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2002 SUBARU LEGACY Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Year: 2002 Codes Chassis Code: BE/BH Platform: Subaru front-engine, all-wheel-drive platform 👋 Introduction Market Position Segment: Mid-size sedan and wagon, known for its standard All-Wheel Drive. Usp: Standard Symmetrical All-Wheel Drive and Boxer engine configuration. Competitive Analysis Competitors: Toyota Camry, Honda Accord, Nissan Altima, Mazda 6. Key Features Features: Symmetrical AWD, horizontally-opposed Boxer engines, comfortable ride, good build quality. Manual Value Proposition Value: Provides professional-level repair and maintenance information essential for DIY enthusiasts and independent shops. 📋 Manual Details Coverage Areas Coverage: Comprehensive service and repair information for all systems. Page Count Pages: Approximately 1500+ Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: 2.5L Naturally Aspirated (EJ253), 2.5L Turbocharged (EJ255/EJ257 - GT models) Fuel System: Fuel injection, fuel pump, lines, tank, emissions control (EVAP). Ignition System: Ignition timing, spark plugs, coils, ignition control module. Cooling System: Radiator, thermostat, water pump, hoses, coolant specifications. Exhaust System: Exhaust manifold, catalytic converter, muffler, oxygen sensors. Transmission: 4-speed automatic (4EAT), 5-speed manual (TY754). Drivetrain: All-Wheel Drive (AWD) system, differentials, driveshafts, CV joints. Suspension: Front struts, rear struts, control arms, bushings, coil springs, stabilizer bars. Steering: Power steering system, pump, rack and pinion, steering column. Brakes: Front ventilated discs, rear solid discs (standard), ABS system, brake fluid specifications. Electrical System: Battery, charging system, starter, lighting, fuses, relays, wiring diagrams. HVAC: Air conditioning, heating, climate control panel, blower motor, refrigerant. Body Exterior: Body panels, doors, hood, trunk, glass, trim, bumpers. Body Interior: Seats, dashboard, door panels, headliner, carpeting. Chassis And Frame: Frame structure, body mounting points, corrosion protection. Diagnostic Troubleshooting: OBD-II diagnostic trouble codes (DTCs), symptom-based troubleshooting guides. Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, tune-ups. Repair: Detailed step-by-step repair procedures for all major components and systems. Diagnostics: Troubleshooting procedures, diagnostic flowcharts, pinpoint tests. Adjustment: Wheel alignment, parking brake adjustment, clutch adjustment. Removal Installation: Component removal and installation procedures (e.g., engine, transmission, suspension components). Specifications Data: Torque specifications, clearances, fluid capacities, pressure readings. Wiring Diagrams: Comprehensive electrical system wiring diagrams for all circuits. Body Repair: Dent repair, panel replacement, glass replacement, seam sealer application. Technical Depth Depth: Extensive, covering everything from basic maintenance to complete engine and transmission rebuilds. Diagnostic Capability: Advanced diagnostic procedures, including oscilloscope usage and sensor testing. Rebuild Procedures: Detailed instructions for rebuilding engines, transmissions, and other major components. 📊 Manual Specifications File Format Format Details: PDF (Portable Document Format), searchable text, printable. Print Quality Quality: High-resolution scans ensuring clarity of diagrams and text. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code Na: EJ253 Displacement Na: 2.5 Liters (2498 cc) Configuration Na: Naturally Aspirated, Boxer-4 Cylinder Horsepower Na: 165 hp @ 5600 rpm Torque Na: 166 lb-ft @ 4000 rpm Turbo Engine Engine Code Turbo: EJ255 (GT models), EJ257 (GT-Limited) Displacement Turbo: 2.5 Liters (2457 cc) Configuration Turbo: Turbocharged, Boxer-4 Cylinder Horsepower Turbo: 220 hp @ 5600 rpm (EJ255), 230 hp @ 5600 rpm (EJ257) Torque Turbo: 236 lb-ft @ 3600 rpm (EJ255), 235 lb-ft @ 4000 rpm (EJ257) Fuel System Fuel Type: Unleaded Gasoline Injection Type: Multi-port Electronic Fuel Injection (MPI) Ignition Type: Distributorless Electronic Ignition (Coil-on-plug for turbo models) 🔧 Transmission Standard Type Manual: 5-speed Manual Transmission Code Manual: TY754 Optional Type Automatic: 4-speed Automatic Transmission Code Automatic: 4EAT Features Drivetrain System: Symmetrical All-Wheel Drive (AWD) for both manual and automatic transmissions. Fluid Spec Automatic: Subaru ATF HP, Dexron III equivalent. Fluid Spec Manual: Subaru Extra-S Gear Oil (75W-90 GL-5) or equivalent. 📐 Dimensions Exterior Length: 189.8 inches (4820 mm) Width: 69.7 inches (1770 mm) Height: 56.1 inches (1425 mm) Wheelbase: 104.3 inches (2650 mm) Ground Clearance: 5.7 inches (145 mm) Weights Curb Weight Na: Approximately 3200 - 3400 lbs (1450 - 1540 kg) Curb Weight Turbo: Approximately 3400 - 3600 lbs (1540 - 1630 kg) Cargo Trunk Volume: Approximately 14.1 cubic feet (sedan), 37.7 cubic feet with rear seats up (wagon) 🛡️ Safety Features Ratings NHTSA Front Driver: Good NHTSA Front Passenger: Good IIHS Side Impact: Acceptable Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Available on some higher trims. Passive Features Airbags: Front airbags, available side airbags. Seatbelts: Front and rear three-point seatbelts, pretensioners. Child Anchors: LATCH (Lower Anchors and Tethers for Children) system. 💡 Technology Features Infotainment Audio System: Standard AM/FM/CD stereo with optional premium sound system, cassette player often included. Navigation: Rarely factory-equipped, typically aftermarket. Driver Assistance Cruise Control: Standard on most models. Connectivity Connectivity Options: Limited to basic audio connectivity, no modern Bluetooth or USB integration from the factory. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 miles or 3 months (severe conditions) / Every 7,500 miles or 7.5 months (normal conditions). Air Filter Replacement: Every...
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2002 SUBARU LEGACY Service Repair Manual2002 SUBARU LEGACY Service Repair Manual2002 SUBARU LEGACY Service Repair Manual2002 SUBARU LEGACY Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy
Year:
2002
Codes
Chassis Code:
BE/BH
Platform:
Subaru front-engine, all-wheel-drive platform
👋 Introduction
Market Position
Segment:
Mid-size sedan and wagon, known for its standard All-Wheel Drive.
Usp:
Standard Symmetrical All-Wheel Drive and Boxer engine configuration.
Competitive Analysis
Competitors:
Toyota Camry, Honda Accord, Nissan Altima, Mazda 6.
Key Features
Features:
Symmetrical AWD, horizontally-opposed Boxer engines, comfortable ride, good build quality.
Manual Value Proposition
Value:
Provides professional-level repair and maintenance information essential for DIY enthusiasts and independent shops.
📋 Manual Details
Coverage Areas
Coverage:
Comprehensive service and repair information for all systems.
Page Count
Pages:
Approximately 1500+
Manual Type
Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
2.5L Naturally Aspirated (EJ253), 2.5L Turbocharged (EJ255/EJ257 - GT models)
Fuel System:
Fuel injection, fuel pump, lines, tank, emissions control (EVAP).
Ignition System:
Ignition timing, spark plugs, coils, ignition control module.
Cooling System:
Radiator, thermostat, water pump, hoses, coolant specifications.
Exhaust System:
Exhaust manifold, catalytic converter, muffler, oxygen sensors.
Transmission:
4-speed automatic (4EAT), 5-speed manual (TY754).
Drivetrain:
All-Wheel Drive (AWD) system, differentials, driveshafts, CV joints.
Suspension:
Front struts, rear struts, control arms, bushings, coil springs, stabilizer bars.
Steering:
Power steering system, pump, rack and pinion, steering column.
Brakes:
Front ventilated discs, rear solid discs (standard), ABS system, brake fluid specifications.
Electrical System:
Battery, charging system, starter, lighting, fuses, relays, wiring diagrams.
HVAC:
Air conditioning, heating, climate control panel, blower motor, refrigerant.
Body Exterior:
Body panels, doors, hood, trunk, glass, trim, bumpers.
Body Interior:
Seats, dashboard, door panels, headliner, carpeting.
Chassis And Frame:
Frame structure, body mounting points, corrosion protection.
Diagnostic Troubleshooting:
OBD-II diagnostic trouble codes (DTCs), symptom-based troubleshooting guides.
Procedures Included
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, tune-ups.
Repair:
Detailed step-by-step repair procedures for all major components and systems.
Diagnostics:
Troubleshooting procedures, diagnostic flowcharts, pinpoint tests.
Adjustment:
Wheel alignment, parking brake adjustment, clutch adjustment.
Removal Installation:
Component removal and installation procedures (e.g., engine, transmission, suspension components).
Specifications Data:
Torque specifications, clearances, fluid capacities, pressure readings.
Wiring Diagrams:
Comprehensive electrical system wiring diagrams for all circuits.
Body Repair:
Dent repair, panel replacement, glass replacement, seam sealer application.
Technical Depth
Depth:
Extensive, covering everything from basic maintenance to complete engine and transmission rebuilds.
Diagnostic Capability:
Advanced diagnostic procedures, including oscilloscope usage and sensor testing.
Rebuild Procedures:
Detailed instructions for rebuilding engines, transmissions, and other major components.
📊 Manual Specifications
File Format
Format Details:
PDF (Portable Document Format), searchable text, printable.
Print Quality
Quality:
High-resolution scans ensuring clarity of diagrams and text.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Na:
EJ253
Displacement Na:
2.5 Liters (2498 cc)
Configuration Na:
Naturally Aspirated, Boxer-4 Cylinder
Horsepower Na:
165 hp @ 5600 rpm
Torque Na:
166 lb-ft @ 4000 rpm
Turbo Engine
Engine Code Turbo:
EJ255 (GT models), EJ257 (GT-Limited)
Displacement Turbo:
2.5 Liters (2457 cc)
Configuration Turbo:
Turbocharged, Boxer-4 Cylinder
Horsepower Turbo:
220 hp @ 5600 rpm (EJ255), 230 hp @ 5600 rpm (EJ257)
Torque Turbo:
236 lb-ft @ 3600 rpm (EJ255), 235 lb-ft @ 4000 rpm (EJ257)
Fuel System
Fuel Type:
Unleaded Gasoline
Injection Type:
Multi-port Electronic Fuel Injection (MPI)
Ignition Type:
Distributorless Electronic Ignition (Coil-on-plug for turbo models)
🔧 Transmission
Standard
Type Manual:
5-speed Manual
Transmission Code Manual:
TY754
Optional
Type Automatic:
4-speed Automatic
Transmission Code Automatic:
4EAT
Features
Drivetrain System:
Symmetrical All-Wheel Drive (AWD) for both manual and automatic transmissions.
Fluid Spec Automatic:
Subaru ATF HP, Dexron III equivalent.
Fluid Spec Manual:
Subaru Extra-S Gear Oil (75W-90 GL-5) or equivalent.
📐 Dimensions
Exterior
Length:
189.8 inches (4820 mm)
Width:
69.7 inches (1770 mm)
Height:
56.1 inches (1425 mm)
Wheelbase:
104.3 inches (2650 mm)
Ground Clearance:
5.7 inches (145 mm)
Weights
Curb Weight Na:
Approximately 3200 - 3400 lbs (1450 - 1540 kg)
Curb Weight Turbo:
Approximately 3400 - 3600 lbs (1540 - 1630 kg)
Cargo
Trunk Volume:
Approximately 14.1 cubic feet (sedan), 37.7 cubic feet with rear seats up (wagon)
🛡️ Safety Features
Ratings
NHTSA Front Driver:
Good
NHTSA Front Passenger:
Good
IIHS Side Impact:
Acceptable
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available on some higher trims.
Passive Features
Airbags:
Front airbags, available side airbags.
Seatbelts:
Front and rear three-point seatbelts, pretensioners.
Child Anchors:
LATCH (Lower Anchors and Tethers for Children) system.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD stereo with optional premium sound system, cassette player often included.
Navigation:
Rarely factory-equipped, typically aftermarket.
Driver Assistance
Cruise Control:
Standard on most models.
Connectivity
Connectivity Options:
Limited to basic audio connectivity, no modern Bluetooth or USB integration from the factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 3 months (severe conditions) / Every 7,500 miles or 7.5 months (normal conditions).
Air Filter Replacement:
Every 30,000 miles or 30 months.
Spark Plug Replacement:
Every 60,000 miles (copper plugs) / 100,000 miles (iridium plugs).
Transmission Fluid Change Auto:
Every 30,000 miles (severe) / 60,000 miles (normal).
Transmission Fluid Change Manual:
Every 30,000 miles (severe) / 60,000 miles (normal).
Coolant Flush:
Every 30,000 miles or 30 months.
Fluid Specifications
Engine Oil Type:
SAE 5W-30, API SG or higher (check owner's manual for specific viscosity)
Coolant Type:
Subaru Super Coolant (50/50 mix of Subaru Super Coolant and distilled water)
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid:
Subaru Genuine Power Steering Fluid or Dexron III ATF.
Known Issues
Head Gaskets:
While less common than in earlier generations, head gasket leaks can occur, particularly on higher-mileage vehicles. The manual details inspection and replacement procedures.
Wheel Bearings:
Front and rear wheel bearings can wear over time. The manual covers diagnosis and replacement.
Cv Axles:
Wear and tear on Constant Velocity (CV) axles and boots is common, especially with AWD components. Repair/replacement procedures are detailed.
Automatic Transmission Slippage:
Some 4EAT transmissions may exhibit slippage issues. The manual provides diagnostic steps for solenoids, clutches, and valve bodies.
Crank Position Sensor:
Failure of the crankshaft position sensor can lead to no-start or stalling conditions. The manual details testing and replacement.
📚 Vehicle History
Brand Heritage
Heritage Focus:
Subaru's reputation for reliability, safety, and All-Wheel Drive technology.
Model Evolution
Generation Start:
Third generation (1999-2004).
Model Line Introduction:
Legacy introduced in 1990.
Production
Manufacturing Location:
Gunma Plant, Japan.
🏆 Awards & Recognition
Recognitions
Safety Award:
Consistently received good ratings from IIHS and NHTSA for its safety features.
Value Award:
Often cited for its value proposition due to standard AWD and Subaru's reputation.
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