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2002 Subaru Legacy Outback Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Legacy Outback Year: 2002 Codes Chassis Code: BE/BH (Global) Platform: Subaru G Platform 👋 Introduction Market Position Segment: Compact Crossover SUV / Station Wagon Niche: All-wheel drive as standard, practicality, go-anywhere capability Competitive Analysis Key Competitors: Toyota RAV4, Honda CR-V, Ford Escape, Nissan Xterra Key Features Standard AWD: Subaru's Symmetrical All-Wheel Drive system standard on all trims Ground Clearance: Enhanced ground clearance for off-road capability Horizontally Opposed Engine: Subaru Boxer engine for a lower center of gravity Versatility: Spacious interior and cargo area, roof rails 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service, repair, and maintenance Secondary Coverage: Diagnostic procedures, electrical schematics, specifications Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system Drivetrain: All-Wheel Drive (AWD) system, differentials (front, center, rear), driveshafts, CV joints Transmission: Automatic Transmission (4EAT/4AT), Manual Transmission (5MT) Chassis: Suspension (front strut, rear multi-link), steering system, braking system (ABS, front ventilated discs, rear solid discs) Electrical: Engine Control Module (ECM), Body Control Module (BCM), lighting, instruments, power accessories, audio system, HVAC controls, airbags (SRS) Body: Exterior body panels, interior trim, doors, windows, seats, roof (including sunroof if equipped) Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection/replacement Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based diagnostics, electrical circuit tracing Repair: Engine component replacement (pistons, rings, valves), transmission overhaul, brake component replacement, suspension part replacement, radiator/AC condenser replacement Installation: Component installation and removal for all major systems Specifications: Torque values, clearances, fluid capacities, diagnostic parameters Technical Depth Depth: Full factory-level diagnostic and repair procedures Diagnostic Tools: Information on using Subaru Select Monitor (SSM) or equivalent OBD-II scanners Wiring Diagrams: Detailed electrical wiring diagrams for all systems 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable for quick information retrieval Print Quality Quality: High-resolution, suitable for printing Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: EJ251 (Naturally Aspirated) Engine Type: 2.5L Flat-4 (Boxer) Displacement: 2457 cc (2.5 Liters) Valvetrain: SOHC (Single Overhead Camshaft), 16 valves Performance Horsepower: 165 hp @ 5600 rpm Torque: 166 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 Octane Recommended) Engine Notes Head Gasket Concern: Known tendency for coolant leaks from head gaskets on some EJ engines of this era; manual covers inspection and replacement. 🔧 Transmission Standard Standard Transmission: 4-speed Automatic Transmission (4EAT/4AT) Optional Optional Transmission: 5-speed Manual Transmission (5MT) Features AWD System: Subaru Symmetrical All-Wheel Drive (Active AWD for automatic, Viscous coupling center differential for manual) Automatic Mode: Driver-selectable modes (Power/Hold) on 4EAT Fluid Specs Automatic Transmission Fluid: Subaru ATF HP (or Dexron III compatible) Manual Transmission Fluid: Gear Oil API GL-5, SAE 75W-90 📐 Dimensions Exterior Length: 4630 mm (182.3 in) Width: 1770 mm (69.7 in) Height: 1640 mm (64.6 in) Wheelbase: 2630 mm (103.5 in) Ground Clearance: 200 mm (7.9 in) Cargo Cargo Volume Rear Seats Up: Approx. 73.2 cu ft (with rear seats folded) Weights Curb Weight Est: 1475 - 1565 kg (3250 - 3450 lbs) Towing Capacity: 2000 lbs (When Properly Equipped) 🛡️ Safety Features Ratings NHTSA Frontal Driver: 5 Stars NHTSA Frontal Passenger: 5 Stars IIHS Frontal Offset: Good Active Features ABS: Anti-lock Braking System standard Traction Control: Available (check specific trim) Passive Features Airbags: Dual front airbags, available side airbags (check specific trim) Seatbelts: Front pretensioners with force limiters 💡 Technology Features Infotainment Audio System: AM/FM stereo with CD player, optional cassette, and premium audio system available on higher trims. Display: Basic digital clock and radio display. Driver Assistance Cruise Control: Standard cruise control Automatic Headlights: Available on higher trims Connectivity Aux Input: Not typically standard; aftermarket solutions common. Climate Control HVAC: Manual or automatic climate control depending on trim. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 miles or 6 months (severe driving), 7,500 miles or 6 months (normal driving) Air Filter Replacement: Every 15,000 miles or 12 months Spark Plug Replacement: Every 60,000 miles (iridium/platinum) Timing Belt Replacement: Every 105,000 miles or 105 months (critical for EJ engines) Fluid Specifications Engine Oil Capacity: 4.5 US quarts (4.3 L) with filter (5W-30 or 10W-30) Coolant Capacity: 7.2 US quarts (6.8 L) (Subaru Super Coolant blue) Brake Fluid Type: DOT 3 Known Issues Head Gaskets: Common failure point, often requiring replacement due to coolant leaks. Manual details diagnostic procedures. Automatic Transmission Shifts: Some reports of rough shifting; fluid changes and solenoid checks covered in manual. Wheel Bearings: Can be prone to wear; manual provides replacement procedures. 📚 Vehicle History Brand Heritage Brand Identity: Subaru is renowned for its Symmetrical All-Wheel Drive system and horizontally...
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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 (Global)
Platform:
Subaru G Platform
👋 Introduction
Market Position
Segment:
Compact Crossover SUV / Station Wagon
Niche:
All-wheel drive as standard, practicality, go-anywhere capability
Competitive Analysis
Key Competitors:
Toyota RAV4, Honda CR-V, Ford Escape, Nissan Xterra
Key Features
Standard AWD:
Subaru's Symmetrical All-Wheel Drive system standard on all trims
Ground Clearance:
Enhanced ground clearance for off-road capability
Horizontally Opposed Engine:
Subaru Boxer engine for a lower center of gravity
Versatility:
Spacious interior and cargo area, roof rails
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service, repair, and maintenance
Secondary Coverage:
Diagnostic procedures, electrical schematics, specifications
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system
Drivetrain:
All-Wheel Drive (AWD) system, differentials (front, center, rear), driveshafts, CV joints
Transmission:
Automatic Transmission (4EAT/4AT), Manual Transmission (5MT)
Chassis:
Suspension (front strut, rear multi-link), steering system, braking system (ABS, front ventilated discs, rear solid discs)
Electrical:
Engine Control Module (ECM), Body Control Module (BCM), lighting, instruments, power accessories, audio system, HVAC controls, airbags (SRS)
Body:
Exterior body panels, interior trim, doors, windows, seats, roof (including sunroof if equipped)
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection/replacement
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based diagnostics, electrical circuit tracing
Repair:
Engine component replacement (pistons, rings, valves), transmission overhaul, brake component replacement, suspension part replacement, radiator/AC condenser replacement
Installation:
Component installation and removal for all major systems
Specifications:
Torque values, clearances, fluid capacities, diagnostic parameters
Technical Depth
Depth:
Full factory-level diagnostic and repair procedures
Diagnostic Tools:
Information on using Subaru Select Monitor (SSM) or equivalent OBD-II scanners
Wiring Diagrams:
Detailed electrical wiring diagrams for all systems
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable for quick information retrieval
Print Quality
Quality:
High-resolution, suitable for printing
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
EJ251 (Naturally Aspirated)
Engine Type:
2.5L Flat-4 (Boxer)
Displacement:
2457 cc (2.5 Liters)
Valvetrain:
SOHC (Single Overhead Camshaft), 16 valves
Performance
Horsepower:
165 hp @ 5600 rpm
Torque:
166 lb-ft @ 4000 rpm
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Engine Notes
Head Gasket Concern:
Known tendency for coolant leaks from head gaskets on some EJ engines of this era; manual covers inspection and replacement.
🔧 Transmission
Standard
Standard Transmission:
4-speed Automatic Transmission (4EAT/4AT)
Optional
Optional Transmission:
5-speed Manual Transmission (5MT)
Features
AWD System:
Subaru Symmetrical All-Wheel Drive (Active AWD for automatic, Viscous coupling center differential for manual)
Automatic Mode:
Driver-selectable modes (Power/Hold) on 4EAT
Fluid Specs
Automatic Transmission Fluid:
Subaru ATF HP (or Dexron III compatible)
Manual Transmission Fluid:
Gear Oil API GL-5, SAE 75W-90
📐 Dimensions
Exterior
Length:
4630 mm (182.3 in)
Width:
1770 mm (69.7 in)
Height:
1640 mm (64.6 in)
Wheelbase:
2630 mm (103.5 in)
Ground Clearance:
200 mm (7.9 in)
Cargo
Cargo Volume Rear Seats Up:
Approx. 73.2 cu ft (with rear seats folded)
Weights
Curb Weight Est:
1475 - 1565 kg (3250 - 3450 lbs)
Towing Capacity:
2000 lbs (When Properly Equipped)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver:
5 Stars
NHTSA Frontal Passenger:
5 Stars
IIHS Frontal Offset:
Good
Active Features
ABS:
Anti-lock Braking System standard
Traction Control:
Available (check specific trim)
Passive Features
Airbags:
Dual front airbags, available side airbags (check specific trim)
Seatbelts:
Front pretensioners with force limiters
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional cassette, and premium audio system available on higher trims.
Display:
Basic digital clock and radio display.
Driver Assistance
Cruise Control:
Standard cruise control
Automatic Headlights:
Available on higher trims
Connectivity
Aux Input:
Not typically standard; aftermarket solutions common.
Climate Control
HVAC:
Manual or automatic climate control depending on trim.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 6 months (severe driving), 7,500 miles or 6 months (normal driving)
Air Filter Replacement:
Every 15,000 miles or 12 months
Spark Plug Replacement:
Every 60,000 miles (iridium/platinum)
Timing Belt Replacement:
Every 105,000 miles or 105 months (critical for EJ engines)
Fluid Specifications
Engine Oil Capacity:
4.5 US quarts (4.3 L) with filter (5W-30 or 10W-30)
Coolant Capacity:
7.2 US quarts (6.8 L) (Subaru Super Coolant blue)
Brake Fluid Type:
DOT 3
Known Issues
Head Gaskets:
Common failure point, often requiring replacement due to coolant leaks. Manual details diagnostic procedures.
Automatic Transmission Shifts:
Some reports of rough shifting; fluid changes and solenoid checks covered in manual.
Wheel Bearings:
Can be prone to wear; manual provides replacement procedures.
📚 Vehicle History
Brand Heritage
Brand Identity:
Subaru is renowned for its Symmetrical All-Wheel Drive system and horizontally opposed Boxer engines, offering robust performance and capability.
Model Evolution
Legacy Generation:
Second Generation Legacy (BG/BK) for Outback variant
Outback Introduction:
The Outback concept originated from the Legacy wagon, with raised suspension and ruggedized styling, becoming a distinct model line.
Production
Production Years:
1990-2004 (Legacy), 1995-present (Outback as distinct model/trim)
Assembly Location:
Gunma, Japan
🏆 Awards & Recognition
Recognitions
Consumer Reports:
Subaru generally received good ratings for reliability and performance in its segment during this period, though head gasket issues were noted.
Ratings
Best Resale Value:
Subarus typically maintain strong resale value due to their durability and AWD capabilities.
Certifications
Emissions Standards:
Meets EPA and California ARB emissions standards for the model year.
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