Subaru Legacy Outback 2002 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Outback Year: 2002 Codes Platform Code: BD/BG/BK 👋 Introduction Market Position Segment: Mid-size Crossover/Wagon Target Audience: Outdoor enthusiasts, families, individuals seeking AWD...

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标签: 2002 Car Cars Legacy Outback Misc Subaru

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy Outback

Year:

Codes

Platform Code:

BD/BG/BK

👋 Introduction

Market Position

Segment:

Mid-size Crossover/Wagon

Target Audience:

Outdoor enthusiasts, families, individuals seeking AWD capability and practicality

Competitive Analysis

Key Competitors:

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

Key Features

Brand Philosophy:

Symmetrical All-Wheel Drive, Boxer Engine, Durability, Practicality

Model Niche:

Raised suspension and ruggedized styling differentiate it from standard Legacy sedans/wagons, offering enhanced ground clearance and capability.

📋 Manual Details

Coverage Areas

Primary Coverage:

North America

Secondary Coverage:

Global (technical principles applicable)

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Workshop Service Repair Manual (Factory Service Manual)

Language

Language:

English

Format

Format:

Downloadable (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine removal, disassembly, inspection, repair, reassembly, torque specifications, timing belt replacement

Engine Management:

ECM diagnosis, sensor testing, ignition system, fuel injection system, emissions control

Transmission Automatic:

Removal, disassembly, repair, valve body diagnosis, torque converter, fluid specifications

Transmission Manual:

Removal, disassembly, repair, clutch system, fluid specifications

Drivetrain AWD:

Center differential, rear differential, propeller shaft, CV joints, fluid specifications

Suspension:

Front and rear suspension components, strut replacement, spring replacement, alignment specifications

Steering:

Power steering system, steering rack, tie rods, fluid type

Brakes:

Front and rear brake system, ABS system, brake fluid specifications, rotor and pad replacement

Electrical System:

Battery, charging system, starter motor, lighting, fuses, relays, wiring diagrams

HVAC:

Air conditioning system, heater core, blower motor, refrigerant type

Body And Interior:

Door panels, seats, dashboard, exterior trim, rust prevention

Procedures Included

Preventative Maintenance:

Oil change intervals, filter replacement, spark plug replacement, fluid checks

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting guides

Repair Procedures:

Step-by-step instructions for component removal and installation

Diagnostics:

OBD-II diagnostic trouble codes (DTCs), sensor data interpretation

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to major overhauls and diagnostics)

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text for quick information retrieval

Print Quality

Print Readability:

High-resolution scans, optimized for printing

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

EJ251

Engine Type:

2.5L Boxer-4 (Naturally Aspirated)

Displacement:

2457 cc (149.9 cubic inches)

Bore X Stroke:

99.5 mm x 79.0 mm

Compression Ratio:

9.7:1

Horsepower:

165 hp @ 5600 rpm

Torque:

166 lb-ft @ 4000 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Regular (87 Octane)

Fuel Capacity:

15.1 gallons (57 liters)

Timing

Timing Belt Replacement Interval:

Recommended every 60,000 miles or 60 months

🔧 Transmission

Standard

Type:

4-speed automatic (with Electronic Control)

Optional

Type:

5-speed manual

Features

AWD System:

Symmetrical All-Wheel Drive (standard on all Outback models)

Automatic Transmission Fluid Type:

Subaru ATF HP (or equivalent)

Manual Transmission Fluid Type:

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

📐 Dimensions

Exterior

Length:

187.4 inches (4760 mm)

Width:

69.1 inches (1755 mm)

Height:

61.4 inches (1560 mm)

Wheelbase:

104.0 inches (2640 mm)

Ground Clearance:

7.7 inches (196 mm)

Interior

Passenger Volume:

99.7 cubic feet (2.82 cubic meters)

Cargo

Cargo Volume Behind Rear Seats:

30.1 cubic feet (0.85 cubic meters)

Cargo Volume With Rear Seats Folded:

66.9 cubic feet (1.89 cubic meters)

Weights

Curb Weight Automatic:

3310 lbs (1501 kg)

Curb Weight Manual:

3200 lbs (1451 kg)

Gross Vehicle Weight Rating Gvwr:

4470 lbs (2027 kg)

Wheels And Tires

Standard Tire Size:

205/70R15 (with 15-inch wheels)

Optional Tire Size:

215/60R16 (with 16-inch wheels on higher trims)

Wheel Bolt Pattern:

5x100

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

4 Stars (for 2002 model year)

NHTSA Frontal Impact Passenger:

4 Stars (for 2002 model year)

IIHS Side Impact:

Acceptable (for similar models of the era, specific Outback ratings may vary)

Active Features

Standard Anti-lock Braking System

Traction Control:

Optional

Passive Features

Airbags Front:

Dual front airbags

Airbags Side:

Optional front side-impact airbags

Seatbelts:

Three-point seatbelts for all occupants, front seatbelt pretensioners

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD player, optional premium sound system with amplifier.

Climate Control:

Manual or automatic climate control depending on trim level.

Driver Assistance

Cruise Control:

Standard cruise control

Connectivity

Bluetooth:

Not available from factory.

Auxiliary Input:

Rarely equipped from factory, aftermarket solutions common.

🔧 Maintenance

Service Intervals

Engine Oil And Filter Change:

Every 7,500 miles or 6 months, whichever comes first (under normal driving conditions).

Engine Coolant Flush:

Every 30,000 miles or 30 months

Air Filter Replacement:

Every 15,000 miles or 12 months

Cabin Air Filter Replacement:

Every 15,000 miles or 12 months (if equipped)

Spark Plug Replacement:

Every 60,000 miles (iridium type)

Fluid Specifications

Engine Oil Viscosity:

5W-30 (API SG or higher)

Engine Coolant:

Subaru Super Coolant (Blue) or equivalent (50/50 mix with distilled water)

Brake Fluid:

DOT 3

Known Issues

Head Gaskets:

Early EJ series engines are known for potential head gasket failures. Early detection and repair are crucial.

Automatic Transmission:

Some early models experienced issues with the torque converter or valve body, often related to heat or fluid degradation. Regular fluid changes are important.

Suspension Bushings:

Worn suspension bushings and control arm components can lead to noise and handling issues over time.

📚 Vehicle History

Brand Heritage

Founding Era:

Founded in 1953 as Fuji Heavy Industries, automotive division began in 1958 with the Subaru 360.

Core Technologies:

Pioneered the use of Boxer engines and Symmetrical All-Wheel Drive in passenger vehicles.

Model Evolution

Outback Origin:

The Outback originated as a trim package on the Subaru Legacy in 1994, later becoming its own distinct model. This 2002 model is part of the second generation (second facelift).

Second Generation Release:

Second generation (second chassis code BD/BG/BK) introduced for the 1995 model year. The 2002 model represents a significant refresh from the original second-generation design.

Production

Manufacturing Location:

Gunma Plant, Japan

🏆 Awards & Recognition

Recognitions

All Wheel Drive Recognition:

Subaru's Symmetrical All-Wheel Drive system consistently praised for its effectiveness and standard inclusion.

Safety Recognition:

Subaru vehicles generally perform well in safety tests, contributing to the brand's reputation for safety.