🏷️ Basic Information

Make:

Subaru

Model:

Legacy Outback

Model Generation:

Second Generation

Model Years Covered:

1998-2004

Platform Code:

BD/BG/BK

Engine Codes Common:

EJ25D (2.5L SOHC), EJ251 (2.5L DOHC), EJ22E (2.2L SOHC)

👋 Introduction

Vehicle Segment:

Mid-size Station Wagon / Crossover SUV

Key Differentiator:

Standard Symmetrical All-Wheel Drive system, robust build, comfortable ride, practical cargo space.

Primary Competitors:

Ford Explorer, Toyota RAV4, Honda CR-V, Nissan Pathfinder, Volvo V70/XC70 (during its era)

Brand Philosophy:

Subaru's focus on all-weather capability, safety, and reliability.

Benefits For Owner:

Empowers owners to perform maintenance and repairs, diagnose issues, and save on service costs.

Benefits For Mechanic:

Provides factory-level data for efficient and accurate repair procedures.

📋 Manual Details

Coverage Scope:

Full Service, Repair, Workshop, Diagnostics, Maintenance, Troubleshooting, Electrical Schematics, Body Repair

Estimated Page Count:

Approximately 2000+ pages (typical for comprehensive factory service manuals of this era)

Type:

Factory Service Manual / Workshop Manual

Language:

English

Format:

Digital Download (PDF/Similar)

📖 Manual Coverage

Engine Mechanical:

Engine removal/installation, disassembly/assembly, cylinder head, pistons, crankshaft, camshafts, timing belt/chain, lubrication system, cooling system, intake and exhaust systems.

Engine Performance:

Fuel injection system (MPI), ignition system, emissions control systems (EVAP, EGR), engine control module (ECM) diagnosis and troubleshooting.

Transmission:

Automatic Transmission (4EAT/4AT) and Manual Transmission (5MT/4MT): removal/installation, disassembly/assembly, torque converter, valve body, clutch operation, gear inspection and adjustment.

Drivetrain:

All-Wheel Drive (AWD) system, front/rear differentials, driveshafts, CV joints, wheel bearings.

Suspension:

Front suspension (struts, control arms, ball joints, sway bar), rear suspension (multi-link, struts, trailing arms), wheel alignment specifications.

Steering:

Power steering system, steering column, steering rack/gearbox, tie rods, power steering fluid type and capacity.

Brakes:

Front/rear disc brakes, ABS system, brake fluid type and capacity, hydraulic system, parking brake operation and adjustment.

Electrical:

Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior), fuses, relays, wiring diagrams, instrument cluster, power windows, power locks, mirrors, wiper system.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, refrigerant types, component testing (compressor, evaporator, condenser), blower motor.

Body:

Body panel removal/installation, doors, hood, trunk, bumpers, interior trim, glass replacement, sealant application, structural repair guidelines.

Chassis:

Frame specifications, rust prevention, undercoating procedures.

Routine Maintenance:

Oil change, filter replacement, fluid checks and top-offs, tire rotation, spark plug replacement, air filter replacement, coolant flush, brake fluid flush.

Diagnostics Troubleshooting:

On-board diagnostics (OBD-II), fault code retrieval, symptom-based troubleshooting charts, common failure points, electrical diagnosis using multimeter.

Major Repairs:

Engine rebuilds, transmission overhaul, head gasket replacement, clutch replacement, suspension component replacement, brake caliper replacement.

Component Installation:

Installation of new or replacement parts for all major systems, including turbocharger (if applicable to specific trims), catalytic converter, muffler, alternator, starter, AC compressor.

Body Paint Refinish:

Repair of dents, scratches, and panel damage; surface preparation, primer application, paint application, clear coat, polishing.

Depth Level:

Comprehensive: Covers from basic preventative maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.

📊 Manual Specifications

File Type:

PDF (Portable Document Format) or similar searchable digital format

Searchability:

Searchable text for quick information retrieval

Print Quality:

High-resolution printable pages

Compatibility:

Compatible with PC, Mac, tablets, and smartphones

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

License Type:

No Expiry Dates, No Extra Fees (Perpetual Use License)

⚙️ Engine Specifications

Engine 2 5L Sohc Ej25D:

2.5L Naturally Aspirated SOHC Flat-4 (EJ25D), 167 hp @ 5700 rpm, 162 lb-ft @ 4000 rpm, Multi-Point Fuel Injection (MPI).

Engine 2 5L DOHc Ej251:

2.5L Naturally Aspirated DOHC Flat-4 (EJ251), 165 hp @ 5600 rpm, 166 lb-ft @ 4000 rpm, Multi-Point Fuel Injection (MPI).

Engine 2 2L Sohc Ej22E:

2.2L Naturally Aspirated SOHC Flat-4 (EJ22E), 135 hp @ 5500 rpm, 135 lb-ft @ 4400 rpm, Multi-Point Fuel Injection (MPI). Primarily for earlier models within the 1998-2004 range.

0 60 Mph Typical:

Approximately 9.0-10.5 seconds (depending on engine and transmission)

Fuel Type:

Unleaded Gasoline (Regular 87 octane recommended, premium may be specified for certain high-performance variants or conditions)

Fuel Delivery:

Sequential Multi-Point Fuel Injection (MPI)

ECU Type:

Subaru Engine Control Unit (ECU), typically OBD-II compliant.

Coolant Type:

Ethylene Glycol based coolant (e.g., Subaru Super Coolant or equivalent).

Oil Capacity Typical:

4.5 - 5.0 US quarts (4.3 - 4.7 liters) with filter, depending on engine variant.

🔧 Transmission

Automatic Transmission:

4-Speed Automatic Transmission (4EAT/4AT) with Lock-Up Torque Converter and AWD.

Manual Transmission:

4-Speed Manual Transmission (4MT) or 5-Speed Manual Transmission (5MT), both with Symmetrical All-Wheel Drive.

AWD System:

Symmetrical All-Wheel Drive standard on all models, typically with a viscous coupling center differential.

Automatic Transmission Fluid:

Subaru ATF-HP or Dexron-III/Mercon compatible fluid.

Manual Transmission Fluid:

Gear Oil API GL-5, SAE 75W-90.

📐 Dimensions

Length Typical:

Approx. 187.4 inches (4760 mm)

Width Typical:

Approx. 69.3 inches (1760 mm)

Height Typical:

Approx. 61.4 inches (1560 mm)

Wheelbase Typical:

Approx. 104.3 inches (2650 mm)

Ground Clearance Typical:

Approx. 8.0 inches (203 mm)

Curb Weight Typical:

Approx. 3200 - 3500 lbs (1450 - 1590 kg)

Cargo Volume Behind Rear Seats:

Approx. 35.3 cubic feet (1000 liters)

Cargo Volume With Rear Seats Folded:

Approx. 73.8 cubic feet (2090 liters)

🛡️ Safety Features

NHTSA Front Impact Driver:

5-Star (for models tested)

NHTSA Front Impact Passenger:

5-Star (for models tested)

IIHS Front Offset Score:

Good (for models tested)

Airbags:

Dual front airbags, optional side airbags (availability varies by trim and year).

Seatbelts:

3-point front and rear seatbelts, pretensioners for front seats.

Rollover Protection:

Reinforced body structure, Subaru's Ring-Shaped Reinforcement Frame.

ABS:

Anti-lock Braking System (ABS) standard on most models.

Traction Control:

Traction control system (TCS) optional or standard on higher trims/later years.

💡 Technology Features

Audio System:

Factory-installed AM/FM/CD player, often with cassette tape functionality. Speaker configurations vary by trim.

Climate Control:

Manual or automatic climate control systems, depending on trim level.

Cruise Control:

Standard cruise control system.

Keyless Entry:

Available keyless entry and security system on higher trims.

Power Accessories:

Power windows, power door locks, power mirrors are common features.

Headlight Type:

Halogen headlights; projector-style headlights available on some higher trims.

🔧 Maintenance

Oil And Filter Change:

Every 3,750 miles (6,000 km) or 3.75 months, or 7,500 miles (12,000 km) or 7.5 months with synthetic oil (check owner's manual for specific recommendation).

Air Filter Replacement:

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

Spark Plug Replacement:

Every 30,000 miles (48,000 km) for standard plugs, potentially longer for platinum/iridium plugs (check specific engine and plug type).

Timing Belt Replacement:

Crucial: Every 60,000 - 105,000 miles (96,000 - 168,000 km) or 5-7 years, as it's an interference engine. Includes tensioner and idler pulleys.

Coolant Flush:

Every 30,000 miles (48,000 km) or 2-3 years.

Engine Oil Viscosity Typical:

5W-30 (check owner's manual for specific recommendations based on climate).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid Type:

Subaru Genuine Power Steering Fluid or Dexron-III/Mercon compatible fluid.

Head Gasket Leaks:

Common on EJ25D engines (pre-2000) due to design flaws. EJ251 and later engines generally improved but can still be affected. Manual provides detailed replacement procedure.

Automatic Transmission Problems:

Some early 4EAT transmissions can develop shifting issues or solenoid failures. Regular fluid changes are critical. Manual covers diagnostic procedures.

Suspension Wear:

Worn control arm bushings, ball joints, and struts are common due to age and mileage. Manual provides replacement and alignment specs.

Cv Joint Boots:

Torn CV joint boots can lead to premature failure. Manual details inspection and replacement.

Oil Filter Example:

Subaru Part # 15208AA001 (or equivalent aftermarket brands)

Timing Belt Kit Example:

Subaru Part # 13028AA080 (includes belt, tensioner, idlers - check specific application)

📚 Vehicle History

Subaru Identity:

Subaru, the automotive division of Subaru Corporation (formerly Fuji Heavy Industries), known for its boxer engines and Symmetrical All-Wheel Drive.

Outback Introduction:

The Outback was introduced as a distinct model in 1995, evolving from the Legacy wagon with increased ground clearance and rugged styling cues, defining the 'crossover wagon' segment.

Second Generation Features:

This generation (BD/BG/BK chassis) saw styling updates, improved interior, and refinement of the AWD system and boxer engines.

Manufacturing Location:

Japan (Ota, Gunma Prefecture)

🏆 Awards & Recognition

Safety Awards General:

Subaru vehicles of this era often received positive safety ratings from organizations like IIHS and NHTSA due to their robust construction and AWD system. (Specific awards would vary by year and trim, details often found in road tests of the period).

Consumer Reports Reliability:

General reliability ratings varied by year and engine, with the EJ25D engines in earlier models experiencing more issues than later DOHC variants. This manual helps address and mitigate those issues.

Emissions Compliance:

Vehicles comply with federal emissions standards for their respective model years; manual covers emissions system diagnosis and repair.