SUBARU LEGACY OUTBACK Service Repair Manual 1998-2004

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Outback Model Generation: Second Generation (BH/BE) Codes Chassis Codes: BH (Outback), BE (Legacy Sedan) 👋 Introduction Market Position Segment: Mid-size Crossover SUV / Wagon with standard All-Wheel Drive Competitive Analysis Key Competitors: Toyota RAV4, Honda CR-V, Ford Escape, Nissan Xterra (though Outback is more car-like) Key Features All Wheel Drive: Standard Symmetrical All-Wheel Drive (AWD) system across all trims. Ground Clearance: Higher ground clearance than standard Legacy sedan, offering enhanced capability over varied terrain. Wagon Design: Combines the comfort and handling of a car with the utility of an SUV. 📋 Manual Details Coverage Areas Years Covered: 1998, 1999, 2000, 2001, 2002, 2003, 2004 Regions Covered: Global (primarily North American specifications likely) Page Count Estimated Page Count: Likely 1500+ pages (typical for comprehensive service manuals of this era) Manual Type Type: Service and Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine removal/installation, cylinder head/valve, cylinder/piston, crankshaft/primary shaft, crankcase, timing belt, oil pump, water pump, engine cooling system, lubrication system Fuel System: Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, evaporative emissions control (EVAP) system Ignition System: Ignition coils, spark plugs, ignition timing, crank angle sensor, camshaft position sensor Transmission Manual: Clutch, gearshift linkage, transmission disassembly/assembly, bearing replacement, synchronizer repair Transmission Automatic: Automatic transmission removal/installation, internal component overhaul (planitary gears, clutch packs), valve body diagnostics, torque converter service Drivetrain: All-Wheel Drive (AWD) system, viscous coupling, front and rear differentials, driveshafts, CV joints Suspension Steering: Front suspension (struts, control arms, ball joints, sway bar), rear suspension (shocks, trailing arms, multi-link setup), wheel bearings, steering rack, power steering system Brakes: Hydraulic brake system, brake pads, brake rotors, calipers, master cylinder, ABS system, parking brake Electrical Charging: Battery, alternator, starter motor, wiring harnesses, fuses, relays Electrical Ignition: Ignition system components, coil-on-plug (COP) system (if applicable), spark plug wires Electrical Lighting: Headlights, taillights, interior lighting, fog lights, bulb replacement Electrical Accessories: Power windows, power locks, sunroof, audio system, climate control system, wipers, horn Body Exterior: Body panel removal/installation, bumpers, doors, hood, trunk lid, glass replacement, exterior trim Body Interior: Dashboard removal, seat removal, headliner, door panels, carpet, trim pieces Climate Control: HVAC system, A/C compressor, refrigerant recharging, heater core, blower motor, climate control unit Safety Systems: Airbag system (SRS), ABS diagnostics and repair Procedures Included Maintenance: Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid flush, transmission fluid change, differential fluid change, timing belt replacement, battery maintenance Diagnostics: Troubleshooting guides for common issues, symptom-based diagnostics, reading diagnostic trouble codes (DTCs) via OBD-II (if applicable for the model year) Repair: Engine rebuilding, transmission overhaul, brake system repair, suspension component replacement, electrical system troubleshooting and repair, body panel repair Installation: Component installation (e.g., new engine, transmission, suspension parts), accessory installation Adjustment: Idle speed adjustment, clutch adjustment (if applicable), parking brake adjustment Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics. 📊 Manual Specifications File Format Compatibility: PC/MAC Compatible Viewing Features: Zoom In/Out Capability Print Quality Print Options: Print selected pages or entire manual Binding Type Binding Type: Digital (PDF - No physical binding) Paper Type Paper Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Code 1: EJ253 (2.5L SOHC Non-Turbo) - Likely the most common Engine Code 2: EJ254 (2.5L DOHC Non-Turbo) - Also common Engine Code 3: EJ25D (2.5L DOHC Turbocharged - GT Models) Performance Horsepower 2 5L Sohc: Approx. 165 hp @ 5600 rpm Torque 2 5L Sohc: Approx. 162 lb-ft @ 4000 rpm Horsepower 2 5L DOHc: Approx. 167 hp @ 5600 rpm Torque 2 5L DOHc: Approx. 166 lb-ft @ 4000 rpm Horsepower 2 5L Turbo: Approx. 212 hp @ 5500 rpm (GT models) Torque 2 5L Turbo: Approx. 230 lb-ft @ 3000-4700 rpm (GT models) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 octane recommended for non-turbo, 91 octane for turbo) Engine Layout Layout: Horizontally Opposed (Boxer) 4-Cylinder Engine Maintenance Timing Belt Interval: Recommended replacement every 60,000-105,000 miles or 5-7 years, depending on model year and conditions (critical maintenance item) 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Transmission Optional Transmission Type Optional: 4-Speed Automatic Transmission (with overdrive) Features AWD Coupling Manual: Viscous Coupling AWD for manual transmission models AWD Coupling Automatic: Active AWD system with electronically controlled clutch pack for automatic transmission models Fluid Specs Manual Transmission Fluid: API GL-4, SAE 75W-90 synthetic gear oil (check specific manual for exact specification and capacity) Automatic Transmission Fluid: Subaru ATF HP (or equivalent) (check specific manual for exact specification and capacity) 📐 Dimensions Exterior Wheelbase: Approx. 104.3 inches (2649 mm) Length: Approx. 185.2 inches (4704 mm) Width: Approx. 69.7 inches (1770 mm) Height: Approx. 59.4 inches (1509 mm) Ground...

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Tipo: Car

Fabricante:

Sku: 303944

Coleções: ALL Subaru

Disponibilidade: Em estoque

Tag: 1998 1999 2000 2001 2002 2003 2004 Car Cars LEGACY OUTBACK Outback Subaru

Variantes do produto

Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Legacy Outback

Model Generation:

Second Generation (BH/BE)

Codes

Chassis Codes:

BH (Outback), BE (Legacy Sedan)

👋 Introduction

Market Position

Segment:

Mid-size Crossover SUV / Wagon with standard All-Wheel Drive

Competitive Analysis

Key Competitors:

Toyota RAV4, Honda CR-V, Ford Escape, Nissan Xterra (though Outback is more car-like)

Key Features

All Wheel Drive:

Standard Symmetrical All-Wheel Drive (AWD) system across all trims.

Ground Clearance:

Higher ground clearance than standard Legacy sedan, offering enhanced capability over varied terrain.

Wagon Design:

Combines the comfort and handling of a car with the utility of an SUV.

📋 Manual Details

Coverage Areas

Years Covered:

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

Regions Covered:

Global (primarily North American specifications likely)

Page Count

Estimated Page Count:

Likely 1500+ pages (typical for comprehensive service manuals of this era)

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine removal/installation, cylinder head/valve, cylinder/piston, crankshaft/primary shaft, crankcase, timing belt, oil pump, water pump, engine cooling system, lubrication system

Fuel System:

Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, evaporative emissions control (EVAP) system

Ignition System:

Ignition coils, spark plugs, ignition timing, crank angle sensor, camshaft position sensor

Transmission Manual:

Clutch, gearshift linkage, transmission disassembly/assembly, bearing replacement, synchronizer repair

Transmission Automatic:

Automatic transmission removal/installation, internal component overhaul (planitary gears, clutch packs), valve body diagnostics, torque converter service

Drivetrain:

All-Wheel Drive (AWD) system, viscous coupling, front and rear differentials, driveshafts, CV joints

Suspension Steering:

Front suspension (struts, control arms, ball joints, sway bar), rear suspension (shocks, trailing arms, multi-link setup), wheel bearings, steering rack, power steering system

Brakes:

Hydraulic brake system, brake pads, brake rotors, calipers, master cylinder, ABS system, parking brake

Electrical Charging:

Battery, alternator, starter motor, wiring harnesses, fuses, relays

Electrical Ignition:

Ignition system components, coil-on-plug (COP) system (if applicable), spark plug wires

Electrical Lighting:

Headlights, taillights, interior lighting, fog lights, bulb replacement

Electrical Accessories:

Power windows, power locks, sunroof, audio system, climate control system, wipers, horn

Body Exterior:

Body panel removal/installation, bumpers, doors, hood, trunk lid, glass replacement, exterior trim

Body Interior:

Dashboard removal, seat removal, headliner, door panels, carpet, trim pieces

Climate Control:

HVAC system, A/C compressor, refrigerant recharging, heater core, blower motor, climate control unit

Safety Systems:

Airbag system (SRS), ABS diagnostics and repair

Procedures Included

Maintenance:

Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid flush, transmission fluid change, differential fluid change, timing belt replacement, battery maintenance

Diagnostics:

Troubleshooting guides for common issues, symptom-based diagnostics, reading diagnostic trouble codes (DTCs) via OBD-II (if applicable for the model year)

Repair:

Engine rebuilding, transmission overhaul, brake system repair, suspension component replacement, electrical system troubleshooting and repair, body panel repair

Installation:

Component installation (e.g., new engine, transmission, suspension parts), accessory installation

Adjustment:

Idle speed adjustment, clutch adjustment (if applicable), parking brake adjustment

Technical Depth

Depth:

Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics.

📊 Manual Specifications

File Format

Compatibility:

PC/MAC Compatible

Viewing Features:

Zoom In/Out Capability

Print Quality

Print Options:

Print selected pages or entire manual

Binding Type

Binding Type:

Digital (PDF - No physical binding)

Paper Type

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

EJ253 (2.5L SOHC Non-Turbo) - Likely the most common

Engine Code 2:

EJ254 (2.5L DOHC Non-Turbo) - Also common

Engine Code 3:

EJ25D (2.5L DOHC Turbocharged - GT Models)

Performance

Horsepower 2 5L Sohc:

Approx. 165 hp @ 5600 rpm

Torque 2 5L Sohc:

Approx. 162 lb-ft @ 4000 rpm

Horsepower 2 5L DOHc:

Approx. 167 hp @ 5600 rpm

Torque 2 5L DOHc:

Approx. 166 lb-ft @ 4000 rpm

Horsepower 2 5L Turbo:

Approx. 212 hp @ 5500 rpm (GT models)

Torque 2 5L Turbo:

Approx. 230 lb-ft @ 3000-4700 rpm (GT models)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane recommended for non-turbo, 91 octane for turbo)

Engine Layout

Layout:

Horizontally Opposed (Boxer) 4-Cylinder

Engine Maintenance

Timing Belt Interval:

Recommended replacement every 60,000-105,000 miles or 5-7 years, depending on model year and conditions (critical maintenance item)

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual Transmission

Optional

Transmission Type Optional:

4-Speed Automatic Transmission (with overdrive)

Features

AWD Coupling Manual:

Viscous Coupling AWD for manual transmission models

AWD Coupling Automatic:

Active AWD system with electronically controlled clutch pack for automatic transmission models

Fluid Specs

Manual Transmission Fluid:

API GL-4, SAE 75W-90 synthetic gear oil (check specific manual for exact specification and capacity)

Automatic Transmission Fluid:

Subaru ATF HP (or equivalent) (check specific manual for exact specification and capacity)

📐 Dimensions

Exterior

Wheelbase:

Approx. 104.3 inches (2649 mm)

Length:

Approx. 185.2 inches (4704 mm)

Width:

Approx. 69.7 inches (1770 mm)

Height:

Approx. 59.4 inches (1509 mm)

Ground Clearance:

Approx. 8.0 inches (203 mm)

Cargo

Cargo Volume Rear Seats Up:

Approx. 39.3 cubic feet (1113 liters)

Cargo Volume Rear Seats Down:

Approx. 71.6 cubic feet (2027 liters)

Weights

Curb Weight:

Approx. 3300-3500 lbs (1497-1588 kg), varies by trim and transmission

Towing Capacity:

Typically around 2,000 lbs (907 kg) when properly equipped (check owner's manual for specific limits)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

Likely 4 out of 5 stars (based on similar era Subaru vehicles)

NHTSA Frontal Impact Passenger:

Likely 4 out of 5 stars

NHTSA Side Impact Front Seat:

Likely 4 out of 5 stars

NHTSA Side Impact Rear Seat:

Likely 3 out of 5 stars

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Available Traction Control System (TCS) on some models/trims

Standard Symmetrical All-Wheel Drive for enhanced traction and stability

Passive Features

Airbags:

Front airbags (driver and passenger), available front side-impact airbags (SRS)

Seatbelts:

Three-point seatbelts with pretensioners for all occupants

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, often with optional premium sound system and subwoofer. Auxiliary input ports were not standard.

Display:

Basic digital clock and radio display. No integrated navigation or color screens typical of modern vehicles.

Driver Assistance

Cruise Control:

Standard cruise control on most models.

All Wheel Drive System:

The core technology, providing all-weather and all-surface capability.

Connectivity

Bluetooth:

Not available in factory configuration for this model year range.

Not available in factory configuration for this model year range.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,750 - 7,500 miles (3,000-6,000 km) or 6 months, depending on oil type (synthetic recommended).

Air Filter Replacement:

Every 15,000 - 30,000 miles (24,000-48,000 km) or as needed based on driving conditions.

Cabin Air Filter Replacement:

Every 15,000 - 30,000 miles (24,000-48,000 km) or annually.

Coolant Flush:

Every 30,000 miles (48,000 km) or 3 years. Subaru Super Coolant is often specified.

Fluid Specifications

Engine Oil Capacity:

Approx. 4.5 quarts (4.3 liters) for 2.5L engines (with filter). Consult manual for exact capacity.

Engine Oil Type:

5W-30 or 10W-30 (depending on climate and specific engine variant). Full synthetic 5W-30 is recommended for optimal protection.

Power Steering Fluid:

Subaru specifies a particular power steering fluid or ATF. Check manual for specification and capacity.

Brake Fluid Type:

DOT 3 or DOT 4, depending on model year and system (ABS). Check manual.

Known Issues

Head Gaskets:

While the EJ253 SOHC is generally more robust, head gasket issues can still occur, particularly on higher mileage or poorly maintained engines. The EJ254 DOHC engines of this era were more prone to head gasket failure.

Timing Belt Tensioner:

Failure of the hydraulic timing belt tensioner can lead to catastrophic engine damage. Replacement of the tensioner along with the belt and idlers is highly recommended.

Automatic Transmission Cooler:

Premature failure of the internal automatic transmission cooler (integrated into the radiator) can lead to coolant contamination of the transmission fluid, causing severe damage. Upgraded external coolers are a popular aftermarket modification.

Wheel Bearings:

Front wheel bearings can wear out prematurely, leading to humming or grinding noises.

Rear Main Seal:

Leaking rear main crankshaft seal is a common issue requiring transmission removal to address.

📚 Vehicle History

Brand Heritage

Heritage Focus:

Subaru has a long history with rugged, all-wheel-drive vehicles, starting with its early SUVs and rally racing heritage.

Model Evolution

Legacy Introduction:

The Subaru Legacy sedan was introduced in 1989. The Outback variant, a more rugged, lifted version, was introduced in 1995 as the 'Outback Sport' and later became the distinct 'Outback' model in 1996.

Second Gen Introduction:

This 1998-2004 generation (BH/BE) represented a significant redesign for the Legacy and Outback, moving to a more modern platform.

Mid Cycle Refresh:

A minor facelift occurred for the 2000 model year, with updated styling and features.

Production

Manufacturing Location:

Gunma Plant, Japan (Subaru's primary manufacturing facility)

🏆 Awards & Recognition

Recognitions

SUV Of The Year Contenders:

While not winning major SUV of the Year awards typically dominated by traditional SUVs, the Outback was often praised for its unique blend of car-like handling and all-weather capability, appearing on 'best of' lists for car-based SUVs/crossovers.

Safety Accolades:

Subaru vehicles of this era consistently received good safety ratings, contributing to the brand's reputation.