standards for this era). Side impact data may vary.

IIHS Ratings:

The 1996 Legacy was generally well-regarded for its safety, especially for its class at the time. Specific frontal offset and side impact scores would need to be referenced from historical IIHS reports.

ABS:

Anti-lock Braking System (ABS) available or standard on higher trims.

Airbags:

Driver and front passenger airbags.

Seatbelts:

Three-point seatbelts for all occupants, with pretensioners for front seats.

Rollover Protection:

Reinforced roof structure and pillars for improved rollover protection.

💡 Technology Features

Audio System:

Factory-installed AM/FM stereo with cassette player and optional CD player. Speaker configurations typically 4 or 6 speakers.

Climate Control Type:

Manual climate control with A/C standard or optional.

ABS:

Available Anti-lock Braking System (ABS) on select trims, improving braking control during hard stops.

Cruise Control:

Standard or optional cruise control system for highway driving.

🔧 Maintenance

Oil Change Interval:

Every 3,750 miles or 3 months, or 7,500 miles/6 months if using synthetic oil and following severe duty guidelines for normal use.

Engine Air Filter Replacement:

Every 15,000 miles or 12 months.

Cabin Air Filter Replacement:

Not typically equipped with a cabin air filter in this model year.

Spark Plug Replacement Ej22:

Every 30,000 miles (platinum-tipped plugs may extend this).

Spark Plug Replacement Ej25D:

Every 30,000 miles (platinum-tipped plugs may extend this).

Timing Belt Replacement Ej22:

Every 60,000 miles or 5 years (Non-interference engine, but belt condition is critical).

Coolant Flush Interval:

Every 30,000 miles or 2 years.

Brake Fluid Flush Interval:

Every 24,000 miles or 2 years.

Engine Oil Capacity Ej22:

4.5 US quarts (4.3 L) with filter, SAE 10W-30 or 5W-30 (check owner's manual for temperature ranges).

Engine Oil Capacity Ej25D:

4.5 US quarts (4.3 L) with filter, SAE 5W-30 recommended.

Coolant Type:

Subaru Super Coolant (blue) or equivalent ethylene glycol-based coolant with de-ionized water (50/50 mix).

Head Gasket Leaks:

While not as prevalent as on later generations (especially EJ253 SOHC), the EJ25D DOHC engine can be prone to head gasket failures, particularly if overheated. The manual will detail inspection and replacement procedures.

Automatic Transmission Failures:

Some '96 models with the 4EAT can experience issues with solenoid failure or wear in the valve body, leading to shifting problems. The manual's diagnostic section is crucial here.

Idle Control Valve Issues:

The Idle Air Control (IAC) valve can become dirty or fail, leading to rough idling or stalling. Cleaning and diagnosis are covered.

Suspension Wear:

Bushings and ball joints in the suspension can wear over time, affecting ride quality and alignment. Replacement procedures are detailed.

📚 Vehicle History

Subaru Identity:

Subaru, the automotive division of Subaru Corporation (formerly Fuji Heavy Industries), is known for its engineering prowess, particularly its horizontally-opposed 'Boxer' engines and standard Symmetrical All-Wheel Drive systems, which have been core to its brand identity since the 1970s.

Second Generation:

The 1996 Subaru Legacy marks the introduction of the second generation (chassis code BD/BG/BK), which replaced the first-generation (BF/BJ/BR) model. This generation saw significant redesigns in styling, interior, and chassis, along with the introduction of the more potent 2.5L DOHC engine.

Trim Levels:

Common trims included L, LS, GT (turbocharged on some variants, though not standard in '96 for US market base models), and Outback (introduced later in the generation as a distinct model). The GT trim would typically feature the more powerful engine and sportier enhancements.

Manufacturing Location:

Mainly manufactured in Japan (e.g., Gunma Plant).

Production Period:

Second generation: 1995-1999.

🏆 Awards & Recognition

Consumer Reports Ratings:

Consumer Reports often rated Subaru vehicles highly for their mechanical soundness and all-weather capability during this period.

Safety Ratings Historical:

The 1996 Legacy generally received good safety ratings for its class, emphasizing its AWD system and body structure as key safety advantages.