2002 Subaru Legacy Outback Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Outback Year: 2002 Codes Chassis Code: BH/BE Series Platform Code: Second Generation Legacy (BD/BG/BK, BH/BE) 👋 Introduction Market Position Segment: Mid-size Crossover/Station...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy Outback

Year:

Codes

Chassis Code:

BH/BE Series

Platform Code:

Second Generation Legacy (BD/BG/BK, BH/BE)

👋 Introduction

Market Position

Segment:

Mid-size Crossover/Station Wagon

Standard All-Wheel Drive (Symmetrical AWD), robust build, practical cargo space, lifted ride height for light off-road capability.

Competitive Analysis

Key Competitors:

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

Key Features

AWD System:

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

Ground Clearance:

Higher ground clearance than standard wagons, offering improved capability on unpaved roads and moderate obstacles.

Engine Layout:

Horizontally opposed 'Boxer' engine design, contributing to a lower center of gravity.

📋 Manual Details

Coverage Areas

Regions Covered:

North America, Global Markets

Models Covered:

All 2002 Subaru Legacy Outback models

Engine Variants Covered:

All 2002 Outback engine options

Page Count

Estimated Page Count:

1000+

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, component diagnostics, timing belt replacement, cooling system, lubrication system, fuel delivery, emissions control.

Engine Performance:

ECU diagnostics, sensor data interpretation, ignition system, fuel injection mapping.

Transmission Automatic:

Operation, diagnostics, fluid service, valve body repair, torque converter service.

Transmission Manual:

Clutch system, gearbox overhaul, shifter linkage adjustment.

Drivetrain:

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

Suspension:

Front struts, rear shocks, control arms, bushings, anti-roll bars, alignment specifications.

Steering:

Power steering system, rack and pinion assembly, steering column, tie rods.

Brakes:

Front and rear disc brakes, ABS system diagnostics, brake fluid specifications, caliper service, rotor replacement.

Electrical System:

Wiring diagrams, fuse box layouts, lighting system, charging system, starting system, battery service.

Climate Control:

HVAC system operation, refrigerant handling, blower motor, A/C compressor diagnostics.

Body And Interior:

Door mechanisms, glass replacement, seat removal, trim panel installation, body panel repair.

Diagnostic Troubleshooting:

OBD-II diagnostic codes, troubleshooting flowcharts, specific component testing.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, tune-ups.

Repair:

Component replacement (e.g., alternator, starter, water pump), engine rebuilds, transmission overhaul, brake caliper replacement, strut replacement.

Diagnostics:

Step-by-step diagnostic procedures for common and complex issues, electrical testing with multimeters, scan tool usage.

Troubleshooting:

System-specific troubleshooting guides, symptom-based repair advice.

Installation:

Installation procedures for common accessories and replacement parts (e.g., spark plugs, brake pads).

Technical Depth

Depth:

Comprehensive: Covers everything from basic routine maintenance to full engine and transmission rebuilds, including detailed diagnostics and electrical system troubleshooting.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content

Printable:

Printable pages

Print Quality

Quality:

High-resolution scans of original factory documentation

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

EJ253

Engine Type:

2.5L SOHC Flat-4 (Boxer)

Displacement:

2457 cc (149.9 cu in)

Bore X Stroke:

99.5 mm x 80.0 mm (3.92 in x 3.15 in)

Compression Ratio:

9.4:1

Performance

Horsepower:

165 hp @ 5,600 rpm

Torque:

166 lb-ft @ 4,000 rpm

Fuel System

Fuel Delivery:

Multi-point fuel injection (MPI)

Fuel Type:

Unleaded gasoline, 87 octane (minimum)

Fuel Tank Capacity:

64 liters (16.9 US gallons)

🔧 Transmission

Standard

Type:

4-speed automatic transmission (4EAT)

Optional

Type:

5-speed manual transmission

Features

AWD Integration Auto:

Viscous coupling center differential with electronic control unit for torque distribution.

AWD Integration Manual:

Viscous coupling center differential with open front and rear differentials.

Fluid Specifications

Automatic Transmission Fluid Type:

Subaru ATF HP (Genuine Subaru Fluid) or equivalent Dexron III/Mercon

Manual Transmission Fluid Type:

GL-5 Gear Oil, SAE 75W-90

📐 Dimensions

Exterior

Length:

4705 mm (185.2 in)

Width:

1770 mm (69.7 in)

Height:

1570 mm (61.8 in)

Wheelbase:

2650 mm (104.3 in)

Ground Clearance:

201 mm (7.9 in)

Cargo

Cargo Volume Seats Up:

37.7 cu ft (1067 liters)

Cargo Volume Seats Down:

71.4 cu ft (2021 liters)

Weights

Curb Weight Manual:

1510 kg (3329 lbs)

Curb Weight Automatic:

1525 kg (3362 lbs)

Gross Vehicle Weight Rating:

2020 kg (4453 lbs)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

NHTSA Frontal Impact Passenger:

NHTSA Side Impact Front Driver:

NHTSA Side Impact Front Passenger:

NHTSA Side Impact Rear Passenger:

IIHS Frontal Offset:

IIHS Side Impact:

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Available Traction Control System (TCS)

Passive Features

Airbags Front:

Driver and front passenger airbags

Airbags Side:

Optional front side-impact airbags

Seatbelts:

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

Child Seats:

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

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD stereo system, with optional premium audio and cassette player.

Navigation:

Optional factory navigation system available on some higher trim levels.

Driver Assistance

Cruise Control:

Standard cruise control.

Keyless Entry:

Available keyless entry and alarm system.

Connectivity

Auxiliary Input:

No standard auxiliary audio input; aftermarket solutions required.

Bluetooth:

No factory Bluetooth connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval Gasoline:

Every 3,750 miles (6,000 km) or 6 months, whichever comes first, under severe driving conditions. Every 7,500 miles (12,000 km) or 12 months under normal conditions (check manual for specific conditions).

Engine Oil Filter Replacement:

With every oil change.

Engine Air Filter Replacement:

Every 30,000 miles (48,000 km)

Cabin Air Filter Replacement:

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

Timing Belt Replacement:

105,000 miles (168,000 km) or 105 months, whichever comes first.

Spark Plug Replacement:

Every 60,000 miles (96,000 km)

Coolant Flush Replacement:

Every 30,000 miles (48,000 km) or 24 months.

Fluid Specifications

Engine Oil Type And Capacity:

5W-30 Synthetic Blend or Full Synthetic; 4.7 US quarts (4.4 liters) with filter change.

Brake Fluid Type:

DOT 3 or DOT 4.

Power Steering Fluid Type:

Genuine Subaru Power Steering Fluid or Dexron II/III ATF.

Coolant Type:

Subaru Super Coolant (Blue) or equivalent silicate-free, long-life antifreeze.

Known Issues

Head Gaskets:

While not as prevalent as in earlier generations, some EJ25 engines can still experience head gasket failures, particularly if maintenance is neglected. The manual will detail inspection and replacement procedures.

Timing Belt Tensioner:

The automatic tensioner for the timing belt can fail, leading to belt slippage or failure. The manual covers inspection and replacement.

Rear Main Seal:

Leaking rear main crankshaft seal is a common, albeit labor-intensive, repair. The manual outlines the process for replacement.

Automatic Transmission Issues:

Early 4EAT transmissions can sometimes develop issues with solenoids or the valve body. Proper fluid maintenance is crucial, and the manual provides diagnostic steps.

Suspension Wear:

Worn control arm bushings and sway bar links are common due to age and mileage. The manual provides replacement procedures and torque specs.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Japan

Brand Specialty:

Known for Symmetrical All-Wheel Drive, Boxer engines, and rally heritage.

Model Evolution

Generation:

Second Generation Legacy (BH/BE) - introduced in 1998.

Outback Introduction:

The Outback variant was introduced in 1995 as a more rugged, lifted version of the Legacy wagon.

Model Year Updates 2002:

The 2002 model year falls within the second generation, which received a mid-cycle refresh for 2000 with updated styling and features.

Production

Production Start Year Legacy:

Production Start Year Outback:

Manufacturing Locations:

Japan (Gunma Plant)

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

The 2002 Outback typically performed well in IIHS crash tests for its era, often earning 'Good' ratings.

Consumer Reports:

Consumer Reports often cited the Outback for its practicality and AWD capability, with varying reliability ratings depending on the specific components tested.

Powertrain Reliability:

The EJ25 engine and AWD system are generally considered robust, though specific component wear (e.g., head gaskets, tensioners) needs attention as detailed in the manual.