2005 Subaru Legacy Service & Repair Manual

FW-2 FOREWORD Foreword 1. Foreword A: FOREWORD These manuals are used when performing maintenance, repair, or diagnosis of the Subaru LEGACY. Applied model: BL*****, BP***** from 2005MY The manuals contain the latest information at the time of publication. Changes in specifications, methods, etc. may be made without notice.

HU-2 HOW TO USE THIS MANUALS How to Use This Manuals 1. How to Use This Manuals A: HOW TO USE THIS MANUALS 1. STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each component. The specification, maintenance and other information for the components are included, and the diagnostic information has also been added where necessary. 2. CONTENTS The first page has an index with tabs.

HU-3 HOW TO USE THIS MANUALS How to Use This Manuals 3. COMPONENT Illustrations are provided for each component. The information necessary for repair work (tightening torque, grease up points, etc.) is described on these illustrations. Information is described using symbol. To order parts, refer to parts catalogue. Example: HU-00017 (14) (9) (8) (7) (6) (10) (4) (10) (22) (11) (19) (17) (15) (13) (12) (18) (16) (1) (2) (3) (4) (5) (6) (7) (8) (11) (10) (9) (12) (13) (19) (18) (20) (17) (16) (24) (10) (25) (5) (4) (4) (4) (3) (3) (3) (2) (1) (21) (15) (23) T7 T2 T2 T2 T2 T2 T2 T4 T5 T5 T8 T6 T6 T6 T11 T10 T1 T1 T3 T3 T3 T1 T9 T4 T5 T5 T3 T4 T3 T2 T4 T2 T1 T3 (20) (21) (23) (22) (10) (24) (25) (26) (35) (34) (27) (14) (28) (29) (31) (32) (37) (30) (33) (36) T3 T2 T1 :Selective part :Replacement part :Should be lubricated with grease. :Should be lubricated with oil. :Sealing point :Tightening torque .... ,

HU-4 HOW TO USE THIS MANUALS How to Use This Manuals 4. SPECIFICATION If necessary, specifications are also included. 5. INSPECTION Inspections to be carried out before and after maintenance are included. 6. MAINTENANCE • Maintenance instructions for serviceable parts describe work area and detailed step with illustration. It also describes the use of special tool, tightening torque, caution for each procedure. • If many serviceable parts are included in one service procedure, appropriate reference is provided for each parts. Example: (A) Component (D) Cautions (G) Tightening torque (B) Process (E) Tool number of special tool (H) Illustration (C) Reference (F) Name of special tool HU-00020 1) Remove the manual transmission assembly from vehicie. <Ref. to MT-33, REMOVAL, Manual Transmission Assembly.> 15.Main Shaft Assembly for Sin- gle-Range A: REMOVAL 11) Tighten the lock nuts to the specified torque using ST1 and ST2. NOTE: Secure the lock nuts in two Places affer tightening. ST1 498937000 TRANSMISSION HOLDER (A) (B) (C) (D) (G) (E) (F) (H) Tightening torque: 118 N m (12.0 kgf-m, 86.8 ft-lb) ST1 ST2 ST2 499987003 SOCKET WRENCH (35)

HU-5 HOW TO USE THIS MANUALS How to Use This Manuals 7. DIAGNOSIS Tables showing a step-by-step process make it easy to conduct diagnosis. 8. SI UNITS Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are also included. Example: Tightening torque: 44 N⋅m (4.5 kgf-m, 33 ft-lb) The figure used in these manuals are described in the SI units and conventional units are described in ( ). Item SI units Conventional unit Remarks Force N (Newton) kgf 1 kgf = 9.80655 N Mass (Weight) kg, g kg, g Capacity 2, m2 or cm 3 2 or cc 1 cc = 1 cm 3 = 1 m2 Torque N⋅m kgf-m, kgf-cm 1 kgf-m = 9.80655 N⋅m Rotating speed rpm rpm Pressure kPa (kilopascal) kgf/cm 2 1 kgf/cm 2 = 98.0655 kPa mmHg 1 mmHg = 0.133322 kPa Power W PS 1 PS = 0.735499 kW Calorie W⋅h cal 1 kcal = 1.16279 W⋅h Fuel consumption rate g/kw⋅h g/PS⋅h 1 g/PS⋅h=1.3596 g/kW⋅h

HU-6 HOW TO USE THIS MANUALS How to Use This Manuals 9. EXPLANATION OF TERMINOLOGY • List AAI : Air Assist Injection M/B : Main Fuse & Relay Box A/B : Airbag MD : Mini Disc ABS : Antilock Brake System MPI : Multi Point Injection A/C : Air Conditioner MP-T : Multi-Plate Transfer A/F : Air Fuel Ratio MT : Manual Transmission ALT : Generator Non-turbo : Natural Aspiration ASSY : Assembly NC : Normal Close (Relay) AT : Automatic Transmission NO : Normal Open (Relay) ATF : Automatic Transmission Fluid OP : Option Parts BATT : Battery P/S : Power Steering CD-R/RW : CD Recordable/Rewritable P/W : Power Window CPU : Central Processing Unit PCD : Pitch Circle Diameter DOHC : Double Overhead Camshaft PCV : Positive Crankcase Ventilation DVD : Digital Versatile Disc RH : RH (Right Hand) ECM : Engine Control Module (ECM) Rr : Rear EGR : Exhaust Gas Recirculation SOHC : Single Overhead Camshaft ELR : Emergency Locking Retractor SRS : Supplemental Restraint System EX : Exhaust SSM : Subaru Select Monitor F/B : Fuse & Joint Box ST : Special Tool FL : Fusible Link SW : Switch Ft : Full-time AWD TCS : Traction Control System FWD : Front Wheel Drive TGV : Tumble Generated Valve GPS : Global Positioning System T/M : Transmission H/U : Hydraulic Unit ViS-C : Viscous Coupling IG : Ignition VSV : Vacuum Switching Valve INT : Intermittent VTD : Variable Torque Distribution ISC : Idle Speed Control W/H : Wiring Harness LH : LH (Left Hand) Pr : Primary LSD : Limited Slip Differential 2ndr : Secondary

SPC-2 SPECIFICATIONS LEGACY 1. LEGACY A: DIMENSION 1. SEDAN MODEL ★1 : With sunroof 2. WAGON MODEL ★1 : With sunroof B: ENGINE Model 2.5 L SOHC 2.5 L DOHC turbo Overall length mm (in) 4,730 (186.2) Overall width mm (in) 1,730 (68.1) Overall height (at C.W.) mm (in) 1,425 (56.1) Compartment Length mm (in) 1,900 (74.8) Width mm (in) 1,445 (56.9) Height mm (in) 1,165 (45.9), 1,100 (43.3) ★1 Wheelbase mm (in) 2,670 (105.1) Tread Front mm (in) 1,495 (58.9) Rear mm (in) 1,485 (58.5) Minimum road clearance mm (in) 150 (5.9) Model 2.5 L SOHC 2.5 L DOHC turbo Overall length mm (in) 4,795 (188.8) Overall width mm (in) 1,730 (68.1) Overall height (at C.W.) mm (in) 1,475 (58.1) Compartment Length mm (in) 1,840 (72.4) Width mm (in) 1,445 (56.9) Height mm (in) 1,190 (46.9), 1,145 (45.1) ★1 Wheelbase mm (in) 2,670 (105.1) Tread Front mm (in) 1,495 (58.9) Rear mm (in) 1,485 (58.5) Minimum road clearance mm (in) 150 (5.9) 155 (6.1) Model 2.5 L SOHC 2.5 L DOHC turbo Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Valve arrangement Overhead camshaft Bore × Stroke mm (in) 99.5 × 79.0 (3.917 × 3.110) Displacement cm 3 (cu in) 2,457 (149.9) Compression ratio 10.0 8.2 Ignition order 1 — 3 — 2 — 4 Idle speed at Park or Neutral position rpm 650 (MT) 700 (AT) 750 Maximum output kW (HP)/ rpm 124 (166)/5,600 (U5 model) 127 (170)/5,600 (Except for U5 model) 186 (250)/6,000 Maximum torque N⋅m (kgf-m, ft-lb)/rpm 225 (22.9, 166)/3,600 (U5 model) 225 (22.9, 166)/4,000 (Except for U5 model) 339 (34.5, 250)/3,600

SPC-3 SPECIFICATIONS LEGACY C: ELECTRICAL D: TRANSMISSION 5MT: 5-forward speeds with synchromesh and 1-reverse 4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse 5AT: Electronically controlled fully-automatic, 5-forward speeds and 1-reverse DSPD: Dry Single Plate Diaphragm TCC: Torque Converter Clutch E: STEERING F: SUSPENSION Model 2.5 L SOHC 2.5 L DOHC turbo Ignition timing (at idling) BTDC 13° MT = 12° AT = 17° Spark plug Type and manufacturer CHAMPION: RC10YC4 NGK: FR5AP-11 NGK: ILFR6B Generator 12V — 110A Battery Type and capacity (5HR) MT 12V — 48AH (55D23L) AT 12V — 52AH (75D23L) Model 2.5 L SOHC 2.5 L DOHC turbo Transmission type 5MT 4AT 5MT 5AT Clutch type DSPD TCC DSPD TCC Gear ratio 1st 3.454 2.785 3.166 3.540 2nd 2.062 1.545 1.882 2.264 3rd 1.448 1.000 1.296 1.471 4th 1.088 0.694 0.972 1.000 5th 0.780 — 0.738 0.834 Rev. 3.333 2.272 3.333 2.370 Reduction gear (Front) 1st reduction Type of gear — Helical — Helical Gear ratio — 1.000 — 1.000 Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid Gear ratio 3.900 4.111 4.111 3.272 Reduction gear (Rear) Transfer reduction Type of gear Helical — Helical — Gear ratio 1.000 — 1.000 — Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid Gear ratio 3.900 4.111 4.111 3.272 Model 2.5 L SOHC 2.5 L DOHC turbo Type Rack and Pinion Turns, lock to lock 3.2 2.8 Minimum turning diameter m (ft) Center of tire width to center of tire width 10.8 (35.4) Wall to wall 11.6 (38.1) Front Macpherson strut type suspension Rear Multi-link type suspension

SPC-4 SPECIFICATIONS LEGACY G: BRAKE H: TIRE I: CAPACITY Model 2.5 L SOHC 2.5 L DOHC turbo Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Rear Disc brake Ventilated disc brake Parking Brake Mechanical on rear brakes Model 2.5 L SOHC 2.5 L DOHC turbo Wheel size 16 × 6 1 / 2 JJ 17 × 7JJ Tire size P205/55 R16 89H 215/45 ZR17 Type Steel belted radial, Tubeless Model 2.5 L SOHC 2.5 L DOHC turbo 5MT 4AT 5MT 5AT Fuel tank 2 (US gal, Imp gal) 64 (16.9, 14.1) Engine oil Capacity (at overhaul) 2 (US qt, Imp qt) 4.4 (4.7, 3.9) 4.9 (5.2, 4.3) Filling amount of engine oil 2 (US qt, Imp qt) At replacement of engine oil and oil filter 4.2 (4.4, 3.7) 4.3 (4.5, 3.8) At replacement of engine oil only 4.0 (4.2, 3.5) Transmission gear oil 2 (US qt, Imp qt) 3.5 (3.7, 3.1) — 3.5 (3.7, 3.1) — ATF 2 (US qt, Imp qt) — 9.5 (10.0, 8.4) — 9.8 (10.4, 8.6) Front differential gear oil 2 (US qt, Imp qt) — 1.2 (1.3, 1.1) — 1.4 (1.5, 1.2) Rear differential gear oil 2 (US qt, Imp qt) 0.8 (0.8, 0.7) Power steering fluid 2 (US qt, Imp qt) 0.7 (0.7, 0.6) Engine coolant 2 (US qt, Imp qt) 6.4 (6.8, 5.6) 6.3 (6.7, 5.5) 7.3 (7.7, 6.4) 7.2 (7.6, 6.3)

SPC-5 SPECIFICATIONS LEGACY J: WEIGHT 1. US MODEL Model Sedan 2.5 L SOHC 2.5 i 2.5 i Limited 5MT 4AT 5MT 4AT Curb weight (C.W.) Front kg (lb) 798 (1,760) 806 (1,780) 818 (1,805) 826 (1,825) 813 (1,795) 821 (1,810) 833 (1,840) 841 (1,855) Rear kg (lb) 652 (1,440) 660 (1,455) 652 (1,440) 660 (1,455) 667 (1,470) 675 (1,490) 667 (1,470) 675 (1,490) Total kg (lb) 1,450 (3,200) 1,466 (3,235) 1,470 (3,240) 1,486 (3,280) 1,480 (3,265) 1,496 (3,300) 1,500 (3,310) 1,516 (3,345) Gross axle weight ratio (G.A.W.R) Front kg (lb) 1,040 (2,295) 1,040 (2,295) 1,040 (2,295) 1,040 (2,295) 1,040 (2,295) 1,040 (2,295) 1,040 (2,295) 1,040 (2,295) Rear kg (lb) 1,060 (2,335) 1,060 (2,335) 1,060 (2,335) 1,060 (2,335) 1,060 (2,335) 1,060 (2,335) 1,060 (2,335) 1,060 (2,335) Gross vehicle weight (G.V.W.) kg (lb) 1,960 (4,325) 1,960 (4,325) 1,960 (4,325) 1,960 (4,325) 1,960 (4,325) 1,960 (4,325) 1,960 (4,325) 1,960 (4,325) Option Vehicle Dynamics Control — — — — — — — — Power package — — — — ❍ ❍ ❍ ❍ Side airbag ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ Curtain airbag ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ Sunroof — — — — ❍ ❍ ❍ ❍ 17-in Alminum wheel — ❍ — ❍ — ❍ — ❍ Model Sedan 2.5 L DOHC turbo 2.5 GT 2.5 GT Limited 5MT 5AT 5MT 5AT Curb weight (C.W.) Front kg (lb) 828 (1,830) 858 (1,895) 843 (1,860) 873 (1,925) Rear kg (lb) 667 (1,470) 667 (1,470) 682 (1,505) 682 (1,505) Total kg (lb) 1,495 (3,300) 1,525 (3,365) 1,525 (3,365) 1,555 (3,435) Gross axle weight ratio (G.A.W.R) Front kg (lb) 1,040 (2,295) 1,040 (2,295) 1,040 (2,295) 1,040 (2,295) Rear kg (lb) 1,060 (2,335) 1,060 (2,335) 1,060 (2,335) 1,060 (2,335) Gross vehicle weight (G.V.W.) kg (lb) 2,010 (4,435) 2,010 (4,435) 2,010 (4,435) 2,010 (4,435) Option Vehicle Dynamics Control — — — — Power package — — ❍ ❍ Side airbag ❍ ❍ ❍ ❍ Curtain airbag ❍ ❍ ❍ ❍ Sunroof — — ❍ ❍ 17-in Alminum wheel — — — —

2005 Subaru Legacy Service & Repair Manual

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