2002 SUBARU LEGACY Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 2002 Codes Chassis Code: BE/BH Platform: Subaru front-engine, all-wheel-drive platform 👋 Introduction Market Position Segment: Mid-size sedan and wagon, known for...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy

Year:

Codes

Chassis Code:

BE/BH

Platform:

Subaru front-engine, all-wheel-drive platform

👋 Introduction

Market Position

Segment:

Mid-size sedan and wagon, known for its standard All-Wheel Drive.

Standard Symmetrical All-Wheel Drive and Boxer engine configuration.

Competitive Analysis

Competitors:

Toyota Camry, Honda Accord, Nissan Altima, Mazda 6.

Key Features

Features:

Symmetrical AWD, horizontally-opposed Boxer engines, comfortable ride, good build quality.

Manual Value Proposition

Value:

Provides professional-level repair and maintenance information essential for DIY enthusiasts and independent shops.

📋 Manual Details

Coverage Areas

Coverage:

Comprehensive service and repair information for all systems.

Page Count

Pages:

Approximately 1500+

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

2.5L Naturally Aspirated (EJ253), 2.5L Turbocharged (EJ255/EJ257 - GT models)

Fuel System:

Fuel injection, fuel pump, lines, tank, emissions control (EVAP).

Ignition System:

Ignition timing, spark plugs, coils, ignition control module.

Cooling System:

Radiator, thermostat, water pump, hoses, coolant specifications.

Exhaust System:

Exhaust manifold, catalytic converter, muffler, oxygen sensors.

Transmission:

4-speed automatic (4EAT), 5-speed manual (TY754).

Drivetrain:

All-Wheel Drive (AWD) system, differentials, driveshafts, CV joints.

Suspension:

Front struts, rear struts, control arms, bushings, coil springs, stabilizer bars.

Steering:

Power steering system, pump, rack and pinion, steering column.

Brakes:

Front ventilated discs, rear solid discs (standard), ABS system, brake fluid specifications.

Electrical System:

Battery, charging system, starter, lighting, fuses, relays, wiring diagrams.

HVAC:

Air conditioning, heating, climate control panel, blower motor, refrigerant.

Body Exterior:

Body panels, doors, hood, trunk, glass, trim, bumpers.

Body Interior:

Seats, dashboard, door panels, headliner, carpeting.

Chassis And Frame:

Frame structure, body mounting points, corrosion protection.

Diagnostic Troubleshooting:

OBD-II diagnostic trouble codes (DTCs), symptom-based troubleshooting guides.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, tune-ups.

Repair:

Detailed step-by-step repair procedures for all major components and systems.

Diagnostics:

Troubleshooting procedures, diagnostic flowcharts, pinpoint tests.

Adjustment:

Wheel alignment, parking brake adjustment, clutch adjustment.

Removal Installation:

Component removal and installation procedures (e.g., engine, transmission, suspension components).

Specifications Data:

Torque specifications, clearances, fluid capacities, pressure readings.

Wiring Diagrams:

Comprehensive electrical system wiring diagrams for all circuits.

Body Repair:

Dent repair, panel replacement, glass replacement, seam sealer application.

Technical Depth

Depth:

Extensive, covering everything from basic maintenance to complete engine and transmission rebuilds.

Diagnostic Capability:

Advanced diagnostic procedures, including oscilloscope usage and sensor testing.

Rebuild Procedures:

Detailed instructions for rebuilding engines, transmissions, and other major components.

📊 Manual Specifications

File Format

Format Details:

PDF (Portable Document Format), searchable text, printable.

Print Quality

Quality:

High-resolution scans ensuring clarity of diagrams and text.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code Na:

EJ253

Displacement Na:

2.5 Liters (2498 cc)

Configuration Na:

Naturally Aspirated, Boxer-4 Cylinder

Horsepower Na:

165 hp @ 5600 rpm

Torque Na:

166 lb-ft @ 4000 rpm

Turbo Engine

Engine Code Turbo:

EJ255 (GT models), EJ257 (GT-Limited)

Displacement Turbo:

2.5 Liters (2457 cc)

Configuration Turbo:

Turbocharged, Boxer-4 Cylinder

Horsepower Turbo:

220 hp @ 5600 rpm (EJ255), 230 hp @ 5600 rpm (EJ257)

Torque Turbo:

236 lb-ft @ 3600 rpm (EJ255), 235 lb-ft @ 4000 rpm (EJ257)

Fuel System

Fuel Type:

Unleaded Gasoline

Injection Type:

Multi-port Electronic Fuel Injection (MPI)

Ignition Type:

Distributorless Electronic Ignition (Coil-on-plug for turbo models)

🔧 Transmission

Standard

Type Manual:

5-speed Manual

Transmission Code Manual:

TY754

Optional

Type Automatic:

4-speed Automatic

Transmission Code Automatic:

Features

Drivetrain System:

Symmetrical All-Wheel Drive (AWD) for both manual and automatic transmissions.

Fluid Spec Automatic:

Subaru ATF HP, Dexron III equivalent.

Fluid Spec Manual:

Subaru Extra-S Gear Oil (75W-90 GL-5) or equivalent.

📐 Dimensions

Exterior

Length:

189.8 inches (4820 mm)

Width:

69.7 inches (1770 mm)

Height:

56.1 inches (1425 mm)

Wheelbase:

104.3 inches (2650 mm)

Ground Clearance:

5.7 inches (145 mm)

Weights

Curb Weight Na:

Approximately 3200 - 3400 lbs (1450 - 1540 kg)

Curb Weight Turbo:

Approximately 3400 - 3600 lbs (1540 - 1630 kg)

Cargo

Trunk Volume:

Approximately 14.1 cubic feet (sedan), 37.7 cubic feet with rear seats up (wagon)

🛡️ Safety Features

Ratings

NHTSA Front Driver:

NHTSA Front Passenger:

IIHS Side Impact:

Acceptable

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Available on some higher trims.

Passive Features

Airbags:

Front airbags, available side airbags.

Seatbelts:

Front and rear three-point seatbelts, pretensioners.

Child Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD stereo with optional premium sound system, cassette player often included.

Navigation:

Rarely factory-equipped, typically aftermarket.

Driver Assistance

Cruise Control:

Standard on most models.

Connectivity

Connectivity Options:

Limited to basic audio connectivity, no modern Bluetooth or USB integration from the factory.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 3 months (severe conditions) / Every 7,500 miles or 7.5 months (normal conditions).

Air Filter Replacement:

Every 30,000 miles or 30 months.

Spark Plug Replacement:

Every 60,000 miles (copper plugs) / 100,000 miles (iridium plugs).

Transmission Fluid Change Auto:

Every 30,000 miles (severe) / 60,000 miles (normal).

Transmission Fluid Change Manual:

Every 30,000 miles (severe) / 60,000 miles (normal).

Coolant Flush:

Every 30,000 miles or 30 months.

Fluid Specifications

Engine Oil Type:

SAE 5W-30, API SG or higher (check owner's manual for specific viscosity)

Coolant Type:

Subaru Super Coolant (50/50 mix of Subaru Super Coolant and distilled water)

Brake Fluid Type:

DOT 3 or DOT 4

Power Steering Fluid:

Subaru Genuine Power Steering Fluid or Dexron III ATF.

Known Issues

Head Gaskets:

While less common than in earlier generations, head gasket leaks can occur, particularly on higher-mileage vehicles. The manual details inspection and replacement procedures.

Wheel Bearings:

Front and rear wheel bearings can wear over time. The manual covers diagnosis and replacement.

Cv Axles:

Wear and tear on Constant Velocity (CV) axles and boots is common, especially with AWD components. Repair/replacement procedures are detailed.

Automatic Transmission Slippage:

Some 4EAT transmissions may exhibit slippage issues. The manual provides diagnostic steps for solenoids, clutches, and valve bodies.

Crank Position Sensor:

Failure of the crankshaft position sensor can lead to no-start or stalling conditions. The manual details testing and replacement.

📚 Vehicle History

Brand Heritage

Heritage Focus:

Subaru's reputation for reliability, safety, and All-Wheel Drive technology.

Model Evolution

Generation Start:

Third generation (1999-2004).

Model Line Introduction:

Legacy introduced in 1990.

Production

Manufacturing Location:

Gunma Plant, Japan.

🏆 Awards & Recognition

Recognitions

Safety Award:

Consistently received good ratings from IIHS and NHTSA for its safety features.

Value Award:

Often cited for its value proposition due to standard AWD and Subaru's reputation.