🏷️ Basic Information

Make:

Subaru

Model:

Outback

Year:

2002

Platform Code:

BD/BG/BK (Second Generation Outback)

Engine Code Primary:

EJ253 (2.5L SOHC Naturally Aspirated)

Engine Code Optional:

EJ254 (2.5L DOHC Turbocharged - 'GT' trim, less common in North America for 2002 model year)

Transmission Code Primary:

TZ1A3ZDAA (4-Speed Automatic)

Transmission Code Optional:

TG5D6C2YAA (5-Speed Manual)

👋 Introduction

Segment:

Mid-size Crossover SUV / Station Wagon with All-Wheel Drive standard.

Niche:

Known for its standard AWD, comfortable ride, and practical cargo space, appealing to families and those in inclement weather regions.

Competitors 2002:

Toyota RAV4, Honda CR-V, Ford Escape, Chevrolet Tracker, Nissan Xterra.

Standard AWD:

Symmetrical All-Wheel Drive is a core Subaru feature, providing enhanced traction and stability.

Horizontally Opposed Engine:

Subaru's signature Boxer engine layout contributes to a lower center of gravity for improved handling.

Practicality:

Ample cargo space, elevated ground clearance, and durable interior materials.

📋 Manual Details

Coverage:

Complete service, repair, and maintenance for the 2002 Subaru Outback

Estimated Pages:

~1500-2000 (typical for comprehensive factory service manuals)

Type:

Factory Service Manual (FSM) / Repair Manual

Language:

English

Format:

Downloadable Digital Format (likely PDF)

📖 Manual Coverage

Engine:

Detailed diagnostics, repair, overhaul, and specifications for EJ253 (2.5L SOHC) and EJ254 (2.5L DOHC Turbo) engines, including timing belt, lubrication, cooling, fuel injection, ignition, and emissions control systems.

Transmission:

Comprehensive coverage for 4-speed automatic (TZ1A series) and 5-speed manual (TG5 series) transmissions, including removal, installation, overhaul, clutch, torque converter, and shift control mechanisms.

Drivetrain:

All-Wheel Drive (AWD) system, viscous coupling center differential, front and rear differentials, axles, CV joints, and driveshafts.

Suspension:

Front and rear suspension components, struts, shock absorbers, control arms, bushings, coil springs, stabilizer bars, alignment procedures, and specifications.

Brakes:

Front and rear brake systems (disc brakes), ABS (Anti-lock Braking System), parking brake, hydraulic lines, master cylinder, calipers, rotors, pads, and bleeding procedures.

Steering:

Power steering system, steering rack, pump, fluid, tie rods, and alignment.

Electrical:

Wiring diagrams, fuse box layouts, relays, battery, charging system (alternator, starter), lighting, power windows, door locks, wipers, horn, and accessory circuits.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, A/C compressor, refrigerant, blower motor, climate controls, and cabin air filter replacement.

Body:

Body panel removal and installation, doors, hood, tailgate, bumpers, interior trim, glass, seals, and corrosion prevention.

Interior:

Dashboard, instrument cluster, seats, airbags, seatbelts, interior lighting, and sound insulation.

Emissions:

Emission control systems, catalytic converter, oxygen sensors, EGR system, evaporative emission control (EVAP), and OBD-II diagnostics.

Maintenance:

Routine maintenance tasks such as oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, timing belt inspection/replacement, brake pad service, and tire rotation.

Diagnostics:

Troubleshooting guides, diagnostic trouble codes (DTCs) interpretation, symptom-based diagnostics, and component testing procedures.

Repair:

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

Overhaul:

Detailed procedures for complete engine and transmission rebuilds, including component tolerances, torque specifications, and assembly sequences.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems, including power distribution, grounds, and signal pathways.

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission overhauls, advanced diagnostics, and component-level repair.

📊 Manual Specifications

File Type:

Digital (PDF recommended for searchability and portability)

Resolution:

High resolution, ensuring clarity of diagrams and text for printing.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Code:

EJ253

Configuration:

2.5L (2457cc) Naturally Aspirated SOHC Flat-4 (Boxer)

Bore X Stroke:

99.5 mm x 79.0 mm

Compression Ratio:

9.7:1

Horsepower:

165 hp @ 5,600 rpm

Torque:

166 lb-ft @ 4,000 rpm

Fuel Type:

Unleaded Regular (87 Octane)

Induction:

Multi-point Fuel Injection (MPI)

Ignition:

Distributorless Electronic Ignition (DS-IE)

Coolant Capacity:

Approx. 7.0 US quarts (6.6 Liters)

Oil Capacity W Filter:

Approx. 4.8 US quarts (4.5 Liters)

Recommended Oil:

SAE 5W-30 (API Service SG or higher)

Replacement Interval:

Every 90,000-105,000 miles or 7 years (whichever comes first), inspect more frequently.

Part Number Example:

Subaru 13028AA090 (example, verify specific application)

🔧 Transmission

Type Automatic:

4-Speed Automatic (TZ1A Series)

Automatic Fluid Capacity:

Approx. 4.0 US quarts (3.8 Liters) for a drain and fill.

Automatic Fluid Type:

Subaru ATF (Dexron III Equivalent)

Type Manual:

5-Speed Manual (TG5 Series)

Manual Fluid Capacity:

Approx. 2.2 US quarts (2.1 Liters)

Manual Fluid Type:

Subaru Manual Transmission Fluid (API GL-5, SAE 75W-90)

AWD System:

Symmetrical AWD with viscous coupling center differential for all variants.

📐 Dimensions

Length:

Approx. 187.4 inches (4760 mm)

Width:

Approx. 69.7 inches (1770 mm)

Height:

Approx. 61.8 inches (1570 mm)

Wheelbase:

Approx. 104.3 inches (2650 mm)

Ground Clearance:

Approx. 7.3 inches (185 mm)

Cargo Volume Behind Rear Seats:

Approx. 35.9 cubic feet (1017 liters)

Cargo Volume With Rear Seats Folded:

Approx. 67.8 cubic feet (1920 liters)

Curb Weight Approx:

3400-3600 lbs (1540-1630 kg), varies by trim and transmission

Towing Capacity:

Approx. 2,000 lbs (907 kg) with trailer brake, 1,500 lbs (680 kg) without trailer brake.

🛡️ Safety Features

NHTSA Frontal Driver:

5 Stars (for 2002 model year testing)

NHTSA Frontal Passenger:

5 Stars (for 2002 model year testing)

IIHS Side Impact:

Acceptable (varies by specific test configuration and equipment)

ABS:

Standard 4-wheel Anti-lock Braking System (ABS)

Traction Control:

Limited Slip Differential (part of AWD system), no dedicated Traction Control System (TCS) in the modern sense.

Airbags:

Front driver and passenger airbags. Optional side airbags in some configurations.

Seatbelts:

3-point height-adjustable front seatbelts with pretensioners, rear 3-point seatbelts.

Child Anchors:

LATCH (Lower Anchors and Tethers for Children) system in rear seats.

💡 Technology Features

Audio System:

Standard AM/FM stereo with CD player. Optional premium audio systems with multiple speakers.

Climate Control:

Manual climate controls. Some higher trims may feature automatic climate control.

Cruise Control:

Standard on most trims.

Power Accessories:

Power windows, power door locks, power mirrors standard on most trims.

🔧 Maintenance

Oil Change Interval:

Every 3,750 miles or 3 months (severe conditions) / 7,500 miles or 6 months (normal conditions), check owner's manual for specific recommendation.

Engine Air Filter:

Replace every 15,000 miles or 12 months, or as needed based on driving conditions.

Cabin Air Filter:

Replace every 15,000 miles or 12 months, or as needed.

Spark Plugs:

Replace every 60,000 miles with iridium-tipped plugs.

Brake Fluid:

DOT 3 or DOT 4

Power Steering Fluid:

Subaru Active Power Steering Fluid or equivalent.

Windshield Wiper Fluid:

Standard automotive windshield washer fluid.

Head Gaskets:

While more prevalent on earlier EJ engines, the 2002 models can still be susceptible to head gasket leaks. Look for coolant loss, milky oil, or white smoke.

Timing Belt Tensioner:

Tensioner failure can lead to belt slippage or breakage. The manual will detail inspection and replacement procedures.

Automatic Transmission Cooler:

Potential for leaks or clogs, particularly in high-mileage vehicles. Manual provides diagnostic and repair steps.

📚 Vehicle History

Subaru Origin:

Founded in 1953, originally Fuji Heavy Industries. Known for its pioneering use of the Boxer engine and Symmetrical All-Wheel Drive.

Outback Genesis:

Introduced in 1995 as the 'Legacy Outback,' a more rugged, lifted version of the Legacy station wagon.

Second Generation:

The 2002 model is part of the second generation (BD/BG/BK platform, 1996-2004), which saw styling updates and powertrain improvements.

Manufacturing Location:

Gunma Manufacturing Plant, Japan.

🏆 Awards & Recognition

Safety Awards:

Consistently received good safety ratings from NHTSA and IIHS for its segment at the time of release.