Subaru Legacy I-II 1989-1999  BC/BF/BD/BG/BK Workshop Manual

This repair manual contains detailed instructions for repair and maintenance of the first and second generation Subaru Legacy. Includes:

EA82, EJ18, EJ20, EJ22, EJ25 engines - characteristics, disassembly, diagnostics.

Transmission (manual, automatic, AWD) - adjustments and repair.

Electrical Diagrams - fuses, relays, sensors.

Suspension, steering, brakes - a complete service manual.

Ideal for owners, mechanics and enthusiasts who want to keep their Legacy in excellent condition!

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1. Engine (EJ20, EJ22, EJ25)

🔹 Oil consumption (EJ25 SOHC 2.5L)

The EJ25 engine increases oil consumption after 150-200 thousand km.

Cause: wear of piston rings and valve stem seals.

Solution: replace rings, overhaul.

🔹 Overheating and breakdown of cylinder head gasket

More common on EJ25, less common on EJ20/EJ22.

Cause: overheating, weak cylinder head gasket.

Solution: install reinforced gaskets and check the cooling system.

🔹 Oil leak through seals and gaskets

Over time, crankshaft, camshaft, and valve cover seals leak.

Solution: replace seals when servicing the timing belt.

2. Cooling system

🔹 Cracks in the plastic radiator

Radiators with plastic tanks crack due to temperature changes.

Solution: replace with an aluminum radiator.

🔹 Thermostat failure

When the engine boils, the thermostat may jam.

Solution: timely replacement of the thermostat.

3. Gearbox and transmission (manual/automatic, AWD)

🔹 Weak 5-speed manual

Gears are engaged with a crunch, gears may fly out.

Solution: replace synchronizers, carefully shift.

🔹 Clutch wear

In cars with mechanics, the clutch may slip after 120-150 thousand km.

Solution: replace the disc and basket.

🔹 Automatic transmission may jerk when shifting

The reason is old oil or contamination of the valve body.

Solution: ATF oil change, valve body flush.

🔹 All-wheel drive clutch (automatic transmission) may jam

Symptom: Shocks when turning at low speeds.

Solution: replacing solenoids in the automatic transmission.

4. Electrics

🔹 Oxidation of ground contacts

Problems with starting, non-working sensors.

Solution: cleaning and processing contact connections.

🔹 Burnout of the heater control unit

Symptom: the heater stops working at certain speeds.

Solution: replacing the heater rheostat.

5. Body and suspension

🔹 Corrosion of arches, sills and rear cups

The most common problem of BG/BK (station wagon).

Solution: anti-corrosion treatment, re-welding.

🔹 Rapid wear of the front struts

On bad roads, the front struts lose rigidity.

Solution: Replace with KYB or Bilstein.

🔹 Suspension arms and silent blocks

Over time, the silent blocks of the front arms break.

Solution: Install polyurethane or reinforced rubber bushings.