Subaru Legacy 2000-2002 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Model Years Covered: 2000, 2001, 2002 Chassis Codes: BE, BH, BD, BG 👋 Introduction Market Position Vehicle Segment: Mid-size sedan/wagon Brand Positioning:...

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Stichworte: 2000 2001 2002 Car Cars Legacy Misc Subaru

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🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy

Model Years Covered:

2000, 2001, 2002

Chassis Codes:

BE, BH, BD, BG

👋 Introduction

Market Position

Vehicle Segment:

Mid-size sedan/wagon

Brand Positioning:

Known for All-Wheel Drive (AWD) capability, reliability, and boxer engine technology.

Competitive Analysis

Key Competitors:

Toyota Camry, Honda Accord, Nissan Altima, Ford Taurus, Mazda 626/Mazda6.

Key Features

Standard AWD:

Subaru's Symmetrical All-Wheel Drive system was a hallmark, offering enhanced traction and stability.

Boxer Engine:

Horizontally opposed (boxer) engines, contributing to a lower center of gravity and balanced weight distribution.

Durability:

Generally regarded as a durable and reliable vehicle, especially with proper maintenance.

Styling:

This generation (third generation) featured a more rounded and modern design compared to its predecessors.

📋 Manual Details

Coverage Areas

Documentation Type:

Workshop Service Repair Manual

Primary Coverage:

Repair and Overhaul Procedures

Assumed Technician Skill Level:

Fully conversant with general automobile practices

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Format:

Language

Language:

English

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed disassembly, inspection, repair, and reassembly of all engine components (e.g., cylinder heads, blocks, pistons, crankshafts, camshafts, valvetrain).

Engine Management:

Fuel injection, ignition system, sensors, actuators, engine control unit (ECU) diagnostics and programming, emission control systems (EVAP, EGR).

Transmission Manual:

Clutch system, gearbox disassembly, repair, and adjustment. Gear shift mechanisms.

Transmission Automatic:

Torque converter, hydraulic control system, valve body, planetary gear sets, electronic control unit (TCU) diagnostics and repair.

Drivetrain:

Front and rear differentials, driveshafts, CV joints, wheel bearings, propeller shafts, transfer cases (if applicable).

Suspension:

Front and rear suspension components (struts, shocks, control arms, bushings, ball joints, sway bars), alignment specifications.

Steering:

Power steering system (pump, rack, hoses), steering column, tie rods, steering angle sensor.

Brakes:

Disc and drum brake systems, hydraulic components (master cylinder, calipers, wheel cylinders, brake lines), ABS system components and diagnostics.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), horn, wipers, power windows, locks, mirrors.

Body And Frame:

Body panel removal and installation, door mechanisms, interior trim, glass replacement, structural repair procedures.

HVAC:

Air conditioning system (compressor, refrigerant, condenser, evaporator), heating system, climate control unit, blower motor, ducting.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, fuel pressure regulator.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, exhaust pipes, oxygen sensors.

Cooling System:

Radiator, coolant hoses, thermostat, water pump, cooling fan, heater core.

Procedures Included

Preventive Maintenance:

Scheduled maintenance tasks, fluid changes, filter replacements, belt inspections and replacements.

Diagnostics:

Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) and their meanings, sensor testing.

Repair And Overhaul:

Step-by-step instructions for component removal, repair, replacement, and reinstallation for all major vehicle systems.

Adjustment And Calibration:

Brake adjustments, clutch adjustments, steering wheel alignment, sensor calibration.

Electrical Troubleshooting:

Wiring diagrams, circuit testing procedures, component testing.

Component Replacement:

Detailed instructions for replacing common wear items and major components.

Specifications And Tolerances:

Torque specifications, clearances, runout measurements, and other critical tolerances for engine and chassis components.

Technical Depth

Depth Of Coverage:

Comprehensive, covering from basic maintenance to complex engine and transmission rebuilds.

Diagnostic Complexity:

Includes detailed diagnostic trees and component testing procedures for advanced troubleshooting.

Wiring Diagrams:

Detailed, system-specific wiring diagrams provided.

📊 Manual Specifications

File Format

Format:

Searchability:

Text-searchable PDF for easy information retrieval.

Printability:

Printable pages for on-site workshop use.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Binding:

N/A (PDF format)

Paper Type

Paper Type:

N/A (PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

EJ253

Engine Type 1:

2.5L SOHC Naturally Aspirated Flat-4 (Boxer)

Displacement 1:

2457 cc

Bore X Stroke 1:

99.5 mm x 79.0 mm

Compression Ratio 1:

9.7:1

Horsepower 1:

165 hp @ 5600 rpm

Torque 1:

166 lb-ft @ 4000 rpm

Engine Variant

Engine Code 2:

EJ224

Engine Type 2:

2.2L SOHC Naturally Aspirated Flat-4 (Boxer)

Displacement 2:

2171 cc

Horsepower 2:

140 hp @ 5600 rpm

Torque 2:

137 lb-ft @ 4400 rpm

Engine Code 3:

EJ254 (GT models)

Engine Type 3:

2.5L DOHC Naturally Aspirated Flat-4 (Boxer)

Horsepower 3:

165 hp @ 5600 rpm

Torque 3:

166 lb-ft @ 4000 rpm

Engine Code 4:

EJ255 (GT models, later production)

Engine Type 4:

2.5L DOHC Turbocharged Flat-4 (Boxer)

Horsepower 4:

212 hp @ 5600 rpm

Torque 4:

236 lb-ft @ 3600 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline

Ignition System:

Distributorless Electronic Ignition System (DEIS)

🔧 Transmission

Standard

Transmission Type Standard:

4-speed Automatic Transmission (with AWD system)

Optional

Transmission Type Optional:

5-speed Manual Transmission (with AWD system)

Features

AWD System Type:

Subaru Symmetrical All-Wheel Drive (Active AWD for automatics, viscous coupling for manuals).

Fluid Type

Automatic Transmission Fluid Spec:

Subaru Genuine ATF-HP or equivalent (check manual for specific PN)

Manual Transmission Fluid Spec:

Subaru Genuine Gear Oil API GL-5 75W-90 or equivalent.

📐 Dimensions

Exterior

Length Sedan:

186.4 inches (4735 mm)

Length Wagon:

187.6 inches (4765 mm)

Width:

68.7 inches (1745 mm)

Height Sedan:

56.1 inches (1425 mm)

Height Wagon:

57.7 inches (1465 mm)

Wheelbase:

104.1 inches (2645 mm)

Ground Clearance:

5.9 inches (150 mm)

Weights

Curb Weight Start:

3190 lbs (1447 kg) - 2.2L Manual Sedan

Curb Weight End:

3580 lbs (1624 kg) - 2.5GT Automatic Wagon

Wheels Tires

Wheelbase Sedan:

104.1 inches

Wheelbase Wagon:

104.1 inches

Wheel Bolt Pattern:

5x100mm

Standard Tire Size:

205/55R16 (various trims)

Optional Tire Size:

215/50R17 (GT trims)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

NHTSA Front Impact Passenger:

NHTSA Side Impact Front Driver:

NHTSA Side Impact Front Passenger:

NHTSA Side Impact Rear Driver:

NHTSA Side Impact Rear Passenger:

IIHS Frontal Offset Score:

IIHS Side Impact Score:

Active Features

Standard (4-wheel disc on most models, front disc/rear drum on some base models)

Traction Control:

Available, especially on higher trims and AWD models.

Passive Features

Airbags Front:

Driver and passenger front airbags standard.

Airbags Side:

Available front side-impact airbags on some models.

Seatbelts:

Three-point seatbelts for all occupants, pretensioners and force limiters for front seats.

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD player. Optional premium audio systems from Clarion or McIntosh were available on some trims.

Navigation:

Factory navigation systems were optional on higher trim levels, typically integrated into a double-DIN head unit.

Driver Assistance

Cruise Control:

Standard on most models.

Limited Driver Assistance:

This generation predates modern advanced driver-assistance systems (ADAS). Features like adaptive cruise control, lane departure warning, and automatic emergency braking were not available.

Connectivity

Auxiliary Input:

Not typically available on factory head units from this era. Aftermarket solutions are common.

Bluetooth:

Not available from the factory. Requires aftermarket installation.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles (6,000 km) or 6 months, whichever comes first, using synthetic oil. Check manual for specific recommendations.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months.

Cabin Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months (if equipped).

Spark Plug Replacement:

Iridium spark plugs: 60,000 miles (96,000 km). Platinum spark plugs: 30,000 miles (48,000 km). Check manual for specific engine type.

Timing Belt Replacement:

Not applicable for these models, as they utilize timing chains.

Fluid Specifications

Engine Oil Spec:

SAE 5W-30, API Service SG, SH, SJ, or ILSAC GF-2 certified synthetic oil recommended. Consult manual for exact PN.

Coolant Spec:

Subaru Super Coolant (blue) or equivalent long-life antifreeze. Check manual for capacity and type.

Brake Fluid Spec:

SAE J1703 or FMVSS No. 116 DOT 3.

Power Steering Fluid Spec:

Subaru Genuine Power Steering Fluid or Dexron III ATF. Consult manual for PN.

Known Issues

Head Gaskets:

While less common in this generation compared to earlier EJ engines, head gasket leaks can still occur, especially in high-mileage vehicles or those with improper cooling maintenance.

O2 Sensors:

Oxygen sensors can fail over time, leading to check engine lights and reduced fuel economy.

Suspension Bushings:

Worn suspension bushings (control arm, sway bar) can lead to knocking noises and degraded handling.

Automatic Transmission:

Some automatic transmissions may exhibit delayed shifting or torque converter shudder, especially with age and mileage. Regular fluid changes are critical.

Cv Joints:

Front CV joint boots can tear, leading to grease loss and potential joint failure if not addressed promptly.

📚 Vehicle History

Brand Heritage

Subaru Origins:

Founded in 1953, Fuji Heavy Industries (now Subaru Corporation) has a long history in aviation and automotive manufacturing.

AWD Tradition:

Subaru is renowned for its pioneering use and widespread adoption of All-Wheel Drive technology in passenger cars starting in the 1970s.

Model Evolution

Legacy Introduction:

The Subaru Legacy was first introduced in 1989 as a replacement for the Subaru Leone.

Third Generation Launch:

The 2000-2002 models represent the third generation of the Subaru Legacy, launched in 1999 for the 2000 model year.

Generation Characteristics:

This generation (chassis codes BE/BH for sedan/wagon) featured a significant redesign with a more contemporary exterior and interior, improved safety, and revised powertrains.

Production

Manufacturing Location:

Primarily manufactured in Japan (Gunma Plant).

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

The 2000-2002 Legacy received good safety ratings from the IIHS for its time, contributing to Subaru's reputation for safety.

Consumer Reports Ratings:

Generally rated as average to above average in reliability by Consumer Reports for this period, with some model year variations.