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Subaru Legacy 2004 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 2004 Generation Generation Code: BP/BL Codes Chassis Codes: BP (Wagon), BL (Sedan) 👋 Introduction Market Position Vehicle Segment: Mid-size sedan and...
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🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy
Year:
2004
Generation
Generation Code:
BP/BL
Codes
Chassis Codes:
BP (Wagon), BL (Sedan)
👋 Introduction
Market Position
Vehicle Segment:
Mid-size sedan and wagon, known for AWD capabilities and reliability
Competitive Analysis
Key Competitors:
Toyota Camry, Honda Accord, Mazda6, Ford Fusion
Key Features
Standard AWD:
Subaru's signature Symmetrical All-Wheel Drive system across most trims
Boxer Engine:
Horizontally opposed (Boxer) engine design for a lower center of gravity
Safety Focus:
Emphasis on occupant safety and all-weather capability
📋 Manual Details
Coverage Areas
Manual Coverage:
Comprehensive repair and overhaul procedures
Page Count
Page Count Estimate:
Likely 1000+ pages (typical for comprehensive workshop manuals)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Repair:
Detailed diagnostics, repair, and overhaul of all engine variants
Transmission Repair:
Manual and automatic transmission service, overhaul, and diagnostics
Drivetrain Repair:
All-Wheel Drive (AWD) system, differentials, axles, and driveshafts
Suspension Steering:
Front and rear suspension components, steering rack, power steering system
Brake System:
Brake calipers, rotors, lines, ABS system, parking brake
Electrical System:
Wiring diagrams, fuse box layouts, component testing, ECUs
HVAC System:
Air conditioning, heating, ventilation system diagnostics and repair
Body And Trim:
Exterior panel removal/installation, interior trim, glass replacement
Fuel System:
Fuel pump, injectors, fuel lines, evaporative emissions system
Cooling System:
Radiator, water pump, thermostat, coolant specifications
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks, tune-ups
Engine Rebuild:
Piston removal, cylinder head reconditioning, crankshaft main bearing replacement
Transmission Overhaul:
Clutch replacement, valve body service, torque converter replacement
Troubleshooting Diagnostics:
System-specific diagnostic charts and fault code interpretation
Component Replacement:
Alternator, starter motor, power steering pump, A/C compressor
Timing Belt Replacement:
Detailed procedures for belt tensioning and alignment
Wheel Alignment:
Specifications for camber, caster, and toe angles
Airbag System Service:
Safety precautions and procedures for airbag module replacement
Technical Depth
Depth Level:
Full workshop level, covering all mechanical, electrical, and body systems
Diagnostic Focus:
Detailed diagnostic flowcharts and component testing procedures
Torque Specifications:
Comprehensive list of torque values for all fasteners
Special Tools:
Identification of special tools required for specific procedures
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable, allowing for quick information retrieval
Print Quality
Image Clarity:
Typically high-resolution for clear diagrams and illustrations
Binding Type
Binding Type:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Options:
2.5L Naturally Aspirated Boxer (EJ253), 2.5L Turbocharged Boxer (EJ255 - GT models)
Performance
Naturally Aspirated Hp:
Approx. 165-175 hp (depending on specific variant)
Turbocharged Hp:
Approx. 250 hp (GT models)
Torque Naturally Aspirated:
Approx. 166-170 lb-ft
Torque Turbocharged:
Approx. 250 lb-ft
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Sequential Port Injection
Fuel Type:
Unleaded Gasoline
Engine Layout
Engine Layout:
Horizontally Opposed (Boxer)
Engine Codes
Engine Codes:
EJ253 (NA), EJ255 (Turbo)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission (on some models)
Optional
Automatic Transmission:
4-speed Automatic Transmission with Sportshift
Features
AWD System:
Symmetrical All-Wheel Drive (AWD) standard on most trims
Differential Type:
Front & Rear Helical LSD (GT models), Front Open, Rear Viscous LSD (NA models)
📐 Dimensions
Exterior
Wheelbase Sedan:
Approx. 104.0 inches (2642 mm)
Wheelbase Wagon:
Approx. 104.3 inches (2649 mm)
Length Sedan:
Approx. 187.4 inches (4760 mm)
Length Wagon:
Approx. 188.0 inches (4775 mm)
Width:
Approx. 69.1 inches (1755 mm)
Height:
Approx. 57.7 inches (1465 mm) Sedan / 58.1 inches (1475 mm) Wagon
Weights
Curb Weight:
Approx. 3200-3500 lbs (1450-1590 kg), varies by trim and drivetrain
Gross Vehicle Weight Rating:
Typically around 4500-4700 lbs
Towing Capacity:
Generally not recommended or rated for towing
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-star rating (for driver and passenger) in many tests
IIHS Side Impact:
Good rating in most tests
Active Features
ABS:
Anti-lock Braking System (ABS)
E Brake Assist:
Electronic Brake-force Distribution (EBD), Brake Assist (BA)
Traction Control:
Traction Control System (TCS)
Stability Control:
Vehicle Dynamics Control (VDC) available on some trims
Passive Features
Airbags:
Frontal airbags, front side-impact airbags, side curtain airbags (on some models)
Seatbelts:
3-point seatbelts with pre-tensioners and force limiters
Child Anchors:
LATCH (Lower Anchors and Tethers for Children) system
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional premium audio systems with amplifier and subwoofer.
Climate Control:
Manual or automatic climate control systems available.
Driver Assistance
Cruise Control:
Standard cruise control.
Keyless Entry:
Available keyless entry and remote start systems.
Connectivity
Auxiliary Input:
Some models may have an auxiliary audio input for external devices.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,750 to 7,500 miles or 6 months, depending on driving conditions and oil type
Timing Belt Interval:
Recommended replacement every 105,000 miles or 105 months (crucial for EJ engines)
Transmission Fluid Change:
Every 30,000-60,000 miles for automatic transmissions, check manual for manual transmission service
Fluid Specifications
Engine Oil Type:
SAE 5W-30 or 10W-30 (API SG or higher, check owner's manual for exact spec)
Coolant Type:
Subaru Super Coolant (Blue) or equivalent silicate-free long-life coolant
Brake Fluid:
DOT 3 or DOT 4 brake fluid
Power Steering Fluid:
Subaru compatible power steering fluid or Dexron III ATF
Known Issues
Head Gaskets:
While less common than earlier models, some EJ25 engines can still experience head gasket leaks.
Wheel Bearings:
Front and rear wheel bearings can wear over time.
Cv Axles:
CV axle boots can tear, leading to joint failure.
Catalytic Converter:
Pre-catalytic converters can sometimes fail, especially on turbo models.
Turbo Charger Issues:
On GT models, the turbocharger may require servicing or replacement due to age/mileage.
📚 Vehicle History
Brand Heritage
Brand Focus:
Subaru is renowned for its symmetrical AWD and Boxer engine configurations.
Model Evolution
Legacy Introduction:
The Subaru Legacy was first introduced in 1989 as a replacement for the Subaru Leone.
Fourth Generation:
The 2004 model year marks the introduction of the fourth generation (BP/BL) Legacy, featuring a significant redesign.
Body Styles:
Available as a 4-door sedan (BL) and a 5-door wagon (BP).
Production
Production Years:
2004-2009 for the BP/BL generation
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick:
Many Subaru models, including the Legacy, have historically performed well in IIHS safety tests.
Ratings
Consumer Reports Reliability:
Consumer Reports ratings can vary by year, but Subaru generally scores well for reliability.