Subaru Legacy Outback 2001 2002 Repair Service Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Outback Model Years Covered: 2001, 2002 Codes Chassis Codes: BH Engine Codes: EJ251, EJ253 (2.5L SOHC), EJ254 (2.5L DOHC) 👋 Introduction Market...

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标签: 2001 2002 Car Cars Legacy Outback Misc Subaru

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy Outback

Model Years Covered:

2001, 2002

Codes

Chassis Codes:

Engine Codes:

EJ251, EJ253 (2.5L SOHC), EJ254 (2.5L DOHC)

👋 Introduction

Market Position

Vehicle Segment:

Mid-size Crossover SUV / Station Wagon.

Target Audience:

Active lifestyle consumers, families seeking AWD capability and versatility.

Competitive Analysis

Key Competitors:

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

Key Features

All Wheel Drive:

Standard Subaru Symmetrical All-Wheel Drive system.

Ground Clearance:

Higher ground clearance than typical sedans, offering mild off-road capability.

Safety Engineering:

Subaru's reputation for safety and robust construction.

Versatility:

Spacious interior, cargo capacity, and roof rails for utility.

📋 Manual Details

Coverage Areas

Diagnostic Troubleshooting:

Comprehensive coverage for all systems.

Maintenance Procedures:

Scheduled maintenance, fluid changes, filter replacements.

Repair Procedures:

Detailed step-by-step instructions for mechanical and electrical repairs.

Engine Overhaul:

Complete engine disassembly, inspection, and reassembly procedures.

Transmission Service:

Automatic and Manual transmission service, repair, and overhaul.

Electrical System:

Wiring diagrams, component testing, diagnostic procedures for all circuits.

Suspension Steering:

Component replacement, alignment specifications, troubleshooting.

Brakes:

Brake system diagnostics, repair, ABS, and components.

Body And Trim:

Panel replacement, interior trim, glass, and exterior components.

HVAC:

Air conditioning and heating system service and repair.

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, pistons, crankshaft, camshafts, timing belt/chain.

Engine Performance:

Fuel injection, ignition system, emissions control, cooling system.

Powertrain Control:

ECU diagnostics, sensor inputs/outputs, actuator controls.

Automatic Transmission:

ATF service, valve body, torque converter, planetary gears, electronic controls.

Manual Transmission:

Clutch service, gear sets, shift mechanisms, transfer case.

All Wheel Drive System:

Center differential, viscous coupling, drivelines, maintenance.

Suspension Components:

Struts, shock absorbers, control arms, sway bars, bushings.

Steering Components:

Power steering pump, rack and pinion, tie rods, steering column.

Brake System Components:

Front/rear discs, calipers, pads, rotors, master cylinder, ABS module.

Body Structure:

Frame, chassis components, body panels, doors, hood, tailgate.

Exterior Trim:

Bumpers, grilles, mirrors, lighting, seals.

Interior Trim:

Dashboard, seats, door panels, headliner, carpeting.

Climate Control:

A/C compressor, condenser, evaporator, blower motor, heater core.

Instrumentation Gauges:

Speedometer, tachometer, warning lights, cluster diagnostics.

Lighting System:

Headlights, taillights, interior lights, fog lamps, wiring.

Audio System:

Radio, speakers, amplifier (if equipped), wiring.

Security System:

Immobilizer, alarm system, keyless entry components.

Airbag System:

SRS components, sensors, diagnostic procedures.

Cruise Control:

Component testing, operation, and troubleshooting.

Windshield Wipers:

Wiper motor, linkages, washer system.

Procedures Included

Preventive Maintenance:

Oil changes, filter replacements, fluid checks, tire rotations.

Troubleshooting Diagnostics:

System-specific diagnostic trees, DTC explanations, component testing.

Component Removal Installation:

Detailed instructions for replacing virtually any part.

Engine Tuning:

Ignition timing adjustments, idle speed control procedures.

Suspension Alignment:

Specifications and procedures for front and rear wheel alignment.

Brake System Maintenance:

Pad and rotor replacement, caliper service, brake fluid flush.

Electrical Wiring Repair:

Splice and repair procedures, connector inspection and cleaning.

HVAC System Servicing:

Refrigerant handling, leak detection, component replacement.

Torque Specifications:

Critical torque values for all fasteners and components.

Special Tools:

Identification and usage of Subaru-specific service tools.

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to complete rebuilds and advanced diagnostics.

📊 Manual Specifications

File Format

Type:

Searchability:

Fully searchable text content.

Readability:

High-resolution scans, clear diagrams and text.

Print Quality

Quality:

N/A (Digital Download)

Binding Type

Type:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

EJ251 / EJ253 (2.5L SOHC) and EJ254 (2.5L DOHC)

Engine Type:

Horizontally Opposed (Boxer) 4-Cylinder

Displacement:

2457 cc (2.5 Liters)

Bore X Stroke:

99.5 mm x 79.0 mm

Compression Ratio:

9.7:1 (SOHC), 10.7:1 (DOHC)

Performance

Horsepower Sohc:

165 hp @ 5600 rpm

Torque Sohc:

166 lb-ft @ 4000 rpm

Horsepower DOHc:

175 hp @ 6000 rpm (GT models)

Torque DOHc:

175 lb-ft @ 4000 rpm (GT models)

Fuel System

Fuel Delivery:

Electronic Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane minimum recommended)

Fuel Tank Capacity:

15.7 gallons (59 Liters)

🔧 Transmission

Standard

Transmission Type:

4-Speed Electronically Controlled Automatic Transmission

Optional

Transmission Type:

5-Speed Manual Transmission

Features

Drive System:

Symmetrical All-Wheel Drive (AWD) with each transmission type.

Automatic Transmission Fluid Spec:

Subaru ATF-HP or equivalent

Manual Transmission Fluid Spec:

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

📐 Dimensions

Exterior

Length:

187.8 inches (4770 mm)

Width:

69.9 inches (1775 mm)

Height:

60.2 inches (1529 mm)

Wheelbase:

104.3 inches (2649 mm)

Ground Clearance:

8.0 inches (203 mm)

Cargo

Cargo Volume Behind Rear Seat:

34.7 cubic feet (982 Liters)

Cargo Volume With Rear Seat Folded:

70.1 cubic feet (1985 Liters)

Weights

Curb Weight Approx:

3300 - 3500 lbs (1497 - 1588 kg), depending on trim and transmission

Towing Capacity:

2000 lbs (907 kg) (with proper equipment)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5-Star (for 2001 model year)

NHTSA Front Impact Passenger:

5-Star (for 2001 model year)

IIHS Front Offset Crash Rating:

Good (for 2001 model year)

Active Features

Braking System:

4-wheel disc brakes; optional Anti-lock Braking System (ABS)

Traction Control:

Not widely available or standard on all models.

Passive Features

Airbags:

Front driver and passenger airbags; optional side-impact airbags.

Seatbelts:

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

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Infotainment

Audio System:

Base models feature a 4-speaker AM/FM/CD player. Higher trims may have 6-speaker or premium audio systems, potentially with a cassette player.

Navigation:

Optional factory navigation system available on some higher trims.

Driver Assistance

Cruise Control:

Standard on most models.

All Wheel Drive:

The defining technological feature, providing enhanced traction and stability in various conditions.

Connectivity

Power Outlets:

12V auxiliary power outlets.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles (6,000 km) or 6 months, whichever comes first.

Air Filter Replacement:

Every 15,000 miles (24,000 km)

Cabin Air Filter Replacement:

Every 15,000 miles (24,000 km) or annually

Spark Plug Replacement:

105,000 miles (168,000 km) for platinum-tipped plugs (SOHC), 60,000 miles (96,000 km) for standard plugs (DOHC).

Timing Belt Replacement:

Every 105,000 miles (168,000 km) or 7 years (whichever comes first) - CRITICAL MAINTENANCE ITEM.

Coolant Flush:

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

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (API SG or higher)

Engine Oil Capacity:

4.7 US quarts (4.4 Liters) with filter

Brake Fluid Type:

SAE J1703 or FMVSS No. 116 DOT 3

Coolant Type:

Subaru Super Coolant (or equivalent silicate-free, long-life coolant)

Known Issues

Head Gaskets:

Premature head gasket failure is a common concern on EJ series engines, particularly early DOHC variants. The manual will detail inspection and replacement procedures.

Timing Belt Tensioner:

While the timing belt itself is robust, the hydraulic tensioner can fail, leading to belt slippage or breakage. Replacement during timing belt service is often recommended.

Oil Leaks:

Valve cover gaskets, oil pan gaskets, and rear main seals can develop leaks over time.

ABS Module Failure:

ABS warning lights can illuminate due to module issues. Diagnostic procedures are covered.

📚 Vehicle History

Brand Heritage

Subaru Philosophy:

Emphasis on safety, reliability, and all-wheel-drive capability.

Model Evolution

First Generation:

Launched in 1995 as a more rugged, lifted version of the Subaru Legacy wagon.

Second Generation Bh:

Introduced for the 2000 model year, representing a significant redesign with a more refined exterior and interior. The 2001-2002 models are part of this generation.

Production

Manufacturing Location:

Gunma Prefecture, Japan

🏆 Awards & Recognition

Recognitions

Safety Awards 2001:

Recognized by IIHS and NHTSA for strong safety performance in its class.

Value Proposition:

Consistently praised for its blend of AWD capability, utility, and affordability in the crossover segment.