Segment:
Mid-size crossover SUV / Wagon, known for its All-Wheel Drive (AWD) system and wagon-like utility.
Competitors:
Ford Escape, Honda CR-V, Toyota RAV4, Nissan X-Trail (not all directly comparable but in the same general utility vehicle space).
Platform Advantage:
Subaru's symmetrical All-Wheel Drive system as standard across most trims, offering superior traction and handling in various conditions.
Design Philosophy:
Practicality, all-weather capability, and a focus on driver engagement, often appealing to outdoorsy individuals.
Years Covered:
2002, 2003, 2004, 2005, 2006, 2007
Estimated Page Count:
Over 2000 pages (typical for a complete workshop manual of this era)
Type:
Complete Workshop Service Repair Manual
Powertrain:
Engine mechanical, fuel system, ignition system, lubrication system, cooling system, exhaust system, engine control systems (ECM/ECU), automatic transmission (AT), manual transmission (MT), transfer case, differentials (front and rear), driveshafts, CV joints.
Chassis:
Suspension (front and rear), steering system (power steering, steering column), brakes (hydraulic system, ABS, parking brake), wheels and tires.
Electrical:
Wiring diagrams, battery, charging system, starting system, lighting system, instrument cluster, power accessories (windows, mirrors, locks), audio system, climate control system, airbags (SRS), body control modules (BCM).
Body And Frame:
Exterior body panels, interior trim, doors, hood, tailgate, bumpers, glass, underbody structure, collision repair information (limited).
Maintenance:
Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid, differential fluid), filter replacements (oil, air, fuel, cabin), spark plug replacement, belt inspection and replacement.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics, testing procedures for various components.
Repair Rebuild:
Component removal and installation, engine overhaul, transmission overhaul, brake caliper and rotor replacement, suspension component replacement, steering rack replacement, electrical component repair.
Specifications Data:
Torque specifications, clearances, fluid capacities, electrical system specifications, engine control data, diagnostic specifications.
Depth:
Comprehensive. Covers everything from basic fluid checks and filter changes to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring schematics.
Searchability:
Searchable text content for quick access to information.
Quality:
High-resolution scans ensuring clarity of diagrams, schematics, and text.
Binding:
N/A (Downloadable Digital Format)
Paper Type:
N/A (Downloadable Digital Format)
Engine Code And Type:
2.5L Naturally Aspirated SOHC EJ253 Boxer-4 (most common for Outback), also 3.0L DOHC EZ30D Boxer-6 (H6) available on higher trims.
Horsepower 2 5L:
Approximately 165-175 hp @ 5600-6000 rpm (depending on year and exact variant)
Torque 2 5L:
Approximately 162-166 lb-ft @ 4000 rpm (depending on year and exact variant)
Horsepower 3 0L:
Approximately 212-250 hp @ 6000 rpm (depending on year and exact variant)
Torque 3 0L:
Approximately 208-217 lb-ft @ 4200 rpm (depending on year and exact variant)
Induction:
Multi-point fuel injection (MPI)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended for H6 engine, 87 octane minimum for 2.5L)
Engine Layout:
Horizontally opposed (Boxer) engine
Valve Train:
SOHC (Single Overhead Camshaft) for 2.5L, DOHC (Double Overhead Camshaft) for 3.0L
Transmission Type Standard:
4-speed Automatic Transmission (4EAT)
Transmission Type Optional:
5-speed Manual Transmission (5MT) - Less common on Outback models, more prevalent on Legacy sedan/wagon
AWD System:
Subaru's Symmetrical All-Wheel Drive system integrated with the transmission. For automatic transmissions, typically a viscous coupling center differential. For manual transmissions, usually a viscous coupling limited-slip center differential.
Automatic Transmission Fluid:
Subaru Genuine ATF HP or equivalent (Dexron III/Mercon compatible fluids may be acceptable but consult manual for exact specification).
Manual Transmission Fluid:
Subaru Genuine 75W-90 GL-5 Gear Oil or equivalent.
Wheelbase:
Approximately 104.3 inches (2649 mm)
Length:
Approximately 187.2 inches (4755 mm)
Width:
Approximately 70.1 inches (1781 mm)
Height:
Approximately 60.4 inches (1534 mm)
Cargo Volume Rear Seats Up:
Approximately 31.1 cubic feet (0.88 m³)
Cargo Volume Rear Seats Folded:
Approximately 68.2 cubic feet (1.93 m³)
Curb Weight:
Approximately 3400-3700 lbs (1542-1678 kg) depending on engine and trim.
Towing Capacity:
Typically rated for 2000 lbs (907 kg) when properly equipped.
Wheelbase:
5x100 mm bolt pattern
Standard Tire Size:
215/60R16 or 225/55R17 depending on trim level.
NHTSA Front Impact Driver:
5 Stars (for comparable models from this generation)
NHTSA Front Impact Passenger:
5 Stars (for comparable models from this generation)
IIHS Front Offset Crash Rating:
Good (for comparable models from this generation)
AWD:
Standard Symmetrical All-Wheel Drive.
ABS:
Standard Anti-lock Braking System (ABS).
Traction Control:
Available Traction Control System (TCS) and/or Vehicle Stability Control (VDC) on higher trims or later model years within this range.
Airbags:
Front dual-stage airbags, front side-impact airbags, available curtain airbags (side-impact and curtain airbags became more common in later years).
Seatbelts:
Three-point seatbelts with pretensioners and load limiters for front occupants.
Audio System:
Factory standard AM/FM/CD audio system, with optional premium sound systems and subwoofer on higher trims. Aux input or iPod integration may be present on later models within this range, or easily added with aftermarket kits.
Navigation:
Optional factory-installed GPS navigation system available on select higher trim levels.
Cruise Control:
Standard electronic cruise control system.
Climate Control:
Manual or automatic climate control systems depending on trim level.
Power Accessories:
Power windows, power door locks, power mirrors are standard or available features.
Engine Oil And Filter:
Every 3,750 miles (6,000 km) or 3 months for severe driving conditions; every 7,500 miles (12,000 km) or 6 months for normal driving conditions (always consult manual for specific recommendation based on driving style and environment).
Service Intervals Coolant
Coolant Replacement:
Initial replacement at 30,000 miles (48,000 km) or 24 months, then every 15,000 miles (24,000 km) or 12 months thereafter.
Service Intervals Filters
Air Filter Replacement:
Inspect every 15,000 miles (24,000 km) or 12 months, replace as needed. Replace at 30,000 miles (48,000 km) if driving in dusty conditions.
Engine Oil Type:
5W-30 (API SG or higher) for 2.5L and 3.0L engines. Consult manual for specific API certification and viscosity grade recommendations.
Coolant Type:
Subaru Super Coolant (blue) or equivalent ethylene glycol-based coolant with long-life additives. Do not mix with other types.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Head Gaskets:
While less prevalent than in earlier generations, some EJ series engines can experience head gasket leaks. The manual will provide diagnostic and repair procedures.
Cv Joints:
Front and rear CV joints and boots are subject to wear and tear, especially with off-road use or improper handling. Manual covers inspection and replacement.
Automatic Transmission Shifting:
Some users report occasional rough shifting or delayed engagement. Manual offers diagnostic procedures for the transmission control unit and hydraulic system.
Power Steering Pump:
Wear can lead to noise or reduced assist. Manual details fluid checks and pump replacement.
Subaru Identity:
Subaru is renowned for its engineering, particularly its Boxer engines and Symmetrical All-Wheel Drive systems, often associated with reliability and capability in adverse weather.
Generation Introduction:
The Subaru Outback transitioned from being a trim level of the Legacy station wagon to its own distinct model in 1996. The generation covered by this manual (2002-2007) is the second generation of the standalone Outback model (chassis codes BP/BL).
Key Changes Within Generation:
Mid-cycle refresh occurred around 2004-2005, introducing updated styling, interior features, and minor powertrain enhancements. Introduction of the 3.0L H6 engine as an option.
Manufacturing Locations:
Primary manufacturing was in Japan.
AWD Reputation:
Subaru's Symmetrical AWD system consistently receives praise for its all-weather capability and handling, often cited as a key selling point in independent reviews.
Safety Awards:
Models from this era frequently earned good safety ratings from organizations like IIHS and NHTSA, reflecting Subaru's commitment to passenger safety.
Consumer Reports Reliability:
Consumer Reports often rated Subaru vehicles favorably for reliability and owner satisfaction during this period, though specific ratings can vary by model year and component.
