Subaru 2002 Legacy User manual

GENERAL INFORMATION SECTION (Pub.No.G2290GE1)
2002 ModelYear
PDF Service Manual
ENGINE 1 SECTION (Pub.No.G2290GE2)
ENGINE 2 SECTION (Pub.No.G2290GE3)
TRANSMISSION SECTION (Pub.No.G2290GE4)
CHASSIS SECTION (Pub.No.G2290GE5)
BODY SECTION (Pub.No.G2290GE6)
WIRING SYSTEM SECTION (Pub.No.G2290GE7)

This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair of
SUBARU vehicles.
This manual includes the procedures for
maintenance, disassembling, reassem-
bling, inspection and adjustment of com-
ponents and diagnostics for guidance of
experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping their
vehicle in optimum condition. When
replacement of parts during repair work is
needed, be sure to use SUBARU genu-
ine parts.
All information, illustration and specifica-
tions contained in this manual are based
on the latest product information avail-
able at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD.
2002 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
GENERAL INFORMATION
SECTION
G2290GE1

This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair of
SUBARU vehicles.
This manual includes the procedures for
maintenance, disassembling, reassem-
bling, inspection and adjustment of com-
ponents and diagnostics for guidance of
experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping their
vehicle in optimum condition. When
replacement of parts during repair work is
needed, be sure to use SUBARU genu-
ine parts.
All information, illustration and specifica-
tions contained in this manual are based
on the latest product information avail-
able at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD.
2002 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE 1 SECTION
G2290GE2

This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair of
SUBARU vehicles.
This manual includes the procedures for
maintenance, disassembling, reassem-
bling, inspection and adjustment of com-
ponents and diagnostics for guidance of
experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping their
vehicle in optimum condition. When
replacement of parts during repair work is
needed, be sure to use SUBARU genu-
ine parts.
All information, illustration and specifica-
tions contained in this manual are based
on the latest product information avail-
able at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD.
2002 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE 2 SECTION
G2290GE3

This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair of
SUBARU vehicles.
This manual includes the procedures for
maintenance, disassembling, reassem-
bling, inspection and adjustment of com-
ponents and diagnostics for guidance of
experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping their
vehicle in optimum condition. When
replacement of parts during repair work is
needed, be sure to use SUBARU genu-
ine parts.
All information, illustration and specifica-
tions contained in this manual are based
on the latest product information avail-
able at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD.
2002 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
TRANSMISSION SECTION
G2290GE4

This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair of
SUBARU vehicles.
This manual includes the procedures for
maintenance, disassembling, reassem-
bling, inspection and adjustment of com-
ponents and diagnostics for guidance of
experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping their
vehicle in optimum condition. When
replacement of parts during repair work is
needed, be sure to use SUBARU genu-
ine parts.
All information, illustration and specifica-
tions contained in this manual are based
on the latest product information avail-
able at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD.
2002 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
CHASSIS SECTION
G2290GE5

This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair of
SUBARU vehicles.
This manual includes the procedures for
maintenance, disassembling, reassem-
bling, inspection and adjustment of com-
ponents and diagnostics for guidance of
experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping their
vehicle in optimum condition. When
replacement of parts during repair work is
needed, be sure to use SUBARU genu-
ine parts.
All information, illustration and specifica-
tions contained in this manual are based
on the latest product information avail-
able at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD.
2002 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
G2290GE6

2002 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
G2290GE6

This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair of
SUBARU vehicles.
This manual includes the procedures for
maintenance, disassembling, reassem-
bling, inspection and adjustment of com-
ponents and diagnostics for guidance of
experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping their
vehicle in optimum condition. When
replacement of parts during repair work is
needed, be sure to use SUBARU genu-
ine parts.
All information, illustration and specifica-
tions contained in this manual are based
on the latest product information avail-
able at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD.
2002 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
WIRING SYSTEM SECTION
G2290GE7

FOREWORD
FW
Page
1. Foreword .....................................................................................................2

1. Foreword SA01674
A: FOREWORD SA01674G21
These manuals are used when performing
maintenance, repair, or diagnosis of the Subaru
Legacy.
Applied model: BE***** and BH***** from 2002MY.
The additional manuals below are also available:
AUTOMATIC TRANSMISSION SERVICE
MANUAL (Pub. No. G0864ZE)
The manuals contain the latest information at the
time of publication. Changes in specifications,
methods, etc. may be made without notice.
FW-2
FOREWORD
Foreword

HOW TO USE THIS MANUAL
HU
Page
1. How to Use This Manual.............................................................................2

1. How to Use This Manual SA02675
A: HOW TO USE THIS MANUAL
SA02675F69
1. STRUCTURE SA02675F6901
Each section consists of SCT that are broken down
into SC that are divided into sections for each com-
ponent. The specifications, maintenance proce-
dures and other information for the components
are included, and diagnostic information has also
been added where necessary.
2. INDEX SA02675F6902
The first page has an index with tabs. And at the
end of each section is an alphabetical index.
3. COMPONENTS SA02675F6903
For each component, a composition drawing is
included.
4. SPECIFICATIONS SA02675F6904
If necessary, specifications are also included.
5. INSPECTION SA02675F6905
Inspections are included to be carried out before
and after maintenance.
6. MAINTENANCE SA02675F6906
Maintenance instructions are provided for each
component. When multiple components comprise
one process, refer to the instructions for that pro-
cess for each component.
7. DIAGNOSIS SA02675F6907
Tables showing a step-by-step process make it
easy to conduct diagnosis.
8. SI UNITS SA02675F6909
Measurements in these manuals are according to
the SI units. Metric and yard/pound measurements
are also included.
HU-2
HOW TO USE THIS MANUAL
How to Use This Manual

SPECIFICATIONS
SPC
Page
1. Legacy.........................................................................................................2
2. OUTBACK .................................................................................................10

1. Legacy SA08704
A: DIMENSIONS SA08704G28
Model Sedan Wagon
AWD
Overall length mm (in) 4,605 (181.3) 4,680 (184.3)
Overall width mm (in) 1,695 (66.7) 1,695 (66.7)
Overall height (at CW) mm (in) 1,415 (55.7) 1,515 (59.6)
Compartment Length mm (in) 1,965 (77.4) 1,925 (75.8)
Width mm (in) 1,440 (56.7), 1,420 (55.9)*1 1,440 (56.7), 1,420 (55.9)*1
Height mm (in) 1,155 (45.5) 1,190 (46.9), 1,175 (46.3)*2
Wheelbase mm (in) 2,650 (104.3) 2,650 (104.3)
Tread Front mm (in) 1,460 (57.5) 1,460 (57.5)
Rear mm (in) 1,460 (57.5) 1,455 (57.3)
Minimum road
clearance
Without catalytic
converter
mm (in) 160 (6.3) 165 (6.5)
With catalytic
converter
mm (in) 155 (6.1) 155 (6.1)
Australia mm (in) 155 (6.1) 155 (6.1)
*1: With leather seat
*2: With sunroof
B: ENGINE SA08704G29
Model Sedan/Wagon
AWD
2.0 L 2.5 L
Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement Overhead camshaft type
Bore ×Stroke mm (in) 92 ×75 (3.62 ×2.95) 99.5 ×79.0 (3.917 ×3.110)
Displacement cm
3
(cu in) 1,994 (121.67) 2,457 (149.9)
Compression ratio 10.0
Firing order 1 — 3 — 2 — 4
Idle speed at Park/Neutral
position
rpm 700±100
Maximum output kW (HP)/rpm 92 (123)/5,600 115 (154)/5,600
Maximum torque N·m (kgf-m, ft-lb)/rpm 184 (18.8, 136.0)/3,600 223 (22.7, 164.2)/3,600
SPC-2
LEGACY
Specifications

C: ELECTRICAL SA08704G30
Model Sedan/Wagon
AWD
2.0 L 2.5 L
Ignition timing at idling speed BTDC/rpm 10°±10°/700
Spark plug Type and manufacturer Without OBD NGK: BKR6E (without catalyst)
CHAMPION: RC10YC4 (with catalyst)
NGK: BKR5E-11 (with catalyst)
With OBD RC10YC4 .......... CHAMPION
Alternate RC8YC4 .......... CHAMPION
BKR6E-11 .......... NGK
K20PR-U11 .......... NIPPONDENSO
Generator 12V —90A
Battery Type and capacity
(5HR)
For Europe and
South America
MT: 12V —48AH (55D23L)
AT: 12V —52AH (65D23L)
MT: 12V —48AH (55D23L)
AT: 12V —52AH (75D23L)
Others 12V —27AH (34B19L)
D: TRANSMISSION SA08704G31
Model Sedan/Wagon
AWD
2.0 L 2.5 L
Transmission type 5MT 4AT 5MT 4AT
Clutch type DSPD TCC DSPD TCC
Gear ratio 1st 3.454 2.785 3.454 2.785
2nd 2.062 1.545 2.062 1.545
3rd 1.448 1.000 1.448 1.000
4th 1.088 0.694 1.088 0.694
5th 0.825 —0.825*1, 0.780*2 —
Reverse 3.333 2.272 3.333 2.272
Auxiliary transmission gear ratio High 1.000 –1.000 –
Low 1.447 –1.196 –
Reduction gear
(Front drive)
1st reduction Type of gear —Helical —Helical
Gear ratio —1.000 —1.000
Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid
Gear ratio 3.900 4.111 3.700*1, 4.111*2 4.111
Reduction gear
(Rear drive)
Transfer reduc-
tion
Type of gear Helical —Helical —
Gear ratio 1.000 —1.000 —
Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid
Gear ratio 3.900 4.111 3.700*1, 4.111*2 4.111
5MT: 5 forward speeds with synchromesh and 1-reverse
4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse
DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
*1: Except Australia spec. vehicles
*2: Australia spec. vehicles
SPC-3
LEGACY Specifications

E: STEERING SA08704G32
Model Models with
185/70R14 tires
Models with
195/60R15 tires
Models with
205/50R16 tires
Type Rack and Pinion
Turns, lock to lock 3.1
Minimum turning circle m (ft) Curb to curb: 10.8±1.0 (35.4±3.3)
Wall to wall: 11.5±1.0 (37.7±3.3)
F: SUSPENSION SA08704G33
Model Conventional suspension
Front Macpherson strut type, Independent, Coil spring
Rear Multi-link type, Independent, Coil spring
G: BRAKE SA08704G34
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Disc brake
Parking brake Mechanical on rear brakes
H: TIRE SA08704G35
Rim size 14 ×5
1
/
2
JJ 15 ×6JJ 16 ×6
1
/
2
JJ
Tire size 185/70R14 195/60R15 205/50R16
Type Steel belted radial, Tubeless
I: CAPACITY SA08704G36
Model Sedan/Wagon
AWD
2.0 L 2.5 L
5MT 4AT 5MT 4AT
Fuel tank (US gal, Imp gal) 64 (16.9, 14.1)
Engine oil Total capacity (US qt, Imp qt) 4.0 (4.2, 3.5)
Engine oil
amount for
refill
(US qt, Imp qt) Approx. 4.0 (4.2, 3.5)
Transmission gear oil (US qt, Imp qt) 3.5 (3.7, 3.1) —3.5 (3.7, 3.1) —
Automatic transmission fluid (US qt, Imp qt) —8.4 –8.7
(8.9 –9.2,
7.4 –7.7)
—9.3 –9.6
(9.8 –10.1,
8.2 –8.4)
AT differential gear oil (US qt, Imp qt) —1.1 –1.3
(1.2 –1.4,
1.0 –1.1)
—1.1 –1.3
(1.2 –1.4,
1.0 –1.1)
AWD rear differential gear oil (US qt, Imp qt) 0.8 (0.8, 0.6)
Power steering fluid (US qt, Imp qt) 0.7 (0.7, 0.6)
Engine coolant (US qt, Imp qt) 7.0 (7.4, 6.2) 6.9 (7.3, 6.1) 6.8 (7.2, 6.0) 6.7 (7.1, 5.9)
SPC-4
LEGACY
Specifications

J: WEIGHT SA08704G37
1. SEDAN SA08704G3708
쐌LHD Vehicle
Option code *1 EC K4 KO, KS
Model 2.0 L
4WD
GL
5MT 4AT 5MT 4AT 5MT 4AT
Curb weight (C.W.) Front kg (lb) 785
(1,730)
810
(1,785)
775
(1,710)
800
(1,765)
790
(1,740)
815
(1,795)
Rear kg (lb) 605
(1,335)
605
(1,335)
610
(1,345)
610
(1,345)
610
(1,345)
610
(1,345)
Total kg (lb) 1,390
(3,065)
1,415
(3,120)
1,385
(3,055)
1,410
(3,110)
1,400
(3,085)
1,425
(3,140)
Maximum permissible
axle weight (M.P.A.W.)
Front kg (lb) 970
(2,140)
970
(2,140)
970
(2,140)
970
(2,140)
970
(2,140)
970
(2,140)
Rear kg (lb) 975
(2,150)
975
(2,150)
975
(2,150)
975
(2,150)
975
(2,150)
975
(2,150)
Maximum permissible
weight (M.P.W.)
Total kg (lb) 1,870
(4,125)
1,870
(4,125)
1,870
(4,125)
1,870
(4,125)
1,870
(4,125)
1,870
(4,125)
Option Side airbag 쎻쎻 ––––
Air conditioner ––––쎻쎻
Audio ––––쎻쎻
Cruise control ––––––
Cold weather pack ––––––
Option code *1 EC K4 KO, KS
Model 2.5 L
4WD
GX
5MT 4AT 5MT 4AT 5MT 4AT
Curb weight (C.W.) Front kg (lb) 805
(1,775)
830
(1,830)
795
(1,755)
820
(1,810)
785
(1,730)
810
(1,785)
Rear kg (lb) 605
(1,335)
610
(1,345)
610
(1,345)
615
(1,355)
610
(1,345)
615
(1,355)
Total kg (lb) 1,410
(3,110)
1,440
(3,175)
1,405
(3,100)
1,435
(3,165)
1,395
(3,075)
1,425
(3,140)
Maximum permissible
axle weight (M.P.A.W.)
Front kg (lb) 985
(2,170)
985
(2,170)
985
(2,170)
985
(2,170)
985
(2,170)
985
(2,170)
Rear kg (lb) 1,000
(2,205)
1,000
(2,205)
1,000
(2,205)
1,000
(2,205)
1,000
(2,205)
1,000
(2,205)
Maximum permissible
weight (M.P.W.)
Total kg (lb) 1,910
(4,210)
1,910
(4,210)
1,910
(4,210)
1,910
(4,210)
1,910
(4,210)
1,910
(4,210)
Option Side airbag 쎻쎻 ––––
Air conditioner 쎻쎻쎻쎻 ––
Audio ––––쎻쎻
Cruise control ––쎻쎻 ––
Cold weather pack ––––––
*1: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>
SPC-5
LEGACY Specifications

쐌RHD Vehicle
Option code *1 K1 EK
Model 2.0 L 2.5 L
4WD
GL GX
4AT 5MT 4AT 5MT 4AT
Curb weight (C.W.) Front kg (lb) 800 (1,765) 785 (1,730) 810 (1,785) 795 (1,755) 820 (1,810)
Rear kg (lb) 605 (1,335) 605 (1,335) 605 (1,335) 605 (1,335) 610 (1,345)
Total kg (lb) 1,405 (3,100) 1,390 (3,065) 1,415 (3,120) 1,400 (3,085) 1,430 (3,155)
Maximum permissible
axle weight (M.P.A.W.)
Front kg (lb) 970 (2,140) 970 (2,140) 970 (2,140) 985 (2,170) 985 (2,170)
Rear kg (lb) 975 (2,150) 975 (2,150) 975 (2,150) 1,000 (2,205) 1,000 (2,205)
Maximum permissible
weight (M.P.W.)
Total kg (lb) 1,870 (4,125) 1,870 (4,125) 1,870 (4,125) 1,910 (4,210) 1,910 (4,210)
Option Side airbag –쎻쎻쎻쎻
Air conditioner –––––
Audio 쎻쎻쎻쎻쎻
Cruise control –––––
Cold weather pack –––––
Option code *1 KA
Model 2.0 L 2.5 L
4WD
GL (GX) GX (RX)
5MT 4AT 5MT 4AT
Unladen mass (U.M.) Front kg (lb) 780 (1,720) 775 (1,710) 775 (1,710) 785 (1,730)
Rear kg (lb) 585 (1,290) 585 (1,290) 595 (1,310) 595 (1,310)
Total kg (lb) 1,365 (3,010) 1,360 (3,000) 1,370 (3,020) 1,380 (3,045)
Gross vehicle mass
(G.V.M.)
Front kg (lb) 930 (2,050) 930 (2,050) 940 (2,075) 940 (2,075)
Rear kg (lb) 970 (2,140) 970 (2,140) 980 (2,160) 980 (2,160)
Total kg (lb) 1,900 (4,190) 1,900 (4,190) 1,920 (4,235) 1,920 (4,235)
Option Side airbag ––––
Air conditioner 쎻–––
Audio 쎻쎻쎻쎻
Cruise control 쎻–––
Cold weather pack ––––
*1: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>
SPC-6
LEGACY
Specifications

2. WAGON SA08704G3709
쐌LHD Vehicle
Option code *1 EC K4 KO, KS
Model 2.0 L
4WD
GL
5MT 4AT 5MT 4AT 5MT 4AT
Curb weight (C.W.) Front kg (lb) 780
(1,720)
800
(1,765)
775
(1,710)
790
(1,740)
790
(1,740)
805
(1,775)
Rear kg (lb) 650
(1,435)
650
(1,435)
655
(1,445)
655
(1,445)
655
(1,445)
655
(1,445)
Total kg (lb) 1,430
(3,155)
1,450
(3,195)
1,430
(3,155)
1,445
(3,185)
1,445
(3,185)
1,460
(3,220)
Maximum permissible
axle weight (M.P.A.W.)
Front kg (lb) 960
(2,115)
960
(2,115)
960
(2,115)
960
(2,115)
960
(2,115)
960
(2,115)
Rear kg (lb) 1,030
(2,270)
1,030
(2,270)
1,030
(2,270)
1,030
(2,270)
1,030
(2,270)
1,030
(2,270)
Maximum permissible
weight (M.P.W.)
Total kg (lb) 1,920
(4,235)
1,920
(4,235)
1,920
(4,235)
1,920
(4,235)
1,920
(4,235)
1,920
(4,235)
Option Side airbag –쎻––––
Air conditioner ––––쎻쎻
Audio ––––쎻쎻
Cruise control ––––––
Cold weather pack ––––––
Option code *1 EC K4 KO, KS
Model 2.5 L
4WD
GX
5MT 4AT 5MT 4AT 5MT 4AT
Curb weight (C.W.) Front kg (lb) 790
(1,740)
820
(1,810)
775
(1,710)
790
(1,740)
790
(1,740)
805
(1,775)
Rear kg (lb) 655
(1,445)
655
(1,445)
655
(1,445)
655
(1,445)
655
(1,445)
655
(1,445)
Total kg (lb) 1,445
(3,185)
1,475
(3,250)
1,430
(3,155)
1,445
(3,185)
1,445
(3,185)
1,460
(3,220)
Maximum permissible
axle weight (M.P.A.W.)
Front kg (lb) 995
(2,195)
995
(2,195)
960
(2,115)
960
(2,115)
960
(2,115)
960
(2,115)
Rear kg (lb) 1,050
(2,315)
1,050
(2,315)
1,030
(2,270)
1,030
(2,270)
1,030
(2,270)
1,030
(2,270)
Maximum permissible
weight (M.P.W.)
Total kg (lb) 1,980
(4,365)
1,980
(4,365)
1,920
(4,235)
1,920
(4,235)
1,920
(4,235)
1,920
(4,235)
Option Side airbag 쎻쎻 ––––
Air conditioner –쎻––쎻쎻
Audio ––––쎻쎻
Cruise control –쎻––––
Cold weather pack –쎻––––
*1: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>
SPC-7
LEGACY Specifications