2002 Subaru Legacy Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 2002 Codes Chassis Code: BE/BH Engine Codes Covered: EJ251, EJ253, EJ204 (depending on market) 👋 Introduction Market Position Positioning: A mid-size...

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标签: 2002 Car Cars Legacy Misc Subaru

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy

Year:

Codes

Chassis Code:

BE/BH

Engine Codes Covered:

EJ251, EJ253, EJ204 (depending on market)

👋 Introduction

Market Position

Positioning:

A mid-size sedan/wagon known for its standard All-Wheel Drive and practical functionality.

Competitive Analysis

Competitors:

Toyota Camry, Honda Accord, Nissan Altima, Ford Mondeo (Contour).

Key Features

AWD Standard:

Subaru's Symmetrical All-Wheel Drive system was standard on most Legacy models, a key differentiator.

Engine Options:

DOHC 2.5L Naturally Aspirated and optional turbocharged variants (GT models).

📋 Manual Details

Coverage Areas

Market Covered:

North America (primarily), with potential overlap for other markets

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, diagnosis, timing belt replacement, cylinder head removal/installation, piston and connecting rod service, crankshaft service.

Engine Management:

Fuel injection system, ignition system, emission control systems (EVAP, EGR), sensor data, diagnostic trouble codes (DTCs), ECU diagnosis.

Transmission Manual:

Operation, diagnosis, overhaul, clutch replacement, shifter linkage adjustments.

Transmission Automatic:

Operation, diagnosis, fluid changes, valve body service, torque converter service, solenoid testing.

Drivetrain:

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

Suspension:

Front struts, rear shocks, control arms, bushings, ball joints, sway bars, alignment procedures.

Brakes:

Front and rear disc brakes, ABS system (including hydraulic unit and sensors), brake fluid flush, caliper and rotor replacement.

Steering:

Power steering system, steering rack diagnosis and replacement, tie rod ends.

Electrical System:

Battery, alternator, starter, lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams.

HVAC:

Air conditioning system (refrigerant, compressor, condenser, evaporator), heater core, blower motor, climate controls.

Body And Chassis:

Body panel removal/installation, door mechanisms, interior trim, glass replacement, structural components.

Safety Systems:

Airbag system (SRS), seat belts, safety restraint system diagnosis.

Procedures Included

Maintenance:

Oil change intervals, filter replacements (oil, air, cabin), spark plug replacement, fluid level checks and top-offs.

Diagnostics:

Troubleshooting guides for common symptoms, diagnostic charts, using OBD-II scanners, component testing procedures.

Repair:

Step-by-step instructions for major component repair and replacement, including torque specifications and special tool requirements.

Troubleshooting Guides:

Systematic approach to diagnosing and resolving issues across all major vehicle systems.

Wiring Diagrams:

Detailed electrical schematics for all major systems, facilitating electrical troubleshooting.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to full engine and transmission rebuilds.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text, allowing quick access to information.

Print Quality

Quality:

High resolution, ensuring clarity of diagrams and text.

Diagram Quality:

Top quality diagrams, illustrative and easy to follow.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Horizontally Opposed (Boxer) 4-Cylinder

Displacement:

2.5 Liters (2498 cc)

Valvetrain:

DOHC (Double Overhead Camshaft), 16 Valves

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Performance

Horsepower Approx:

165 hp @ 5600 rpm (Naturally Aspirated EJ251/EJ253)

Torque Approx:

166 lb-ft @ 4000 rpm (Naturally Aspirated EJ251/EJ253)

Turbocharged Variants:

GT models featured turbocharged EJ205 or EJ255 engines with higher output.

Fuel System

Fuel Type:

Unleaded Gasoline

Ignition System:

Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or Coil-Near-Plug.

🔧 Transmission

Standard

Type:

4-Speed Automatic Transmission (4EAT)

Optional

Type:

5-Speed Manual Transmission

Features

AWD Integration:

All-Wheel Drive integrated into both manual and automatic transmissions.

Automatic Modes:

Full-time AWD with viscous coupling center differential in automatics; active torque split AWD on manual transmissions.

📐 Dimensions

Exterior

Body Styles:

4-Door Sedan, 5-Door Wagon

Wheelbase:

Approx. 104.1 inches (2644 mm)

Length Sedan:

Approx. 187.8 inches (4770 mm)

Length Wagon:

Approx. 189.0 inches (4800 mm)

Weights

Curb Weight Range:

Approx. 3100 - 3400 lbs (1406 - 1542 kg)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

5-Star (Driver), 4-Star (Passenger)

IIHS Side Impact:

Good (for applicable models/tests)

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System (TCS) on some trims.

Passive Features

Airbags:

Dual front airbags, optional front side-impact airbags.

Seat Belts:

3-point front seat belts with pretensioners and load limiters, rear 3-point seat belts.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD audio systems, with optional premium audio and cassette players available.

Driver Assistance

Cruise Control:

Standard cruise control system.

Anti Lock Brakes:

ABS is a key driver assistance feature for enhanced braking control.

Connectivity

Power Windows Locks:

Power windows, power door locks, and remote keyless entry (on select trims).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 3.75 months (severe driving) or 7,500 miles or 7.5 months (normal driving) depending on oil type and driving conditions.

Timing Belt Replacement:

Every 105,000 miles or 105 months (critical maintenance item).

Spark Plug Replacement:

Every 60,000 miles (platinum tipped).

Fluid Specifications

Engine Oil:

API SG or SH, SAE 5W-30 recommended (refer to manual for exact specification based on temperature).

Coolant:

Subaru Super Coolant (Blue) or equivalent silicate-free OAT coolant, mixed 50/50 with distilled water.

Transmission Fluid Automatic:

Subaru ATF (Dexron III Compatible) or equivalent.

Transmission Fluid Manual:

API GL-5, SAE 75W-90 gear oil.

Brake Fluid:

DOT 3 or DOT 4.

Known Issues

Head Gaskets:

While not as prevalent as earlier generations, minor coolant leaks from head gaskets can occur. The manual provides diagnostic and repair procedures.

Wheel Bearings:

Front wheel bearings can be a wear item. The manual details replacement procedures and specifications.

Cv Joints:

Front and rear CV joints may require inspection and replacement due to wear. Manual covers diagnosis and replacement.

Catalytic Converter:

Can become clogged over time, affecting performance. Manual assists in diagnosing exhaust system issues.

📚 Vehicle History

Brand Heritage

Brand Focus:

Subaru, a division of Fuji Heavy Industries, is renowned for its horizontally opposed engines and standard All-Wheel Drive.

Model Evolution

Generation:

This is the second generation (BE/BH) of the Subaru Legacy, introduced for the 1999 model year.

Production

Manufacturing Location:

Japan (Gunma Plant)

🏆 Awards & Recognition

Recognitions

Safety Awards:

The second-generation Legacy generally performed well in safety tests of its era, often earning good ratings from IIHS and NHTSA.

Overall Reputation:

Praised for its go-anywhere capability due to standard AWD, comfort for its class, and reliable Boxer engine.