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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 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: PDF 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 ABS: 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...
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Subaru Legacy Outback 2002 Workshop Service Repair Manual
🏷️ 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 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:
PDF
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
ABS:
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.
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