🏷️ Basic Information

Make:

Subaru

Model:

Legacy Outback

Year:

2002

Chassis Code:

BP/BL

Engine Code:

EJ253 (2.5L SOHC)

👋 Introduction

Positioning:

The 2002 Subaru Legacy Outback positioned itself as a versatile, family-oriented all-wheel-drive vehicle, blending the comfort of a station wagon with the capability of a light SUV. It appealed to those seeking all-weather confidence and a rugged, adventurous image.

Competitors:

Competed against vehicles like the Toyota RAV4, Honda CR-V, Ford Escape, and similarly positioned crossover SUVs and AWD wagons from other manufacturers.

Features:

Subaru's signature Symmetrical All-Wheel Drive system, raised ground clearance, distinctive rugged styling, comfortable and spacious interior, boxer engine layout.

📋 Manual Details

Systems Covered:

Engine mechanical, fuel injection, emission control, exhaust system, cooling system, lubrication system, speed control, ignition system, starting system, charging system, automatic transmission, clutch system, front suspension, rear suspension, differentials, drive shaft system, brake system.

Estimated Page Count:

Extensive (Typical for a comprehensive shop manual, likely 1000+ pages)

Type:

Shop Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Detailed information on engine disassembly, assembly, component specifications, torque values, timing belt replacement, cylinder head service, piston and ring installation, crankshaft and bearing service.

Fuel Injection:

Service procedures for fuel injectors, fuel pump, fuel pressure regulator, throttle body, Mass Airflow (MAF) sensor, oxygen sensors, and troubleshooting fuel delivery and performance issues.

Emission Control:

Coverage of EGR system, PCV system, evaporative emission control (EVAP) system, catalytic converter operation, and emission control component testing and replacement.

Exhaust Cooling:

Repair and maintenance for the exhaust system (pipes, muffler, catalytic converter) and the cooling system (radiator, water pump, thermostat, hoses, coolant specifications).

Lubrication Speed Control:

Lubrication system details including oil pump, oil filter replacement, oil capacity, and speed control system (cruise control) diagnosis and repair.

Ignition Starting Charging:

Service procedures for ignition coils, spark plugs, ignition timing, starter motor, starter solenoid, alternator, battery testing, and charging system diagnosis.

Automatic Transmission:

Detailed procedures for automatic transmission fluid (ATF) change and filter replacement, transmission diagnosis, internal component service, torque converter replacement, and transmission control system troubleshooting.

Clutch Front Suspension:

Information on clutch system components (if applicable to specific models or if manual covers manual transmission variants), front suspension geometry, component replacement (struts, control arms, ball joints), wheel alignment specifications.

Rear Suspension:

Service and repair for rear suspension components, including shocks, springs, trailing arms, and bushings. Wheel alignment for the rear axle.

Differentials:

Service and repair procedures for front, center (if applicable), and rear differentials, including fluid changes, seal replacement, and gear inspection. All-Wheel Drive (AWD) system specifics.

Drive Shaft System:

Maintenance and repair of drive shafts, CV joints, and axle shafts. Torque specifications for U-joints and CV boots.

Brakes:

Detailed procedures for brake pad and rotor replacement, brake caliper service, brake fluid flush and bleeding, parking brake adjustment, ABS system diagnosis and repair.

Maintenance:

Scheduled maintenance, fluid checks and changes, filter replacements, belt inspections and replacements, tire rotations, brake inspections.

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common and complex issues across all vehicle systems, often including diagnostic trouble codes (DTCs).

Repair:

Step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly for virtually all mechanical and electrical systems.

Installation:

Instructions for installing new or replacement parts and components, including proper torquing sequences and specifications.

Depth:

Comprehensive. Covers everything from basic fluid changes and inspections to complete engine and transmission rebuilds, advanced electrical diagnostics, and bodywork repair.

📊 Manual Specifications

Quality:

High-resolution PDF, allowing for clear printing of text and diagrams. Searchable text for quick information retrieval.

Printability:

Designed for printing, with clear formatting and legible diagrams suitable for workshop use.

Binding:

Digital (PDF) - No physical binding type.

Paper Type:

Digital (PDF) - No physical paper type.

⚙️ Engine Specifications

Engine Type:

Naturally Aspirated Boxer 4-Cylinder

Displacement:

2.5 Liters (2498 cc)

Bore X Stroke:

99.5 mm x 80.0 mm

Compression Ratio:

9.7:1

Valve Train:

SOHC (Single Overhead Camshaft), 16 Valves (4 valves per cylinder)

Engine Code Variant:

EJ253

Horsepower:

165 hp @ 5,600 rpm

Torque:

166 lb-ft @ 4,000 rpm

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline

Fuel Tank Capacity:

15.7 Gallons

🔧 Transmission

Transmission Type:

4-Speed Electronically Controlled Automatic Transmission (4EAT)

Transmission Type Optional:

5-Speed Manual Transmission (available on some trims/markets)

AWD System:

Symmetrical All-Wheel Drive System

Transmission Fluid Type:

Subaru ATF HP (or equivalent)

📐 Dimensions

Length:

187.8 inches

Width:

69.7 inches

Height:

63.8 inches

Wheelbase:

104.3 inches

Ground Clearance:

8.1 inches

Curb Weight:

Approx. 3,300 - 3,400 lbs (depending on trim and equipment)

Gross Vehicle Weight Rating:

Approx. 4,700 lbs

Cargo Volume Seats Up:

Approximately 37.5 cubic feet

Cargo Volume Seats Down:

Approximately 69.7 cubic feet

🛡️ Safety Features

NHTSA Front Impact Driver:

5 Star

NHTSA Front Impact Passenger:

5 Star

NHTSA Side Impact Front Seat:

4 Star

NHTSA Side Impact Rear Seat:

4 Star

IIHS Front Crash Rating:

Good

IIHS Side Crash Rating:

Acceptable

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System (TCS) on some models

Airbags:

Dual front airbags, front side-impact airbags (optional on some trims)

Seatbelts:

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

💡 Technology Features

Audio System:

Standard AM/FM stereo with CD player and 4-6 speakers depending on trim level. Premium audio options may include a subwoofer.

Climate Control:

Manual climate control standard, automatic climate control available on higher trims.

Cruise Control:

Standard cruise control system for highway driving.

Connectivity Features:

Limited connectivity by modern standards. Basic power outlets for charging devices.

🔧 Maintenance

Oil Change Interval:

Every 3,750 miles or 3.75 months (severe driving) or 7,500 miles or 7.5 months (normal driving). Refer to manual for specific conditions.

Engine Air Filter:

Inspect every 15,000 miles, replace as needed (typically every 30,000 miles).

Cabin Air Filter:

Inspect every 15,000 miles, replace as needed (typically every 15,000-30,000 miles).

Transmission Fluid Change:

Recommended every 30,000 miles for severe service, consult manual for normal service. Filter replacement often recommended with fluid change.

Timing Belt Replacement:

Crucial: 105,000 miles or 105 months. This is an interference engine, so belt failure will cause significant internal damage.

Engine Oil Type:

API SG or higher, SAE 5W-30 Synthetic or Conventional Engine Oil

Engine Oil Capacity:

4.7 US quarts (with filter)

Coolant Type:

Subaru Super Coolant (Blue) or equivalent extended life coolant

Brake Fluid Type:

DOT 3

Head Gaskets:

While less prevalent than on earlier EJ series engines, some 2.5L SOHC engines (EJ253) can still experience head gasket leaks over time. Early detection is key.

Oxygen Sensors:

Failure of O2 sensors can lead to poor fuel economy and check engine lights. Regular testing and replacement as needed is recommended.

Catalytic Converter:

Can become clogged or fail over time, impacting engine performance and emissions. Diagnosis is covered in the manual.

Cv Joint Boots:

Torn CV joint boots can lead to premature failure of the CV joints due to contamination. Regular inspection of these is advised.

📚 Vehicle History

Heritage:

Subaru, a division of Subaru Corporation (formerly Fuji Heavy Industries), has a long history of producing reliable vehicles, known for their Boxer engines and Symmetrical All-Wheel Drive systems, often associated with outdoor and adventurous lifestyles.

Generation:

The 2002 model year marked the beginning of the second generation (BP/BL) for the Subaru Legacy, with the Outback variant representing the raised-suspension, ruggedized version of the Legacy wagon.

Production Years:

The second generation Legacy (including Outback) was produced from 2000 to 2004.

Manufacturing Location:

Primary manufacturing location was Subaru of Indiana Automotive, Inc. (SIA) in Lafayette, Indiana, USA, and Gunma Prefecture, Japan.

🏆 Awards & Recognition

AWD Recognition:

Subaru's Symmetrical All-Wheel Drive system is consistently recognized for its effectiveness in various weather conditions, contributing to the Outback's reputation for capability.

Consumer Reports:

While specific ratings vary, the Subaru Outback has generally been considered a reliable vehicle in its class by publications like Consumer Reports.

Safety Certifications:

Achieved high safety ratings from NHTSA and IIHS for its model year, demonstrating a commitment to occupant protection.