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SUBARU LEGACY-OUTBACK 2002 Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Outback Year: 2002 Chassis Code: BG/BH (Second Generation) 👋 Introduction Market Position Positioning: The Subaru Legacy Outback is positioned as a versatile, capable wagon with SUV-like attributes, blending on-road comfort with off-road prowess. It appeals to individuals and families seeking a practical vehicle for diverse lifestyles and varying weather conditions. Competitive Analysis Competitors: Competed against vehicles like the Toyota Camry/Camry All-Trac, Honda Accord Wagon, and later, crossover SUVs. Key Features All Wheel Drive: Standard Symmetrical All-Wheel Drive system, a hallmark of Subaru vehicles, providing superior traction and stability. Ground Clearance: Elevated ride height compared to standard Legacy sedans, offering better clearance for light off-roading. Practicality: Spacious interior and cargo area, making it a practical choice for families and outdoor enthusiasts. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for the 2002 Subaru Legacy Outback. Secondary Coverage: Maintenance, troubleshooting, electrical systems, and technical specifications. Page Count Estimated Page Count: Likely extensive, typical for a full service manual (specific count not provided). Manual Type Type: Service and Repair Manual. Language Language: English (implied by product description and typical market). Format Format: Digital (implied by ease of storage and use, likely PDF). 📖 Manual Coverage Systems Covered Engine: Cylinder Head/Valve, Crankcase, Lubrication System, Ignition System, Engine Removal/Installation. Drivetrain: Transmission, Clutch, Gearshift Linkage, Front Driving Mechanism, Rear Driving Mechanism, Selectable 4WD System. Suspension Steering: Wheel, Suspension, Steering, Electric Power Steering. Brakes: Brake System. Electrical: Alternator/Starter Clutch, Electric Starter, Lights/Meters/Switches, Wiring Diagrams, Ignition System. Procedures Included Maintenance: Scheduled maintenance, fluid changes, inspections, general upkeep. Repair: Component repair and replacement for all major vehicle systems. Troubleshooting: Diagnostic procedures and solutions for common and uncommon issues. Diagnostics: Includes troubleshooting and likely diagnostic codes. Ignition System: Details on spark plugs, ignition coils, wiring, and troubleshooting ignition issues. Lubrication System: Oil pump, oil filter, oil pan, lubrication passages, and oil pressure checks. Front Driving Mechanism: Front differential, axles, and related components. Rear Driving Mechanism: Rear differential, axles, and related components. Electric Starter: Starter motor, solenoid, and associated circuitry diagnostics and repair. Selectable 4Wd System: Details on the operation and maintenance of the Symmetrical All-Wheel Drive system, including center differential and axle components. Technical Depth Depth: Covers from basic maintenance to advanced repair and troubleshooting, suitable for DIY enthusiasts and entry-level technicians. 📊 Manual Specifications File Format Format: Likely PDF, optimized for digital storage and accessibility. Print Quality Quality: High quality, designed with clear diagrams and easy-to-follow instructions. Binding Type Type: Not applicable (digital format). Paper Type Type: Not applicable (digital format). ⚙️ Engine Specifications Primary Engine Engine Code And Type: EJ251 (2.5L Naturally Aspirated SOHC Boxer-4) and EJ253 (2.5L Naturally Aspirated DOHC Boxer-4) depending on region and specific trim. Performance Horsepower: Approximately 165-175 hp (varies by engine variant and specific market). Torque: Approximately 162-166 lb-ft (varies by engine variant). Fuel System Type: Electronic Fuel Injection (EFI). Technical Details Displacement: 2.5 Liters (2498 cc). Bore X Stroke: 99.5 mm x 79.0 mm (typical for EJ25). Compression Ratio: Typically 9.7:1 or 10.0:1 depending on engine variant. 🔧 Transmission Standard Type: 4-Speed Automatic Transmission (4EAT). Optional Type: 5-Speed Manual Transmission. Features Subaru Traction Control System: Features Subaru's Symmetrical All-Wheel Drive system integrated with either the automatic or manual transmission. Fluid Specifications Automatic Transmission Fluid: Subaru ATF-HP (High Performance) or equivalent DEXRON III/MERCON compatible fluid. 📐 Dimensions Exterior Length: Approximately 189.0 inches. Width: Approximately 70.5 inches. Height: Approximately 63.0 inches (standard) to 65.0 inches (Outback). Wheelbase: Approximately 104.3 inches. Ground Clearance: Approximately 8.0 inches for Outback models. Weights Curb Weight: Approximately 3,300 - 3,500 lbs. Towing Capacity: Typically rated for 2,000 lbs when properly equipped. 🛡️ Safety Features Ratings NHTSA Front Impact: 5-star rating (driver and passenger) for 2002 models. NHTSA Side Impact: 4-star rating (front) for 2002 models. Active Features All Wheel Drive: Standard Symmetrical All-Wheel Drive for enhanced stability and traction. ABS: Standard Anti-lock Braking System (ABS). Passive Features Airbags: Front airbags, optional side airbags. Seat Belts: Front and rear three-point seat belts. 💡 Technology Features Infotainment Audio System: Standard AM/FM stereo with CD player and cassette deck. Upgraded systems with more speakers were available. Driver Assistance Cruise Control: Standard cruise control system. Connectivity Remote Keyless Entry: Available on certain trim levels. 🔧 Maintenance Service Intervals Oil Change: Every 3,000-7,500 miles or 6-12 months, depending on oil type and driving conditions (refer to manual for specific recommendation). Coolant Flush: Typically every 30,000 miles or 2 years. Timing Belt: For EJ25 engines, typically every 90,000-100,000 miles. **Crucial to check if it's an interference engine, requiring immediate replacement if broken.** Fluid Specifications Engine Oil: SAE 5W-30, API SG or higher (check manual for specific viscosity and certification). Coolant: Subaru Genuine Coolant or equivalent ethylene glycol-based coolant with corrosion inhibitors. Brake Fluid: DOT 3 or DOT 4. Known Issues Head Gaskets: Head gasket...
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Sku: 369017
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SUBARU LEGACY-OUTBACK 2002 Service Repair ManualSUBARU LEGACY-OUTBACK 2002 Service Repair ManualSUBARU LEGACY-OUTBACK 2002 Service Repair ManualSUBARU LEGACY-OUTBACK 2002 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy Outback
Year:
2002
Chassis Code:
BG/BH (Second Generation)
👋 Introduction
Market Position
Positioning:
The Subaru Legacy Outback is positioned as a versatile, capable wagon with SUV-like attributes, blending on-road comfort with off-road prowess. It appeals to individuals and families seeking a practical vehicle for diverse lifestyles and varying weather conditions.
Competitive Analysis
Competitors:
Competed against vehicles like the Toyota Camry/Camry All-Trac, Honda Accord Wagon, and later, crossover SUVs.
Key Features
All Wheel Drive:
Standard Symmetrical All-Wheel Drive system, a hallmark of Subaru vehicles, providing superior traction and stability.
Ground Clearance:
Elevated ride height compared to standard Legacy sedans, offering better clearance for light off-roading.
Practicality:
Spacious interior and cargo area, making it a practical choice for families and outdoor enthusiasts.
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service and repair for the 2002 Subaru Legacy Outback.
Secondary Coverage:
Maintenance, troubleshooting, electrical systems, and technical specifications.
Page Count
Estimated Page Count:
Likely extensive, typical for a full service manual (specific count not provided).
Manual Type
Type:
Service and Repair Manual.
Language
Language:
English (implied by product description and typical market).
Format
Format:
Digital (implied by ease of storage and use, likely PDF).
📖 Manual Coverage
Systems Covered
Engine:
Cylinder Head/Valve, Crankcase, Lubrication System, Ignition System, Engine Removal/Installation.
Drivetrain:
Transmission, Clutch, Gearshift Linkage, Front Driving Mechanism, Rear Driving Mechanism, Selectable 4WD System.
Suspension Steering:
Wheel, Suspension, Steering, Electric Power Steering.
Brakes:
Brake System.
Electrical:
Alternator/Starter Clutch, Electric Starter, Lights/Meters/Switches, Wiring Diagrams, Ignition System.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, inspections, general upkeep.
Repair:
Component repair and replacement for all major vehicle systems.
Troubleshooting:
Diagnostic procedures and solutions for common and uncommon issues.
Diagnostics:
Includes troubleshooting and likely diagnostic codes.
Ignition System:
Details on spark plugs, ignition coils, wiring, and troubleshooting ignition issues.
Lubrication System:
Oil pump, oil filter, oil pan, lubrication passages, and oil pressure checks.
Front Driving Mechanism:
Front differential, axles, and related components.
Rear Driving Mechanism:
Rear differential, axles, and related components.
Electric Starter:
Starter motor, solenoid, and associated circuitry diagnostics and repair.
Selectable 4Wd System:
Details on the operation and maintenance of the Symmetrical All-Wheel Drive system, including center differential and axle components.
Technical Depth
Depth:
Covers from basic maintenance to advanced repair and troubleshooting, suitable for DIY enthusiasts and entry-level technicians.
📊 Manual Specifications
File Format
Format:
Likely PDF, optimized for digital storage and accessibility.
Print Quality
Quality:
High quality, designed with clear diagrams and easy-to-follow instructions.
Binding Type
Type:
Not applicable (digital format).
Paper Type
Type:
Not applicable (digital format).
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
EJ251 (2.5L Naturally Aspirated SOHC Boxer-4) and EJ253 (2.5L Naturally Aspirated DOHC Boxer-4) depending on region and specific trim.
Performance
Horsepower:
Approximately 165-175 hp (varies by engine variant and specific market).
Torque:
Approximately 162-166 lb-ft (varies by engine variant).
Fuel System
Type:
Electronic Fuel Injection (EFI).
Technical Details
Displacement:
2.5 Liters (2498 cc).
Bore X Stroke:
99.5 mm x 79.0 mm (typical for EJ25).
Compression Ratio:
Typically 9.7:1 or 10.0:1 depending on engine variant.
🔧 Transmission
Standard
Type:
4-Speed Automatic Transmission (4EAT).
Optional
Type:
5-Speed Manual Transmission.
Features
Subaru Traction Control System:
Features Subaru's Symmetrical All-Wheel Drive system integrated with either the automatic or manual transmission.
Fluid Specifications
Automatic Transmission Fluid:
Subaru ATF-HP (High Performance) or equivalent DEXRON III/MERCON compatible fluid.
📐 Dimensions
Exterior
Length:
Approximately 189.0 inches.
Width:
Approximately 70.5 inches.
Height:
Approximately 63.0 inches (standard) to 65.0 inches (Outback).
Wheelbase:
Approximately 104.3 inches.
Ground Clearance:
Approximately 8.0 inches for Outback models.
Weights
Curb Weight:
Approximately 3,300 - 3,500 lbs.
Towing Capacity:
Typically rated for 2,000 lbs when properly equipped.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-star rating (driver and passenger) for 2002 models.
NHTSA Side Impact:
4-star rating (front) for 2002 models.
Active Features
All Wheel Drive:
Standard Symmetrical All-Wheel Drive for enhanced stability and traction.
ABS:
Standard Anti-lock Braking System (ABS).
Passive Features
Airbags:
Front airbags, optional side airbags.
Seat Belts:
Front and rear three-point seat belts.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM stereo with CD player and cassette deck. Upgraded systems with more speakers were available.
Driver Assistance
Cruise Control:
Standard cruise control system.
Connectivity
Remote Keyless Entry:
Available on certain trim levels.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,000-7,500 miles or 6-12 months, depending on oil type and driving conditions (refer to manual for specific recommendation).
Coolant Flush:
Typically every 30,000 miles or 2 years.
Timing Belt:
For EJ25 engines, typically every 90,000-100,000 miles. **Crucial to check if it's an interference engine, requiring immediate replacement if broken.**
Fluid Specifications
Engine Oil:
SAE 5W-30, API SG or higher (check manual for specific viscosity and certification).
Coolant:
Subaru Genuine Coolant or equivalent ethylene glycol-based coolant with corrosion inhibitors.
Brake Fluid:
DOT 3 or DOT 4.
Known Issues
Head Gaskets:
Head gasket leaks are a known concern in some EJ series engines, particularly with the DOHC variants, though less common on the SOHC 2.5L of this era compared to later models. The manual will detail inspection and replacement procedures.
Cv Axle Boots:
Wear and tear on CV axle boots can lead to grease leakage and potential damage. Regular inspection is recommended.
Wheel Bearings:
Front wheel bearings can be susceptible to wear, especially with off-road use. The manual will cover diagnostic and replacement steps.
Exhaust Manifold Cracks:
Cracks can develop in the exhaust manifold, leading to exhaust leaks and noise. This is a common issue on many naturally aspirated Subarus of this era.
📚 Vehicle History
Brand Heritage
Subaru Philosophy:
Subaru, a division of Subaru Corporation (formerly Fuji Heavy Industries), has a heritage rooted in aviation engineering, emphasizing durability, safety, and unique engineering solutions like the Boxer engine and Symmetrical All-Wheel Drive.
Model Evolution
Outback Origin:
The Outback was introduced in 1995 as a more rugged, lifted version of the Legacy station wagon, effectively creating the 'crossover wagon' segment.
Second Generation:
The 2002 model year represents the second generation of the Outback (BG/BH chassis), launched for the 1996 model year, which received styling updates and mechanical refinements over its predecessor.
Production
Manufacturing Location:
Primarily manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Car And Driver:
The Subaru Outback was frequently lauded by automotive publications like Car and Driver for its blend of practicality, capability, and value, often appearing on their '10Best' lists in various categories.
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