Subaru Outback 1994–1999 BD/BG (Legacy Outback)  Workshop Manual

Welcome to the complete Subaru Outback BD/BG (1994-1999) repair and maintenance manual! This manual contains all the information you need to diagnose, repair, and maintain the first generation Subaru Outback, also known as the Legacy Outback.

What does the manual include?

🔧 Engines – specifications, disassembly, assembly and repair (2.2L EJ22, 2.5L EJ25)

⚙️ Transmission – manual and automatic transmission, all-wheel drive AWD

🛠️ Chassis and suspension – maintenance and adjustment of suspension elements

🔩 Brake system – disc brakes, handbrake, ABS

⚡ Electrical equipment – electrical circuits, fault diagnostics, connectors

🛑 Safety system – airbags (SRS), seat belts

🌡️ Cooling and fuel system – radiator, thermostat, fuel lines

🚗 Body and interior – repair and replacement of body elements, adjustment of doors and windows

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1. Cylinder head and engine overheating

🔧 Problem: The 2.5L EJ25 DOHC engine is prone to cylinder head gasket failures. This leads to coolant leakage, overheating, and major repairs.

✅ Solution: Install reinforced gaskets and regularly check the coolant level.

2. Oil and coolant leakage

🔧 Problem: Old seals and gaskets lose their tightness over time. The most vulnerable areas are:

Rear crankshaft oil seal

Camshaft oil seals

Oil pump gasket

✅ Solution: Replace the seals at every major maintenance, monitor the oil level.

3. Automatic transmission (4EAT)

🔧 Problem:

Long gear shifts

"Kicks" when shifting

Delay in engaging reverse gear

✅ Solution:

Timely replacement of transmission oil (every 40,000–50,000 km)

Cleaning solenoids and checking the valve body

4. Corrosion of the body and underbody

🔧 Problem: Due to age and climate features, rust appears on the arches, thresholds and underbody. Cars in regions with salt on the roads are especially affected.

✅ Solution: Anti-corrosion treatment, repair of rusty elements, installation of mudguards.

5. Suspension malfunctions

🔧 Problem:

The stabilizer struts and bushings wear out quickly

The front strut support bearings start to creak

✅ Solution:

Use reinforced parts (for example, polyurethane bushings)

Regularly check the condition of the struts and replace them if there is knocking

6. Electronics and wiring

🔧 Problem:

Burning out of climate control buttons

Oxidation of contacts on headlights and side lights

Problems with the heater motor

✅ Solution:

Clean the contacts, use dielectric grease

Check fuses and relays