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2002 Subaru Legacy Outback Service Repair Manual

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$141.00
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🏷️ Basic Information Identification Make: Subaru Model: Legacy Outback Year: 2002 Codes Chassis Code: BE/BH 👋 Introduction Market Position Positioning: A versatile all-wheel-drive wagon/SUV crossover, known for its practicality and capability in various weather conditions. Competitive Analysis Competitors: Ford Escape, Toyota RAV4, Honda CR-V, Nissan Xterra. Key Features Standard AWD: Subaru's signature Symmetrical All-Wheel Drive system provides enhanced traction and stability. Ground Clearance: Higher ground clearance compared to traditional wagons, offering mild off-road capability. Interior Versatility: Spacious interior with foldable rear seats for cargo hauling. 📋 Manual Details Coverage Areas Primary Coverage: North America Secondary Coverage: Global (technical principles apply) Page Count Estimated Page Count: 2000+ Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete diagnostics, repair, and overhaul procedures for all engine variants. Engine Electrical: Detailed wiring diagrams, ECU functions, sensor diagnostics, and ignition system repair. Fuel System: Fuel injection system diagnostics, fuel pump testing, injector cleaning, and evaporative emission control (EVAP). Transmission Manual: Repair, overhaul, and fluid specifications for manual transmissions. Transmission Automatic: Diagnostics, repair procedures, valve body operation, torque converter testing, and fluid specifications for automatic transmissions. Drivetrain AWD: Subaru's Symmetrical All-Wheel Drive system, including differential service, viscous coupling unit (VCU) inspection, and transfer case maintenance. Brakes: Front and rear brake system repair, ABS diagnostics and component replacement, parking brake adjustment. Suspension: Front and rear suspension component replacement (struts, springs, bushings), alignment specifications, and troubleshooting. Steering: Power steering system diagnosis, pump replacement, steering gear and linkage repair. HVAC: Air conditioning system servicing, refrigerant handling, heater core replacement, and climate control unit diagnostics. Electrical System: Lighting systems, power windows, door locks, mirrors, horn, wipers, and other body electrical components. Interior: Seat removal and repair, dashboard disassembly, trim panel replacement, and interior accessory installation. Exterior: Fascia removal and installation, panel alignment, door and trunk hinge adjustment, glass replacement. Body And Frame: Frame specifications, body panel repair, rust prevention, and structural component diagnosis. Procedures Included Preventative Maintenance: Detailed service intervals, fluid changes, filter replacements, and inspections. Troubleshooting Diagnostics: Systematic diagnostic flowcharts, fault code interpretation, and component testing procedures. Repair And Rebuild: Step-by-step instructions for component removal, installation, and complete overhaul. Torque Specifications: Comprehensive list of torque values for all critical fasteners. Special Tools: Identification and usage of Subaru-specific specialty tools required for certain repairs. Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text enabled for quick information retrieval. Printability: Printable pages for workshop use. Print Quality Quality: High-resolution scans ensuring clarity of diagrams and text. Binding Type Binding: Digital (PDF file) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type 1: 2.5L DOHC 16-valve Subaru Boxer Engine Code 1: EJ253 Horsepower 1: 165 hp @ 5600 rpm Torque 1: 166 lb-ft @ 4000 rpm Performance Induction Type 1: Naturally Aspirated Fuel System Fuel Delivery 1: Electronic Fuel Injection (EFI) Fuel Type 1: Unleaded gasoline (87 octane recommended) Cooling System Coolant Capacity: 7.6 US Quarts (7.2 Liters) Lubrication Oil Capacity: 4.5 US Quarts (4.3 Liters) with filter Recommended Oil Viscosity: 5W-30 API SG or higher 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transmission Optional Transmission Type: 4-Speed Automatic Transmission (4EAT) Features AWD System: Symmetrical All-Wheel Drive with viscous coupling center differential (manual) or electronically controlled multi-plate clutch system (automatic). Fluid Specifications Manual Transmission Fluid: GL-5 75W-90 Gear Oil Automatic Transmission Fluid: Subaru ATF-HP (Type H6) 📐 Dimensions Exterior Wheelbase: 104.3 inches (2649 mm) Length: 187.4 inches (4760 mm) Width: 70.1 inches (1781 mm) Height: 62.0 inches (1575 mm) Ground Clearance: 7.7 inches (196 mm) Weights Curb Weight Manual: Approx. 3350 lbs (1520 kg) Curb Weight Automatic: Approx. 3450 lbs (1565 kg) Cargo Cargo Volume Seats Up: 37.7 cu ft (1067 Liters) Cargo Volume Seats Down: 72.7 cu ft (2058 Liters) Tires Wheels Standard Tire Size: 215/60R16 Optional Tire Size: 225/55R17 Wheel Bolt Pattern: 5x100mm Wheel Size: 16x6.5 inches (standard), 17x7.0 inches (optional) 🛡️ Safety Features Ratings NHTSA Front Impact: 5-Star (Driver and Passenger) NHTSA Side Impact: 4-Star (Front), 4-Star (Rear) IIHS Front Offset: Good Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional Traction Control System (TCS) Passive Features Airbags: Dual front airbags, optional front side-impact airbags. Seatbelts: 3-point height-adjustable front seatbelts with pretensioners, rear 3-point seatbelts. 💡 Technology Features Infotainment Audio System: Aftermarket head units commonly installed. Original systems were basic AM/FM/CD or cassette players. Driver Assistance Cruise Control: Standard on most trims. Connectivity N A: No integrated Bluetooth or advanced connectivity features in this era. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 miles (6,000 km) or 3 months, whichever comes first. Air Filter Replacement: Every 15,000 miles (24,000 km) or 12 months. Spark Plug Replacement: Every 60,000 miles (96,000 km) (platinum-tipped)....
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2002 Subaru Legacy Outback Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Legacy Outback
Year:
2002
Codes
Chassis Code:
BE/BH
👋 Introduction
Market Position
Positioning:
A versatile all-wheel-drive wagon/SUV crossover, known for its practicality and capability in various weather conditions.
Competitive Analysis
Competitors:
Ford Escape, Toyota RAV4, Honda CR-V, Nissan Xterra.
Key Features
Standard AWD:
Subaru's signature Symmetrical All-Wheel Drive system provides enhanced traction and stability.
Ground Clearance:
Higher ground clearance compared to traditional wagons, offering mild off-road capability.
Interior Versatility:
Spacious interior with foldable rear seats for cargo hauling.
📋 Manual Details
Coverage Areas
Primary Coverage:
North America
Secondary Coverage:
Global (technical principles apply)
Page Count
Estimated Page Count:
2000+
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete diagnostics, repair, and overhaul procedures for all engine variants.
Engine Electrical:
Detailed wiring diagrams, ECU functions, sensor diagnostics, and ignition system repair.
Fuel System:
Fuel injection system diagnostics, fuel pump testing, injector cleaning, and evaporative emission control (EVAP).
Transmission Manual:
Repair, overhaul, and fluid specifications for manual transmissions.
Transmission Automatic:
Diagnostics, repair procedures, valve body operation, torque converter testing, and fluid specifications for automatic transmissions.
Drivetrain AWD:
Subaru's Symmetrical All-Wheel Drive system, including differential service, viscous coupling unit (VCU) inspection, and transfer case maintenance.
Brakes:
Front and rear brake system repair, ABS diagnostics and component replacement, parking brake adjustment.
Suspension:
Front and rear suspension component replacement (struts, springs, bushings), alignment specifications, and troubleshooting.
Steering:
Power steering system diagnosis, pump replacement, steering gear and linkage repair.
HVAC:
Air conditioning system servicing, refrigerant handling, heater core replacement, and climate control unit diagnostics.
Electrical System:
Lighting systems, power windows, door locks, mirrors, horn, wipers, and other body electrical components.
Interior:
Seat removal and repair, dashboard disassembly, trim panel replacement, and interior accessory installation.
Exterior:
Fascia removal and installation, panel alignment, door and trunk hinge adjustment, glass replacement.
Body And Frame:
Frame specifications, body panel repair, rust prevention, and structural component diagnosis.
Procedures Included
Preventative Maintenance:
Detailed service intervals, fluid changes, filter replacements, and inspections.
Troubleshooting Diagnostics:
Systematic diagnostic flowcharts, fault code interpretation, and component testing procedures.
Repair And Rebuild:
Step-by-step instructions for component removal, installation, and complete overhaul.
Torque Specifications:
Comprehensive list of torque values for all critical fasteners.
Special Tools:
Identification and usage of Subaru-specific specialty tools required for certain repairs.
Technical Depth
Depth:
Comprehensive from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text enabled for quick information retrieval.
Printability:
Printable pages for workshop use.
Print Quality
Quality:
High-resolution scans ensuring clarity of diagrams and text.
Binding Type
Binding:
Digital (PDF file)
Paper Type
Paper Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type 1:
2.5L DOHC 16-valve Subaru Boxer
Engine Code 1:
EJ253
Horsepower 1:
165 hp @ 5600 rpm
Torque 1:
166 lb-ft @ 4000 rpm
Performance
Induction Type 1:
Naturally Aspirated
Fuel System
Fuel Delivery 1:
Electronic Fuel Injection (EFI)
Fuel Type 1:
Unleaded gasoline (87 octane recommended)
Cooling System
Coolant Capacity:
7.6 US Quarts (7.2 Liters)
Lubrication
Oil Capacity:
4.5 US Quarts (4.3 Liters) with filter
Recommended Oil Viscosity:
5W-30 API SG or higher
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Transmission
Optional
Transmission Type:
4-Speed Automatic Transmission (4EAT)
Features
AWD System:
Symmetrical All-Wheel Drive with viscous coupling center differential (manual) or electronically controlled multi-plate clutch system (automatic).
Fluid Specifications
Manual Transmission Fluid:
GL-5 75W-90 Gear Oil
Automatic Transmission Fluid:
Subaru ATF-HP (Type H6)
📐 Dimensions
Exterior
Wheelbase:
104.3 inches (2649 mm)
Length:
187.4 inches (4760 mm)
Width:
70.1 inches (1781 mm)
Height:
62.0 inches (1575 mm)
Ground Clearance:
7.7 inches (196 mm)
Weights
Curb Weight Manual:
Approx. 3350 lbs (1520 kg)
Curb Weight Automatic:
Approx. 3450 lbs (1565 kg)
Cargo
Cargo Volume Seats Up:
37.7 cu ft (1067 Liters)
Cargo Volume Seats Down:
72.7 cu ft (2058 Liters)
Tires Wheels
Standard Tire Size:
215/60R16
Optional Tire Size:
225/55R17
Wheel Bolt Pattern:
5x100mm
Wheel Size:
16x6.5 inches (standard), 17x7.0 inches (optional)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (Driver and Passenger)
NHTSA Side Impact:
4-Star (Front), 4-Star (Rear)
IIHS Front Offset:
Good
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional Traction Control System (TCS)
Passive Features
Airbags:
Dual front airbags, optional front side-impact airbags.
Seatbelts:
3-point height-adjustable front seatbelts with pretensioners, rear 3-point seatbelts.
💡 Technology Features
Infotainment
Audio System:
Aftermarket head units commonly installed. Original systems were basic AM/FM/CD or cassette players.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
N A:
No integrated Bluetooth or advanced connectivity features in this era.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 3 months, whichever comes first.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Spark Plug Replacement:
Every 60,000 miles (96,000 km) (platinum-tipped).
Coolant Replacement:
Initial: 30,000 miles (48,000 km) or 24 months. Subsequent: Every 30,000 miles (48,000 km) or 24 months.
Timing Belt Replacement:
Every 105,000 miles (168,000 km) or 7 years.
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 (check cap/reservoir)
Power Steering Fluid:
Subaru Genuine Power Steering Fluid or DEXRON III/VI ATF.
Known Issues
Head Gaskets:
While less prone than earlier generations, 2002 models can still develop head gasket leaks. The manual provides diagnostic and repair procedures.
O2 Sensors:
Failure of oxygen sensors can lead to poor fuel economy and check engine lights. Manual covers sensor testing.
Automatic Transmission Line Leaks:
Leaking transmission cooler lines can cause fluid loss. Manual details replacement procedures.
📚 Vehicle History
Brand Heritage
Brand Focus:
Subaru is renowned for its commitment to Symmetrical All-Wheel Drive and horizontally-opposed Boxer engines.
Model Evolution
Generation:
Second Generation (Second generation for Outback model, distinct from Legacy sedan/wagon).
Platform:
Shared platform with the Subaru Legacy (BD/BG chassis for earlier generations, BE/BH for this generation).
Production
Manufacturing Location:
Gunma, Japan
Production Years:
1999-2004 (for this generation)
🏆 Awards & Recognition
Recognitions
Past Recognitions:
Often praised for its all-weather capability and practicality, though specific awards for the 2002 model are less publicized than modern iterations.
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