Subaru Legacy Outback Workshop Manual 1998 1999 2000 2001 2002 2003 2004

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Outback Model Generation: BD/BG/BK (Second Generation) Applicable Years: 1998, 1999, 2000, 2001, 2002, 2003, 2004 Codes Chassis Codes: BD5, BG5, BK5 (Export), BH5, BH9 (Japan) Platform: Subaru FF-S Platform 👋 Introduction Market Position Vehicle Segment: Mid-size crossover/station wagon with standard All-Wheel Drive. Usp: Standard Symmetrical All-Wheel Drive system, raised ground clearance, wagon practicality. Competitive Analysis Key Competitors: Toyota Camry/Scepter Wagon, Honda Accord Wagon, Ford Mondeo Wagon, Volkswagen Passat Wagon, Volvo V70. Key Features Standard AWD: Subaru's signature Symmetrical All-Wheel Drive system for enhanced traction and stability in various conditions. Wagon Body Style: Practical wagon body offering ample cargo space and versatility for families and outdoor activities. Raised Suspension: Higher ground clearance compared to a standard Legacy sedan, providing better capability on unpaved roads. 📋 Manual Details Coverage Areas Coverage Scope: All Models & Repairs A-Z, Mechanical & Electrical Page Count Estimated Page Count: Extensive (Specific count not provided, but implied to be comprehensive) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (Printable) File Format Details: Digital format, ensuring all pages are printable. 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder heads, crankshaft, pistons, connecting rods, camshafts, valve train, timing belts/chains, lubrication system, cooling system. Engine Management: Fuel injection system, ignition system, emissions control, sensors (MAF, O2, TPS, etc.), ECU diagnostics and programming. Transmission Manual: Clutch system, gearbox disassembly and assembly, gear selection, synchronizers, bearings, seals, fluid specifications. Transmission Automatic: Torque converter, valve body, planetary gear sets, hydraulic control system, transmission fluid, shift solenoids, electronic control unit (TCU) diagnostics. Drivetrain AWD: Center differential, front and rear differentials, drive shafts, CV joints, viscous coupling unit (VCU), AWD system operation and diagnostics. Brakes: Hydraulic system, master cylinder, brake calipers, brake pads, brake discs/rotors, ABS system (sensors, modulator, control module), parking brake. Suspension: Front suspension (struts, control arms, ball joints, sway bar), rear suspension (multi-link, struts, trailing arms), wheel bearings, alignment specifications. Steering: Power steering system (pump, rack and pinion, fluid), steering column, linkage, alignment. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams, component testing. Body Exterior: Body panel removal and installation, doors, hood, tailgate, bumpers, glass, seals, trim, rust prevention and repair. Body Interior: Dashboard removal, seating, upholstery, door panels, headliner, HVAC system components (dash removal, blower motor, evaporator), trim panels. HVAC: Air conditioning system (compressor, condenser, evaporator, refrigerant, charging procedures), heating system, climate control unit, blower motor, ducting. Safety Systems: Airbag system (SRS components, deployment, sensors, control module), seatbelt mechanisms, ABS diagnostics. Procedures Included Preventive Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, tire rotation, brake inspections. Troubleshooting: Diagnostic charts, symptom-based troubleshooting, fault code interpretation, electrical circuit testing, component testing. Repair Procedures: Detailed step-by-step instructions for component removal, installation, rebuilding, and adjustment. Component Rebuilding: Engine, transmission, differential, brake caliper, power steering rack rebuilding procedures. Electrical Diagnostics: Wiring diagrams, pinout charts, continuity testing, voltage drop testing, component resistance testing. Suspension Alignment: Wheel alignment angles (camber, caster, toe), adjustment procedures. HVAC Service: Refrigerant charging, leak detection, component replacement, blower motor replacement, cabin filter replacement. Bodywork: Panel alignment, door hinge adjustment, glass replacement, bumper repair/replacement. Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics and body repair. Diagrams Illustrations: Tons of detailed pictures and diagrams included for visual guidance. Data Tables: Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic data. 📊 Manual Specifications File Format Print Quality: High-resolution printable pages for clear visualization of diagrams and text. Binding Type Binding Type: N/A (Digital Product) Paper Type Paper Type: N/A (Digital Product) ⚙️ Engine Specifications Primary Engine Engine Code 1: EJ25D (2.5L SOHC) Engine Code 2: EJ251 (2.5L SOHC - Facelift 2000+) Engine Code 3: EJ22E (2.2L SOHC - Early Models/Base Trims) Engine Code 4: EJ253 (2.5L SOHC - Later Facelift Models) Engine Displacement 1: 2457 cc Engine Displacement 2: 2212 cc Performance Horsepower Ej25D: 165 hp @ 5,500 rpm Torque Ej25D: 175 lb-ft @ 4,000 rpm Horsepower Ej251: 165 hp @ 5,600 rpm (slight variations) Torque Ej251: 170 lb-ft @ 4,000 rpm (slight variations) Horsepower Ej22E: 135 hp @ 5,500 rpm Torque Ej22E: 140 lb-ft @ 4,000 rpm Fuel System Fuel Delivery: Multi-point Electronic Fuel Injection (MPI) Recommended Fuel: 87 Octane Unleaded Gasoline Fuel Tank Capacity: 60 Liters (15.9 US Gallons) 🔧 Transmission Standard Transmission Type Primary: 4-Speed Automatic Transmission with Lock-Up Torque Converter Optional Transmission Type Optional: 5-Speed Manual Transmission Features AWD Coupling Auto: Viscous Coupling AWD system (standard on automatics) AWD Coupling Manual: Viscous Coupling AWD system with driver-controlled center differential (standard on manuals) Fluid Specifications Automatic Transmission Fluid: Subaru ATF-HP or equivalent (check specific year/model) Manual Transmission Fluid: Subaru Extra-S Gear Oil (75W-90) or equivalent 📐 Dimensions Exterior Length: Approx....

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy Outback

Model Generation:

BD/BG/BK (Second Generation)

Applicable Years:

1998, 1999, 2000, 2001, 2002, 2003, 2004

Codes

Chassis Codes:

BD5, BG5, BK5 (Export), BH5, BH9 (Japan)

Platform:

Subaru FF-S Platform

👋 Introduction

Market Position

Vehicle Segment:

Mid-size crossover/station wagon with standard All-Wheel Drive.

Standard Symmetrical All-Wheel Drive system, raised ground clearance, wagon practicality.

Competitive Analysis

Key Competitors:

Toyota Camry/Scepter Wagon, Honda Accord Wagon, Ford Mondeo Wagon, Volkswagen Passat Wagon, Volvo V70.

Key Features

Standard AWD:

Subaru's signature Symmetrical All-Wheel Drive system for enhanced traction and stability in various conditions.

Wagon Body Style:

Practical wagon body offering ample cargo space and versatility for families and outdoor activities.

Raised Suspension:

Higher ground clearance compared to a standard Legacy sedan, providing better capability on unpaved roads.

📋 Manual Details

Coverage Areas

Coverage Scope:

All Models & Repairs A-Z, Mechanical & Electrical

Page Count

Estimated Page Count:

Extensive (Specific count not provided, but implied to be comprehensive)

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital (Printable)

File Format Details:

Digital format, ensuring all pages are printable.

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder heads, crankshaft, pistons, connecting rods, camshafts, valve train, timing belts/chains, lubrication system, cooling system.

Engine Management:

Fuel injection system, ignition system, emissions control, sensors (MAF, O2, TPS, etc.), ECU diagnostics and programming.

Transmission Manual:

Clutch system, gearbox disassembly and assembly, gear selection, synchronizers, bearings, seals, fluid specifications.

Transmission Automatic:

Torque converter, valve body, planetary gear sets, hydraulic control system, transmission fluid, shift solenoids, electronic control unit (TCU) diagnostics.

Drivetrain AWD:

Center differential, front and rear differentials, drive shafts, CV joints, viscous coupling unit (VCU), AWD system operation and diagnostics.

Brakes:

Hydraulic system, master cylinder, brake calipers, brake pads, brake discs/rotors, ABS system (sensors, modulator, control module), parking brake.

Suspension:

Front suspension (struts, control arms, ball joints, sway bar), rear suspension (multi-link, struts, trailing arms), wheel bearings, alignment specifications.

Steering:

Power steering system (pump, rack and pinion, fluid), steering column, linkage, alignment.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams, component testing.

Body Exterior:

Body panel removal and installation, doors, hood, tailgate, bumpers, glass, seals, trim, rust prevention and repair.

Body Interior:

Dashboard removal, seating, upholstery, door panels, headliner, HVAC system components (dash removal, blower motor, evaporator), trim panels.

HVAC:

Air conditioning system (compressor, condenser, evaporator, refrigerant, charging procedures), heating system, climate control unit, blower motor, ducting.

Safety Systems:

Airbag system (SRS components, deployment, sensors, control module), seatbelt mechanisms, ABS diagnostics.

Procedures Included

Preventive Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, tire rotation, brake inspections.

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting, fault code interpretation, electrical circuit testing, component testing.

Repair Procedures:

Detailed step-by-step instructions for component removal, installation, rebuilding, and adjustment.

Component Rebuilding:

Engine, transmission, differential, brake caliper, power steering rack rebuilding procedures.

Electrical Diagnostics:

Wiring diagrams, pinout charts, continuity testing, voltage drop testing, component resistance testing.

Suspension Alignment:

Wheel alignment angles (camber, caster, toe), adjustment procedures.

HVAC Service:

Refrigerant charging, leak detection, component replacement, blower motor replacement, cabin filter replacement.

Bodywork:

Panel alignment, door hinge adjustment, glass replacement, bumper repair/replacement.

Technical Depth

Depth:

Comprehensive from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics and body repair.

Diagrams Illustrations:

Tons of detailed pictures and diagrams included for visual guidance.

Data Tables:

Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic data.

📊 Manual Specifications

File Format

Print Quality:

High-resolution printable pages for clear visualization of diagrams and text.

Binding Type

Binding Type:

N/A (Digital Product)

Paper Type

Paper Type:

N/A (Digital Product)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

EJ25D (2.5L SOHC)

Engine Code 2:

EJ251 (2.5L SOHC - Facelift 2000+)

Engine Code 3:

EJ22E (2.2L SOHC - Early Models/Base Trims)

Engine Code 4:

EJ253 (2.5L SOHC - Later Facelift Models)

Engine Displacement 1:

2457 cc

Engine Displacement 2:

2212 cc

Performance

Horsepower Ej25D:

165 hp @ 5,500 rpm

Torque Ej25D:

175 lb-ft @ 4,000 rpm

Horsepower Ej251:

165 hp @ 5,600 rpm (slight variations)

Torque Ej251:

170 lb-ft @ 4,000 rpm (slight variations)

Horsepower Ej22E:

135 hp @ 5,500 rpm

Torque Ej22E:

140 lb-ft @ 4,000 rpm

Fuel System

Fuel Delivery:

Multi-point Electronic Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline

Fuel Tank Capacity:

60 Liters (15.9 US Gallons)

🔧 Transmission

Standard

Transmission Type Primary:

4-Speed Automatic Transmission with Lock-Up Torque Converter

Optional

Transmission Type Optional:

5-Speed Manual Transmission

Features

AWD Coupling Auto:

Viscous Coupling AWD system (standard on automatics)

AWD Coupling Manual:

Viscous Coupling AWD system with driver-controlled center differential (standard on manuals)

Fluid Specifications

Automatic Transmission Fluid:

Subaru ATF-HP or equivalent (check specific year/model)

Manual Transmission Fluid:

Subaru Extra-S Gear Oil (75W-90) or equivalent

📐 Dimensions

Exterior

Length:

Approx. 4,755 mm (187.2 in)

Width:

Approx. 1,765 mm (69.5 in)

Height:

Approx. 1,570 mm (61.8 in)

Wheelbase:

Approx. 2,630 mm (103.5 in)

Ground Clearance:

Approx. 190 mm (7.5 in)

Interior

Seating Capacity:

5 Passengers

Cargo

Cargo Volume Seats Up:

Approx. 0.9 m³ (32 cu ft)

Weights

Curb Weight:

Approx. 1,450 - 1,550 kg (3,200 - 3,420 lbs) depending on trim and transmission.

Towing Capacity:

Typically around 1,000 lbs (450 kg) for unbraked, 2,000 lbs (900 kg) for braked (check local regulations and specific model).

🛡️ Safety Features

Ratings

NHTSA Front Driver Side Impact:

Likely rated 'Good' or 'Acceptable' for the era (specific ratings may vary by test year and region).

NHTSA Front Passenger Side Impact:

Likely rated 'Good' or 'Acceptable' for the era (specific ratings may vary by test year and region).

Active Features

Standard Anti-lock Braking System (ABS) on most models.

Traction Control:

Available Traction Control System (TCS) on some models.

Passive Features

Airbags:

Driver and Passenger Frontal Airbags (SRS), potentially side airbags on later/higher trims.

Seatbelts:

Three-point inertia-reel seatbelts with pre-tensioners and force limiters.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system potentially introduced on later models.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette/CD player with optional premium sound system. Speaker configurations vary by trim.

Climate Control:

Manual or automatic climate control depending on trim level.

Driver Assistance

Cruise Control:

Standard cruise control on most models.

Connectivity

Auxiliary Input:

N/A (Not standard; aftermarket solutions exist).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 - 7,500 miles (5,000 - 12,000 km) or 6-12 months, depending on driving conditions and oil type used (consult manual for specifics).

Timing Belt Replacement:

Recommended every 60,000 - 105,000 miles (96,000 - 168,000 km) or 5-7 years for EJ engines. Critical replacement item.

Coolant Flush:

Every 30,000 - 50,000 miles (48,000 - 80,000 km) or 2-3 years.

Brake Fluid Flush:

Every 24,000 - 30,000 miles (38,000 - 48,000 km) or 2 years.

Fluid Specifications

Engine Oil Specification:

5W-30 or 10W-30 API SG or higher, synthetic blend or full synthetic recommended.

Coolant Type:

Subaru Super Coolant (Blue) or equivalent Ethylene Glycol based coolant.

Power Steering Fluid:

Subaru Genuine Power Steering Fluid or Dexron III equivalent.

Known Issues

Head Gasket Failure:

Common issue on EJ25D engines (internal coolant leaks, oil contamination). EJ251 engines are generally more robust but can still be affected.

Oil Leaks:

Valve cover gasket, oil pan gasket, and front crankshaft seal leaks can occur with age.

Automatic Transmission Issues:

Some units may experience delayed shifts or solenoid issues, particularly with neglected fluid maintenance.

Suspension Wear:

Worn ball joints, tie rod ends, and sway bar links are common due to age and driving conditions.

Exhaust System Corrosion:

Rust and corrosion on the exhaust system, particularly in areas with road salt.

📚 Vehicle History

Brand Heritage

Subaru Heritage:

Subaru, the automotive division of Subaru Corporation, has a history rooted in aviation engineering, emphasizing four-wheel drive technology and boxer engines.

Model Evolution

Legacy Outback Origin:

The Outback was introduced in 1995 as an 'all-road' wagon variant of the Subaru Legacy, with increased ground clearance and rugged styling cues.

Second Gen Debut:

The BD/BG/BK generation debuted for the 1995 model year, with the Outback variant quickly gaining popularity.

Facelift Timing:

A significant facelift occurred for the 2000 model year, introducing revised styling, updated interior, and improved engines (e.g., EJ251).

Production

Production Period:

1995-2004 for this generation (with the manual covering the latter half of its production run).

Production Locations

Manufacturing Sites:

Primarily manufactured in Japan (Gunma Prefecture) and also in Taiwan and other locations for specific markets.

🏆 Awards & Recognition

Recognitions

Car And Driver Outback Reviews:

Car and Driver often praised the Outback for its all-weather capability and practicality during its production years.

Consumer Reports Ratings:

Consumer Reports ratings varied for this generation, with some praise for AWD and reliability of certain components, but notable concerns about head gaskets on specific engines.