🏷️ Basic Information

Make:

Subaru

Model:

Legacy Outback

Year:

2002

Chassis Code:

BH/BP Series (Second Generation)

👋 Introduction

Vehicle Segment:

Compact Crossover SUV / Station Wagon

Unique Selling Proposition:

Symmetrical All-Wheel Drive (AWD) as standard, Subaru's signature boxer engine, robust and practical for outdoor activities.

Key Competitors 2002:

Toyota RAV4, Honda CR-V, Ford Escape, Mazda Tribute, Nissan Xterra

AWD System:

Standard Subaru Symmetrical All-Wheel Drive with either a viscous coupling limited-slip center differential (for automatic transmissions) or a viscous coupling limited-slip center differential with a rear limited-slip differential (for manual transmissions).

Ground Clearance:

Elevated ground clearance compared to traditional sedans, aiding in light off-road conditions.

Engine Layout:

Horizontally opposed 'boxer' engine for a lower center of gravity.

📋 Manual Details

Engine Coverage:

EJ251 (2.5L SOHC), EJ253 (2.5L DOHC - rare in this model year but manual likely covers variations), EJ254 (2.5L DOHC, often referred to as EJ25 SOHC/DOHC)

Transmission Coverage:

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

Trim Level Coverage:

All US market trim levels (e.g., Base, Limited)

Estimated Pages:

1500-2500+ (typical for a complete factory service manual)

Manual Type:

Factory Service Manual (FSM) / Repair Manual

Language:

English

Format:

Digital Download (likely PDF)

📖 Manual Coverage

Engine Mechanical:

Complete engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication system, cooling system, fuel system (injection, pump, lines), exhaust system.

Transmission Drivetrain:

Automatic transmission (4EAT) service, manual transmission service, clutch system, differentials (front, center, rear), driveshafts, axles.

Suspension Steering:

Front and rear suspension components, struts, springs, control arms, bushings, sway bars, steering rack, power steering system, wheel alignment specifications.

Brakes:

Front and rear brake systems (disc brakes), ABS (Anti-lock Braking System) diagnosis and repair, brake fluid specifications, master cylinder, calipers, rotors, pads.

Electrical System:

12V battery system, charging system (alternator), starting system (starter motor), ignition system, lighting system, body control modules, fuses, relays, wiring diagrams for all circuits.

HVAC:

Heating, ventilation, and air conditioning system diagnosis, refrigerant recharge, blower motor, climate control unit.

Body Chassis:

Body panel repair, interior trim removal, glass replacement, chassis lubrication, structural components.

Routine Maintenance:

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

Engine Repair:

Engine tune-ups, cylinder head gasket replacement, timing belt replacement (critical for EJ engines), piston and ring replacement, bearing replacement, oil seal replacement.

Transmission Service:

Automatic transmission fluid and filter change, manual gearbox overhaul, clutch replacement, differential fluid service.

Braking System Repair:

Brake pad and rotor replacement, caliper service, brake line replacement, ABS sensor diagnosis and replacement, brake bleeding procedures.

Suspension Steering Repair:

Strut and shock absorber replacement, ball joint and tie rod end replacement, power steering pump and rack service, wheel bearing replacement.

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, starter motor testing, alternator testing, ECU diagnosis (OBD-II scanning), sensor testing.

Troubleshooting Guides:

Detailed diagnostic flowcharts for common and uncommon issues across all vehicle systems.

Diagnostic Capabilities:

Comprehensive OBD-II diagnostic trouble codes (DTCs), sensor data interpretation, actuator testing procedures.

Repair Procedures:

Step-by-step instructions for disassembly, repair, and reassembly of all major vehicle components.

Specifications:

Torque specifications for all fasteners, engine clearances, fluid capacities, electrical specifications, emissions control data.

Wiring Diagrams:

Detailed, high-resolution wiring diagrams for all electrical systems, including power distribution, grounds, and component connections.

📊 Manual Specifications

File Format:

PDF

Searchability:

Searchable text content for quick information retrieval.

Printability:

Printable pages, allowing for offline use and physical reference.

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type:

N/A (Digital)

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Engine Code:

EJ251 (most common)

Engine Type:

Naturally aspirated, 2.5-liter, 16-valve, DOHC (Dual Overhead Camshaft) or SOHC (Single Overhead Camshaft) depending on exact sub-model and market. The EJ251 is typically SOHC.

Bore X Stroke:

99.5 mm x 79.0 mm

Displacement:

2457 cc (2.5 Liters)

Horsepower Hp:

Approx. 165 hp @ 5600 rpm (EJ251 SOHC)

Torque Lb Ft:

Approx. 166 lb-ft @ 3600 rpm (EJ251 SOHC)

Fuel Delivery:

Electronic Fuel Injection (EFI)

Recommended Fuel:

87 Octane Unleaded Gasoline

Timing Belt:

Yes, requires periodic replacement. Critical component.

Head Gasket Material:

Multi-layer Steel (MLS) - generally robust in this generation, but previous generations had issues.

🔧 Transmission

Standard Transmission:

5-speed Manual Transmission

Optional Transmission:

4-speed Automatic Transmission (4EAT)

AWD Type:

Full-time Symmetrical All-Wheel Drive

Automatic Transmission Features:

Driver-selectable modes (e.g., Power/Normal), viscous coupling center differential.

Manual Transmission Features:

Viscous coupling limited-slip center differential and rear limited-slip differential.

Automatic Transmission Fluid:

Subaru ATF (Dexron III compatible, but Subaru specific is recommended)

Manual Transmission Fluid:

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

Differential Fluid:

API GL-5, SAE 75W-90 Gear Oil (front and rear)

📐 Dimensions

Length:

Approx. 187.4 inches (4760 mm)

Width:

Approx. 70.5 inches (1790 mm)

Height:

Approx. 63.6 inches (1615 mm) (with standard roof rails)

Wheelbase:

Approx. 104.3 inches (2650 mm)

Ground Clearance:

Approx. 8.1 inches (205 mm)

Cargo Volume Behind Rear Seats:

Approx. 36.7 cu ft (1039 Liters)

Cargo Volume With Rear Seats Folded:

Approx. 70.4 cu ft (1993 Liters)

Curb Weight Min:

Approx. 3265 lbs (1481 kg) (manual transmission)

Curb Weight Max:

Approx. 3375 lbs (1531 kg) (automatic transmission)

Gross Vehicle Weight Rating Gvwr:

Approx. 4710 lbs (2136 kg)

Towing Capacity:

2000 lbs (907 kg) (with proper trailer brakes)

Standard Wheel Size:

16-inch Alloy

Standard Tire Size:

215/60R16

Bolt Pattern:

5 x 100 mm

Wheel Offset:

Approx. +48 mm

🛡️ Safety Features

NHTSA Front Driver Side Impact:

5 Stars

NHTSA Front Passenger Side Impact:

5 Stars

NHTSA Side Driver Front Impact:

4 Stars

NHTSA Side Passenger Front Impact:

4 Stars

NHTSA Side Driver Rear Impact:

4 Stars

NHTSA Side Passenger Rear Impact:

4 Stars

IIHS Frontal Offset Score:

Good

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Available (on some models/trims, integrated with AWD/ABS)

Airbags Front:

Standard front driver and passenger airbags

Airbags Side:

Optional front side-impact airbags (depending on trim level)

Seatbelts:

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

💡 Technology Features

Audio System:

Standard AM/FM stereo with CD player. Premium audio system with amplifier and subwoofer may be available on higher trims.

Navigation:

Factory navigation systems were not widely available or common in this model year.

Cruise Control:

Standard electronic cruise control.

Anti Lock Brakes:

Standard ABS.

Aux Input:

Not typically available. Aftermarket solutions are common.

Bluetooth:

Not available from the factory.

🔧 Maintenance

Oil Change Interval:

Every 3,750 miles or 3 months (severe driving) or 7,500 miles or 6 months (normal driving) - consult owner's manual for specifics.

Engine Air Filter Replacement:

Every 15,000 miles or 12 months

Cabin Air Filter Replacement:

Every 15,000 miles or 12 months

Spark Plug Replacement:

Every 60,000 miles (platinum-tipped plugs)

Timing Belt Replacement:

Crucial: Every 105,000 miles or 105 months. Failure can cause catastrophic engine damage.

Transmission Fluid Change Auto:

Every 30,000 miles (severe duty) or 45,000 miles (normal duty), or as per manual. Filter replacement recommended at same time.

Differential Fluid Change:

Every 30,000 miles

Engine Oil Type:

SAE 5W-30 (Synthetic blend or full synthetic recommended)

Engine Oil Capacity:

Approx. 4.7 US quarts (4.4 Liters) with filter change

Coolant Type:

Subaru Super Coolant (Blue) or equivalent silicate-free, extended-life coolant (50/50 mix with distilled water)

Coolant Capacity:

Approx. 7.2 US quarts (6.8 Liters)

Brake Fluid Type:

DOT 3 or DOT 4

Head Gaskets:

While less prone than earlier generations, head gasket leaks can still occur, particularly external oil leaks around the front of the engine. Internal coolant leaks are less common but possible.

Oil Consumption:

Some EJ25 engines can exhibit increased oil consumption with age and mileage. Regular checks are vital.

Automatic Transmission Behavior:

The 4EAT can sometimes develop harsh shifting or hesitation with high mileage; regular fluid and filter changes are critical for longevity.

Suspension Components:

Worn sway bar links, bushings, and front struts are common wear items due to the vehicle's design and intended use.

Rear Main Seal Leaks:

Can develop rear main seal leaks over time, requiring transmission removal to replace.

📚 Vehicle History

Subaru Identity:

Known for symmetrical AWD and boxer engines, focus on safety and durability, often catering to outdoor enthusiasts.

First Generation Legacy Outback:

Introduced in 1995 as an evolution of the Subaru Legacy station wagon, featuring increased ground clearance and ruggedized styling.

Second Generation Legacy Outback:

Launched for the 1999 model year (BG/BH chassis), this generation saw significant styling updates, improved interior, and refined powertrains. The 2002 model falls within this generation.

Third Generation Legacy Outback:

Introduced for the 2005 model year (BP chassis), marking a further evolution in design and technology.

Production Years For Bh Chassis:

1999-2004

Manufacturing Location:

Gunma Plant, Japan

🏆 Awards & Recognition

Car And Driver Best All Wheel Drive Vehicle:

Subaru vehicles, including the Outback, frequently receive accolades from automotive publications for their AWD capabilities.

Consumer Reports Reliability:

Subaru generally has a good reputation for reliability, though specific model years and engine variants can vary. This manual provides the knowledge to maintain optimal reliability.

Emissions Certification:

Meets EPA and CARB emissions standards for the 2002 model year. Manual includes relevant diagnostic procedures for emissions control systems.