Subaru Legacy Outback Owners Maintenance Service Repair Manual 2006

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Outback Year: 2006 Codes Chassis Code: BP (Wagon/Outback) Platform: Subaru Third Generation Legacy Platform 👋 Introduction Market Position Segment: Mid-size Crossover/SUV (Outback),...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy Outback

Year:

Codes

Chassis Code:

BP (Wagon/Outback)

Platform:

Subaru Third Generation Legacy Platform

👋 Introduction

Market Position

Segment:

Mid-size Crossover/SUV (Outback), Mid-size Sedan/Wagon (Legacy)

Subaru's signature Symmetrical All-Wheel Drive, boxer engine, and higher ground clearance for the Outback variant.

Competitive Analysis

Competitors:

Toyota Camry/RAV4, Honda Accord/CR-V, Mazda6/CX-7, Ford Fusion/Edge, Nissan Altima/Murano.

Key Features Vehicle

AWD Standard:

Symmetrical All-Wheel Drive is standard across all trims and engine options.

Outback Ground Clearance:

Outback offers increased ground clearance (8.7 inches) for light off-road capability.

Key Features Manual

Reliability:

Essential for maintaining the longevity and performance of the boxer engine and AWD system.

Diy Support:

Empowers owners and independent mechanics with detailed, factory-level repair information.

📋 Manual Details

Coverage Areas

Model Variants Covered:

Subaru Legacy Outback, Legacy Sedan, Legacy Station Wagon

Engine Variants Covered:

2.5L Naturally Aspirated (EJ253), 2.5L Turbocharged (EJ255), 3.0L Naturally Aspirated (EZ30D)

Page Count

Estimated Page Count:

Approx. 2000-3000 pages (typical for comprehensive factory service manuals)

Manual Type

Type:

Factory Service Manual (FSM) / Workshop Manual

Language

Language:

English

Format

Format:

Likely Digital (PDF) or Printed, depending on source

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication, cooling.

Engine Management:

Fuel injection, ignition system, emission controls, sensors, actuators, ECU troubleshooting, diagnostic trouble codes (DTCs).

Transmission Manual:

Clutch, gearbox assembly, shift mechanism, maintenance, repair, and overhaul.

Transmission Automatic:

Torque converter, valve body, planetary gear sets, hydraulic controls, transmission control module (TCM), maintenance, repair, and overhaul.

Drivetrain:

All-Wheel Drive (AWD) system, front and rear differentials, driveshafts, CV joints, wheel bearings.

Suspension:

Front and rear suspension components, struts, shocks, control arms, bushings, springs, anti-roll bars, alignment specifications.

Brakes:

Front and rear brake systems (disc brakes), ABS, EBD, brake fluid specifications, caliper, rotor, and pad replacement, bleeding procedures.

Steering:

Power steering system, steering column, tie rods, rack and pinion, steering fluid, alignment.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting, fuses, relays, wiring diagrams.

Body And Chassis:

Body panels, doors, hood, trunk, interior trim, structural components, corrosion protection.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, climate control unit.

Safety Systems:

Airbag system, SRS module, seat belts, pre-tensioners.

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid flushes (coolant, brake fluid, transmission fluid, power steering fluid), belt inspections/replacements.

Diagnostics:

Troubleshooting guides for various symptoms, diagnostic trouble code (DTC) interpretation and resolution, component testing procedures.

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair for all covered systems.

Overhaul Rebuild:

Detailed instructions for complete engine, transmission, and differential rebuilds.

Electrical Troubleshooting:

Use of wiring diagrams, circuit testing, component diagnosis, repair of electrical faults.

Body Repair:

Minor body panel repair, door adjustment, glass replacement, interior trim removal/installation.

Technical Depth

Depth:

Comprehensive: Covers from basic maintenance and fluid checks to complete engine, transmission, and driveline overhauls.

Diagnostic Tools:

References use of Subaru Select Monitor (SSM) or similar OBD-II scan tools.

Torque Specifications:

Detailed torque specifications for all fasteners across all systems.

Clearances Tolerances:

Specifications for critical component clearances and tolerances (e.g., piston ring gap, bearing clearance).

📊 Manual Specifications

File Format

File Type:

PDF (if digital), Printed Pages (if physical)

Searchability:

Typically searchable text in PDF format for quick information retrieval.

Print Quality

Print Quality:

High quality with clear diagrams, schematics, and illustrations.

Binding Type

Binding:

Coil-bound or Perfect bound (if printed) for ease of use on workbench.

Paper Type

Paper Quality:

Durable paper stock suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Code Base:

EJ253

Engine Description Base:

2.5-liter DOHC 16-valve horizontally opposed (boxer) 4-cylinder engine.

Displacement Base:

2457 cc (149.9 cu in)

Horsepower Base:

Approx. 175-180 hp @ 5,800-6,000 rpm

Torque Base:

Approx. 170-173 lb-ft @ 4,000-4,400 rpm

Turbocharged Engine

Engine Code Turbo:

EJ255

Engine Description Turbo:

2.5-liter DOHC 16-valve turbocharged horizontally opposed (boxer) 4-cylinder engine.

Horsepower Turbo:

Approx. 243-250 hp @ 5,200-5,600 rpm

Torque Turbo:

Approx. 250-255 lb-ft @ 3,200-4,400 rpm

V6 Engine

Engine Code V6:

EZ30D

Engine Description V6:

3.0-liter DOHC 24-valve horizontally opposed (boxer) 6-cylinder engine.

Displacement V6:

2999 cc (183.1 cu in)

Horsepower V6:

Approx. 250 hp @ 6,600 rpm

Torque V6:

Approx. 217 lb-ft @ 4,200 rpm

Fuel System

Fuel Delivery:

Multi-point fuel injection (MPI).

Fuel Type:

Unleaded gasoline (87 octane recommended for NA, 91 octane recommended for Turbo).

Performance

Compression Ratio Base:

10.7:1

Compression Ratio Turbo:

8.4:1

Bore X Stroke Base:

92.0 mm x 91.0 mm

🔧 Transmission

Standard

Transmission Type:

5-speed manual transmission (for some Legacy variants) or 4-speed automatic transmission.

Optional

Transmission Type Optional:

5-speed automatic transmission (with Sportshift/manual mode) for some trims, especially with the 3.0L engine.

Features

AWD Integration:

Integrated with Subaru's Symmetrical All-Wheel Drive system.

Automatic Transmission Fluid:

Subaru ATF HP (or equivalent specification).

Manual Transmission Fluid:

Subaru Extra S (or GL-5 75W-90 specification).

📐 Dimensions

Exterior

Length Outback:

Approx. 189.4 inches (4810 mm)

Width Outback:

Approx. 70.5 inches (1790 mm)

Height Outback:

Approx. 61.1 inches (1550 mm)

Wheelbase:

Approx. 104.3 inches (2650 mm)

Ground Clearance Outback:

8.7 inches (221 mm)

Cargo

Cargo Volume Outback Behind Rear Seat:

Approx. 33.5 cu ft (948 L)

Cargo Volume Outback Max:

Approx. 71.4 cu ft (2022 L) with rear seats folded.

Weights

Curb Weight Base:

Approx. 3,400 - 3,600 lbs (1542 - 1633 kg), varies by trim and drivetrain.

🛡️ Safety Features

Ratings

IIHS Crash Test Rating 2006:

Good in front and side impact tests (IIHS).

NHTSA Crash Test Rating 2006:

Generally achieved 4 or 5 stars in frontal and side impact tests (NHTSA), specific ratings may vary by year and configuration.

Active Features

Standard Anti-lock Braking System (ABS).

Standard Electronic Brake-force Distribution (EBD).

Passive Features

Airbags:

Frontal airbags, front side-impact airbags, side curtain airbags (standard on many Outback trims).

Seatbelts:

Three-point seatbelts for all occupants, front seatbelt pretensioners.

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM stereo with CD player, optional satellite radio, and premium audio systems with subwoofer.

Navigation System:

Optional factory-installed GPS navigation system, typically integrated into the dashboard display.

Driver Assistance

Cruise Control:

Standard cruise control, often with steering wheel mounted buttons.

Tire Pressure Monitoring System:

TPMS sensors in wheels, with warning light on dashboard.

Connectivity

Auxiliary Input:

Optional auxiliary audio input jack for connecting external media devices.

Keyless Entry:

Standard on most trims, often includes remote keyless entry and alarm system.

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Engine Oil Filter Replacement:

Replace with every oil change. Common part numbers include 15208AA031, 15208AA021.

Air Filter Replacement:

Every 30,000 miles or as needed based on driving conditions. Part number: 16546AA020.

Spark Plug Replacement:

NGK Iridium: 60,000 miles for EJ253, 30,000 miles for EJ255 (check manual for specific type). Part number examples: SILFR6A, PFR7B (for turbo).

Coolant Flush:

Every 30,000 miles or 24 months. Use Subaru Super Coolant or equivalent P-HOAT coolant.

Transmission Fluid Change Auto:

Every 30,000 miles for severe conditions, 60,000 miles for normal. Capacity: Approx. 7.8 quarts (7.4 L).

Transmission Fluid Change Manual:

Every 30,000-60,000 miles. Capacity: Approx. 2.5 quarts (2.4 L).

Brake Fluid Flush:

Every 30,000 miles or 24 months. Use DOT 3 or DOT 4 brake fluid.

Differential Fluid Change Front Rear:

Every 30,000 miles. Front capacity: Approx. 1.1 quarts (1.0 L). Rear capacity: Approx. 1.3 quarts (1.2 L). Use GL-5 75W-90.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (API SG, SH, or SJ certified).

Engine Oil Capacity:

4.8 US quarts (4.5 L) with filter for 2.5L; 5.1 US quarts (4.8 L) with filter for 3.0L.

Coolant Type:

Subaru Super Coolant (Blue) or equivalent P-HOAT coolant.

Known Issues

Head Gasket Failure:

While less prone than earlier Subaru generations, head gasket leaks can still occur, particularly on the EJ253. The manual will detail inspection and replacement procedures.

Oxygen Sensor Failure:

Premature failure of upstream O2 sensors can affect fuel economy and emissions. Manual covers diagnosis and replacement.

Catalytic Converter Issues:

Can become clogged over time, leading to performance loss. Manual assists in diagnosis.

Automatic Transmission Longevity:

Regular fluid changes are crucial for the longevity of the 4-speed automatic. Manual provides correct fluid types and capacities.

📚 Vehicle History

Brand Heritage

Subaru History:

Subaru, a division of Fuji Heavy Industries, has a long history of producing robust, reliable vehicles with a focus on All-Wheel Drive technology since the 1970s.

Model Evolution

Legacy History:

The Subaru Legacy was introduced in 1989 as a replacement for the Leone. The Outback variant, originally an Outback Sport trim of the Legacy wagon, became a distinct model in 1995, creating the crossover segment.

Third Gen Legacy Outback:

The 2005-2009 generation (BP/BL chassis) represented the third generation for the Legacy and second generation for the dedicated Outback model. It featured a more refined design, improved interiors, and enhanced AWD systems.

Production

Manufacturing Location:

Gunma Plant, Japan.

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

Often recognized by the Insurance Institute for Highway Safety (IIHS) for good crash test performance.

Consumer Reports Ratings:

Generally received good to excellent ratings from consumer publications for reliability and performance in previous years, though 2006 specific ratings should be checked.