Subaru Legacy III 1998-2003 (BE/BH)  Workshop Manual

This is a detailed repair and maintenance manual for the third generation Subaru Legacy. Includes information on engines, transmission, suspension, electrical, all-wheel drive system and body work. Contains diagrams, troubleshooting instructions and maintenance recommendations, helping owners and mechanics in repairing and operating the car.

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1. Engines and their problems

Main engines:

2.0 EJ201 / EJ202 – naturally aspirated, 125-138 hp

2.5 EJ251 / EJ252 – naturally aspirated, 156-165 hp

3.0 EZ30 – naturally aspirated, 209-220 hp (H6 version).

2.0 EJ205 / 2.0 EJ208 – turbocharged, 260-280 hp (GT, B4 RSK).

🔻 Typical engine problems:

Overheating of 2.5-liter engines (EJ251/EJ252) – weak point of the cylinder head gasket, prone to burnout and antifreeze leaks.

Oil consumption (EJ20, EJ25, EZ30) – increased oil consumption due to wear of piston rings.

Crankshaft and camshaft sensors – may fail, causing problems with starting.

Knocks and vibrations – associated with wear of hydraulic compensators and camshaft beds.

Turbine (on EJ205/EJ208) – overheating and coking of oil if not replaced in a timely manner.

🛠 How to avoid problems:

Monitor the coolant, change the thermostat in time.

Use high-quality oil and change it every 5-7 thousand km.

Check the condition of the cylinder head if it overheats.

Turbocharged versions require high-quality fuel (98th gasoline).

2. Transmission

Gearboxes:

5-speed manual transmission (manual) – reliable, but requires oil check.

4-АКПП (4EAT) – an old but reliable automatic, prone to overheating.

5-АКПП (5EAT) – a more modern version, but sensitive to oil quality.

There were no CVTs in this generation!

🔻 Problems:

Automatic transmission: jerking when shifting – due to wear of the valve body or contaminated oil.

Manual transmission: gears may fly out, especially 2nd and 3rd.

Transfer case and differentials: oil leaks, wear of the viscous coupling.

🛠 Tips:

Change the oil in the automatic/manual transmission every 40-50 thousand km.

Check the oil level in the transfer case and gearboxes.

Do not slip for a long time – overheating can kill the all-wheel drive clutch.

3. Electrics and wiring

🔻 Problem areas:

Fuse box glitches – due to oxidation of contacts.

Problems with electric windows and central locking – motors break or buttons stick.

Burnt-out headlights – bad contacts and outdated wiring.

ABS sensor failure – often fails due to dirt or broken wires.

🛠 How to avoid:

Clean the contacts in the connectors and fuses once a year.

Monitor the condition of the generator and battery.

Check the wiring in the doors – it often wears out in the corrugations.

4. Chassis

Legacy 3 received a stiffer suspension, but it remained reliable. However, over time, problems appear:

🔻 Typical malfunctions:

Knocks and squeaks in the front suspension – wear of the silent blocks of the levers.

Rear shock absorbers – especially on station wagons (BH) often leak.

Wear of wheel bearings – accompanied by a hum when driving.

Steering rack play – appears due to wear of bushings.

🛠 Tips:

It is better to replace silent blocks with reinforced polyurethane ones.

Use high-quality shock absorbers (KYB, Sachs).

Check wheel alignment after replacing parts.

5. Body and corrosion

🔻 Problem areas:

Rear arches, thresholds, underbody – especially on cars operated in regions with salt.

Front subframe – can rot at the attachment points.

Rear door of a station wagon – rust spots often appear near the glass.

🛠 Tips:

Treat hidden cavities with anti-corrosion agent once every 2-3 years.

Wash the underbody after winter.

If rust appears, immediately remove and treat the metal.