2002 Subaru Legacy Outback Service Manual

2002 Model Year PDF Service Manual
GENERAL INFORMATION SECTION
Foreword
Foreword
How to Use This Manual
How to Use This Manual
Specifications
Legacy
OUTBACK
Precaution
Precaution
Note
Note
Identification
Identification
Recommended Materials
Recommended Materials
Pre-delivery Inspection
Pre-delivery Inspection
Periodic Maintenance Services
General Description
Schedule
Engine Oil
Engine Oil Filter
Spark Plugs
Drive Belt(s)
Camshaft Drive Belt
Fuel Line
Fuel Filter
Air Cleaner Element
Cooling System
Coolant
Idle Mixture
Clutch System
Hill-holder System
Transmission Oil
ATF
Front & Rear Differential Oil
Brake Line
Brake Fluid
Disc Brake Pads and Discs
Parking Brake
Suspension
Wheel Bearing
Axle Boots & Joints
Steering System (Power Steering)
Supplemental Restraint System
ENGINE 1 SECTION
Fuel Injection (Fuel Systems)
General Description
Throttle Body
Intake Manifold
Engine Coolant Temperature Sensor
Crankshaft Position Sensor
Camshaft Position Sensor
Knock Sensor
Throttle Position Sensor
Intake Air Temperature and Pressure Sensor
Atmospheric Pressure Sensor
Idle Air Control Solenoid Valve
Air Assist Injector Solenoid Valve
Fuel Injector
Front Oxygen (A/F) Sensor
Rear Oxygen Sensor
Engine Control Module
Main Relay
Fuel Pump Relay
Fuel
Fuel Tank
Fuel Filler Pipe
Fuel Pump
Fuel Level Sensor
Fuel Sub Level Sensor
Fuel Filter
Fuel Cut Valve
Fuel Dumper Valve
Fuel Delivery, Return and Evaporation Lines
Fuel System Trouble in General
Fuel Injection (Fuel Systems)
General Description
Throttle Body
Intake Manifold
Engine Coolant Temperature Sensor
Crankshaft Position Sensor
Camshaft Position Sensor
Knock Sensor
Throttle Position Sensor
Intake Air Temperature and Pressure Sensor
Idle Air Control Solenoid Valve
Fuel Injector
Oxygen Sensor
Engine Control Module
Main Relay
Fuel Pump Relay
Fuel
Fuel Tank
Fuel Filler Pipe
Fuel Pump
Fuel Level Sensor
Fuel Sub Level Sensor
Fuel Filter
Fuel Cut Valve
Fuel Dumper Valve
Fuel Delivery, Return and Evaporation Lines
Fuel System Trouble in General
Emission Control (AUX. Emission Control Devices)
General Description
Front Catalytic Converter
Rear Catalytic Converter
Canister
Purge Control Solenoid Valve
Two-way Valve
Emission Control (AUX. Emission Control Devices)
General Description
Front Catalytic Converter
Rear Catalytic Converter
Canister
Purge Control Solenoid Valve
Two-way Valve
Intake (Induction)
General Description
Air Cleaner Element
Air Cleaner Case
Air Intake Duct
Resonator Chamber
Mechanical
General Description
Compression
Idle Speed
Ignition Timing
Intake Manifold Vacuum
Engine Oil Pressure
Fuel Pressure
Valve Clearance
Engine Assembly
Engine Mounting
Preparation for Overhaul
V-belt
Crankshaft Pulley
Belt Cover
Timing Belt Assembly
Camshaft Sprocket
Crankshaft Sprocket
Valve Rocker Assembly
Camshaft
Cylinder Head Assembly
Cylinder Block
Engine Trouble in General
Engine Noise
Exhaust
General Description
Front Exhaust Pipe
Center Exhaust Pipe
Rear Exhaust Pipe
Muffler
Exhaust
General Description
Front Exhaust Pipe
Center Exhaust Pipe
Rear Exhaust Pipe
Muffler
Cooling
General Description
Radiator Main Fan System
Radiator Sub Fan System
Engine Coolant
Water Pump
Thermostat
Radiator
Radiator Cap
Radiator Main Fan and Fan Motor
Radiator Sub Fan and Fan Motor
Reservoir Tank
Engine Cooling System Trouble in General
Lubrication
General Description
Oil Pressure System
Engine Oil
Oil Pump
Oil Pan and Strainer
Oil Pressure Switch
Engine Oil Filter
Engine Lubrication System Trouble in General
Speed Control Systems
General Description
Accelerator Pedal
Accelerator Control Cable
Ignition
General Description
Spark Plug
Ignition Coil and Ignitor Assembly
Spark Plug Cord
Ignition
General Description
Spark Plug
Ignition Coil and Ignitor Assembly
Spark Plug Cord
Starting/Charging Systems
General Description
Starter
Generator
Battery
Engine (Diagnostics)
Basic Diagnostic Procedure
Check List for Interview
General Description
Electrical Components Location
Engine Control Module (ECM) I/O Signal
Engine Condition Data
Transmission Control Module (TCM) I/O Signal
Data Link Connector
OBD-II General Scan Tool
Subaru Select Monitor
Read Diagnostic Trouble Code (DTC)
Inspection Mode
Clear Memory Mode
Compulsory Valve Operation Check Mode
Engine Malfunction Indicator Lamp (MIL)
Diagnostics for Engine Starting Failure
List of Diagnostic Trouble Code (DTC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
General Diagnostic Table
Engine (Diagnostics)
Basic Diagnostic Procedure
Check List for Interview
General Description
Electrical Components Location
Engine Control Module (ECM) I/O Signal
Subaru Select Monitor
Read Diagnostic Trouble Code (DTC)
Inspection Mode
Clear Memory Mode
Compulsory Valve Operation Check Mode
Engine Malfunction Indicator Lamp (MIL)
Diagnostics for Engine Starting Failure
List of Diagnostic Trouble Code (DTC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
General Diagnostic Table
ENGINE 2 SECTION
Fuel Injection (Fuel Systems)
General Description
Throttle Body
Intake Manifold
Engine Coolant Temperature Sensor
Crankshaft Position Sensor
Camshaft Position Sensor
Knock Sensor
Throttle Position Sensor
Intake Manifold Pressure Sensor
Intake Air Temperature Sensor
Idle Air Control Solenoid Valve
Induction Valve
Induction Valve Control Solenoid
Fuel Injector
Front Oxygen (A/F) Sensor
Rear Oxygen Sensor
Engine Control Module
Main Relay
Fuel Pump Relay
Fuel
Fuel Tank
Fuel Filler Pipe
Fuel Pump
Fuel Level Sensor
Fuel Sub Level Sensor
Fuel Filter
Fuel Cut Valve
Fuel Damper Valve
Fuel Delivery, Return and Evaporation Lines
Fuel System Trouble in General
Emission Control (Aux. Emission Control Devices)
General Description
Front Catalytic Converter
Rear Catalytic Converter
Canister
Purge Control Solenoid Valve
EGR Valve
Two-way Valve
Intake (Induction)
General Description
Air Cleaner
Air Intake Chamber
Air Intake Duct
Resonator Chamber
Mechanical
General Description
Compression
Idle Speed
Ignition Timing
Valve Clearance
V-belt
Engine Assembly
Engine Mounting
Preparation for Overhaul
Crankshaft Pulley
Front Chain Cover
Timing Chain Assembly
Camshaft Sprocket
Crankshaft Sprocket
Rear Chain Cover
Camshaft
Cylinder Head Assembly
Cylinder Block
Engine Trouble in General
Engine Noise
Exhaust
General Description
Front Exhaust Pipe
Rear Exhaust Pipe
Muffler
Cooling
General Description
Radiator Main Fan System
Radiator Sub Fan System
Engine Coolant
Water Pump
Thermostat
Radiator
Radiator Cap
Radiator Main Fan and Fan Motor
Radiator Sub Fan and Fan Motor
Reservoir Tank
Engine Cooling System Trouble in General
Lubrication
General Description
Oil Pressure System
Engine Oil
Oil Pump
Oil Pump Relief Valve
Oil Pan and Strainer
Oil Pressure Switch
Engine Oil Filter
Oil Cooler
Engine Lubrication System Trouble in General
Speed Control Systems
General Description
Accelerator Pedal
Accelerator Control Cable
Ignition
General Description
Spark Plug
Ignition Coil and Ignitor Assembly
Starting/Charging Systems
General Description
Starter
Generator
Battery
Engine (DIAGNOSTICS)
Basic Diagnostic Procedure
Check List for Interview
General Description
Electrical Components Location
Engine Control Module (ECM) I/O Signal
Engine Condition Data
Transmission Control Module (TCM) I/O Signal
Data Link Connector
OBD-II General Scan Tool
Subaru Select Monitor
Read Diagnostic Trouble Code
Inspection Mode
Clear Memory Mode
Compulsory Valve Operation Check Mode
Engine Malfunction Indicator Lamp (MIL)
Diagnostics for Engine Starting Failure
List of Diagnostic Trouble Code (DTC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
General Diagnostic Table
TRANSMISSION SECTION
Control Systems
General Description
Select Lever
Select Cable
MT Gear Shift Lever
MT Drive Select Lever
Drive Select Cable
General Diagnostic Table
Automatic Transmission
General Description
Automatic Transmission Fluid
Differential Gear Oil
Road Test
Stall Test
Time Lag Test
Line Pressure Test
Transfer Clutch Pressure Test
Automatic Transmission Assembly
Transmission Mounting System
Extension Case Oil Seal
Inhibitor Switch
Front Vehicle Speed Sensor
Rear Vehicle Speed Sensor
Torque Converter Turbine Speed Sensor
Control Valve Body
Shift Solenoids, Duty Solenoids and ATF Temperature Sensor
ATF Filter
Transmission Control Module (TCM)
ATF Cooler Pipe and Hose
Manual Transmission and Differential
General Description
Transmission Gear Oil
Manual Transmission Assembly
Transmission Mounting System
Oil Seal
Switches and Harness
Vehicle Speed Sensor
Preparation for Overhaul
Transfer Case and Extension Case Assembly
Transfer Drive Gear
Transfer Driven Gear
Center Differential
Reverse Check Sleeve
Transmission Case
Main Shaft Assembly for Single-Range
Main Shaft Assembly for Dual-Range
Input Shaft Assembly
Drive Pinion Shaft Assembly
Front Differential Assembly
Speedometer Gear
Reverse Idler Gear
Shifter Fork and Rod
Counter Gear
General Diagnostic
Clutch System
General Description
Clutch Disc and Cover
Flywheel
Release Bearing and Lever
Operating Cylinder
Master Cylinder
Clutch Pipe and Hose
Clutch Fluid
Clutch Fluid Air Bleeding
Clutch Pedal
Clutch Switch
General Diagnostic Table
Automatic Transmission (Diagnostics)
Basic Diagnostic Procedure
Check List for Interview
General Description
Electrical Components Location
Transmission Control Module (TCM) I/O Signal
Subaru Select Monitor
Read Diagnostic Trouble Code (DTC)
Inspection Mode
Clear Memory Mode
POWER Indicator Light Display
List of Diagnostic Trouble Code (DTC)
Diagnostic Procedure for POWER Indicator Light
Diagnostic Procedure for Select Monitor Communication
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Diagnostic Procedure for No-diagnostic Trouble Code (DTC)
Symptom Related Diagnostic
CHASSIS SECTION
Front Suspension
General Description
Wheel Alignment
Front Transverse Link
Front Ball Joint
Front Strut
Front Stabilizer
Front Crossmember
General Diagnostic Table
Rear Suspension
General Description
Wheel Alignment
Rear Stabilizer
Rear Arm
Link Upper
Rear Shock Absorber
Link Front
Link Rear
Support Sub Frame Front
Rear Sub Frame
Helper
General Diagnostic Table
Wheel and Tire System
General Description
Tire
Steel Wheel
Aluminum Wheel
Wheel Balancing
Full Wheel Cap
General Diagnostic Table
Differentials
General Description
Differential Gear Oil
Front Differential
Rear Differential for T-type
Rear Differential for VA-type
Rear Differential Front Oil Seal
Rear Differential Front Member
General Diagnostic Table
Transfer Case
General Description
Transfer Case and Extension for MT
Transfer Clutch and Extension for AT
Oil Seal
Transfer Drive Gear (MT)
Transfer Driven Gear (MT)
Reduction Drive Gear without VTD
Reduction Drive Gear with VTD
Reduction Driven Gear without VTD
Reduction Driven Gear with VTD
Center Differential
Transfer Clutch Pressure Test
Transfer Duty Solenoid and Valve Body
Drive Shaft System
General Description
Propeller Shaft
Front Axle
Hub Unit Bearing
Front Drive Shaft
Rear Drive Shaft
General Diagnostic Table
ABS
General Description
ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)
ABS Sequence Control
Front ABS Sensor
Rear ABS Sensor
Front Tone Wheel
Rear Tone Wheel
G Sensor
VDC
General Description
VDC Control Module (VDCCM)
Hydraulic Control Unit (H/U)
ABS Sequence Control
VDC Sequence Control
Yaw Rate and Lateral G Sensor
Steering Angle Sensor
Front ABS Sensor
Rear ABS Sensor
Front Tone Wheel
Rear Tone Wheel
VDC Off Switch
Brake
General Description
Front Brake Pad
Front Disc Rotor
Front Disc Brake Assembly
Rear Brake Pad
Rear Disc Rotor
Rear Disc Brake Assembly
Master Cylinder
Brake Booster
Proportioning Valve
Brake Fluid
Air Bleeding
Brake Hose
Brake Pipe
Hill Holder
Brake Pedal
Stop Light Switch
General Diagnostics
Parking Brake
General Description
Parking Brake Lever
Parking Brake Cable
Parking Brake Assembly
General Diagnostic Table
Power Assisted System (Power Steering)
General Description
Steering Wheel
Universal Joint
Tilt Steering Column
Steering Gearbox [LHD Model]
Steering Gearbox [RHD Model]
Pipe Assembly
Oil Pump
Reservoir Tank
Power Steering Fluid
General Diagnostic Table
ABS (Diagnostics)
Basic Diagnostic Procedure
Check List for Interview
General Description
Electrical Components Location
Control Module I/O Signal
Subaru Select Monitor
Read Diagnostic Trouble Code (DTC)
Inspection Mode
Clear Memory Mode
ABS Warning Light Illumination Pattern
List of Diagnostics Trouble Code (DTC)
Diagnostics Chart with Diagnosis Connector
Diagnostics Chart with Subaru Select Monitor
General Diagnostics Table
VDC (Diagnostics)
Basic Diagnostic Procedure
Check List for Interview
General Description
Electrical Components Location
Control Module I/O Signal
VDCCM Connector Cover
Subaru Select Monitor
Read Diagnostic Trouble Code (DTC)
Inspection Mode
Clear Memory Mode
Warning Light Illumination Pattern
List of Diagnostic Trouble Code (DTC)
Diagnostics Chart with Diagnosis Connector
Diagnostics Chart with Select Monitor
General Diagnostic Table
BODY SECTION
HVAC System (Heater, Ventilator and A/C)
General Description
Refrigerant Pressure with Manifold Gauge Set
Refrigerant Recovery Procedure
Refrigerant Charging Procedure
Refrigerant Leak Check
Compressor Oil
Heater Unit
Blower Motor Assembly
Heater Blower Resistor
Heater Core
Control Unit
Compressor
Condenser
Receiver Drier
Intake Unit
Flexible Hose
Relay and Fuse
Pressure Switch (Dual Switch)
Pressure Switch (Triple Switch)
Ambient Sensor (Auto A/C)
Sunload Sensor (Auto A/C)
Air Vent Grille
Heater Duct
Heater Vent Duct
General Diagnostics
Airbag System
General Description
Airbag Connector
Inspection Locations After a Collision
Driver's Airbag Module
Passenger's Airbag Module
Side Airbag Module
Main Harness
Side Airbag Harness
Airbag Control Module
Side Airbag Sensor
Roll Connector
Front Sub Sensor
Front Sub Sensor Harness
Disposal of Airbag Module (Deploying While Installed in Vehicle)
Disposal of Airbag Module (Deploying After Removal from Vehicle)
Seat Belt System
General Description
Inspection Locations After a Collision
Front Seat Belt
Rear Seat Belt
Disposal of Pretensioner
Lighting System
General Description
Headlight and Tail Light System
Front Fog Light System
Rear Fog Light System
Turn Signal and Hazard Light System
Back-up Light System
Stop Light System
Interior Light System
Headlight Beam Leveler System
Combination Switch (Light)
Headlight Assembly
Headlight Bulb
Front Turn Signal Light Bulb
Parking Light Bulb
Front Fog Light Assembly
Front Fog Light Bulb
Rear Combination Light Assembly
Rear Finisher Light Assembly
Brake/Tail Light Bulb
Back-up Light Bulb
Rear Turn Signal Light Bulb
Rear Fog Light Bulb
License Plate Light
High-mounted Stop Light
Side Turn Signal Light
Spot Light
Room Light
Luggage Room Light
Trunk Room Light
Glove Box Light
Wiper and Washer Systems
General Description
Wiper and Washer System
Combination Switch (Wiper)
Wiper Blade
Washer Tank and Motor
Front Wiper Arm
Front Wiper Motor and Link
Front Washer Nozzle
Rear Wiper Arm
Rear Wiper Motor
Rear Washer Nozzle
Wiper Control Relay
Entertainment
General Description
Radio System
Cigarette Lighter System
Radio Body
Front Speaker
Front Tweeter
Rear Speaker
Antenna
Antenna Amplifier
Cigarette Lighter
Communication System
General Description
Horn System
Horn
Horn Switch
Glass/Windows/Mirrors
General Description
Power Window System
Rear Window Defogger System
Windshield Wiper Deicer System
Remote Control Mirror System
Front Door Glass
Front Regulator and Motor Assembly
Rear Door Glass
Rear Regulator and Motor Assembly
Windshield Glass
Rear Gate Glass
Rear Quarter Glass
Rear Window Glass
Roof Window Glass
Inner Rearview Mirror
Power Window Control Switch
Rear Window Defogger Switch
Rear Window Defogger
Outer Mirror Assembly
Outer Mirror
Remote Control Mirror Switch
Wiper Deicer
Wiper Deicer Switch
Body Structure
General Description
Datum Points
Datum Dimensions
Instrumentation/Driver Info
General Description
Combination Meter System
Combination Meter Assembly
Speedometer
Tachometer
Fuel Gauge
Water Temperature Gauge
Ambient Sensor
Seats
General Description
Front Seat
Rear Seat
Security and Locks
General Description
Door Lock Control System
Keyless Entry System
Front Inner Remote
Front Outer Handle
Front Door Latch Assembly
Front Door Lock Actuator
Rear Inner Remote
Rear Outer Handle
Rear Door Latch Assembly
Rear Door Lock Actuator
Rear Gate Outer Handle
Rear Gate Latch Assembly
Rear Gate Latch Lock Actuator
Trunk Lid Lock Assembly
Front Hood Lock Assembly
Remote Openers
Ignition Key Lock
Key Lock Cylinders
Immobilizer Control Module
Immobilizer Antenna
Keyless Entry Control Module
Keyless Transmitter
Sunroof/T-top/Convertible Top (Sunroof)
General Description
Sunroof Control System
Sunroof Lid
Sunroof Assembly
Sunroof Motor
Sunroof Switch
Exterior/Interior Trim
General Description
Front Grille
Front Under Cover
Front Bumper
Rear Bumper
Mud Guard
Protector
Cowl Panel
Spoiler
Side Sill Spoiler
Front Door Trim
Rear Door Trim
Glove Box
Roof Rail
Console Box
Instrument Panel Assembly
Upper Inner Trim
Lower Inner Trim
Rear Quarter Trim
Sun Visor
Roof Trim
Rear Gate Trim
Rear Shelf Trim
Trunk Trim
Trunk Lid Trim
Floor Mat
Luggage Floor Mat
Trunk Room Mat
Exterior Body Panels
General Description
Front Hood
Fender Panel
Front Door Panel
Front Sealing Cover
Rear Door Panel
Rear Sealing Cover
Trunk Lid Panel
Rear Gate Panel
Cruise Control System
General Description
Actuator
Cruise Control Module
Cruise Control Main Switch
Cruise Control Command Switch
Stop and Brake Switch
Clutch Switch
Inhibitor Switch
HVAC System (Auto A/C) (Diagnostics)
Basic Diagnostic Procedure
General Description
Electrical Components Location
A/C Control Module I/O Signal
Diagnostics Chart for Diagnosis System (LHD Model)
Diagnostics Chart for Diagnosis System (RHD Model)
Diagnostics for A/C System Failure (LHD Model)
Diagnostics for A/C System Failure (RHD Model)
List of Diagnostic Trouble Code (DTC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC) (LHD Model)
Diagnostic Procedure with Diagnostic Trouble Code (DTC) (RHD Model)
Symptom Related Diagnostic
Airbag System (Diagnostics)
Basic Diagnostic Procedure
Check List for Interview
General Description
Electrical Components Location
Airbag Connector
Airbag Warning Light Illumination Pattern
Read Diagnostic Trouble Code (DTC)
Inspection Mode
Clear Memory Mode
Airbag Warning Light Failure
List of Diagnostic Trouble Code (DTC)
Diagnostic Chart with Diagnostic Trouble Code (DTC)
Cruise Control System (Diagnostics)
Basic Diagnostic Procedure
General Description
Electrical Components Location
Cruise Control Module I/O Signal
Subaru Select Monitor
Diagnostics Chart with Symptom
List of Diagnostic Trouble Code (DTC)
Diagnostics Chart with Trouble Code
Immobilizer (Diagnostics)
Basic Diagnostic Procedure
General Description
Electrical Components Location
Immobilizer Control Module I/O Signal
Subaru Select Monitor
Diagnostics Chart for Immobilizer Indicator Light
List of Diagnostic Trouble Code (DTC)
Diagnostics Chart with Trouble Code (DTC)
WIRING SYSTEM SECTION
Wiring System
Basic Diagnostics Procedure
Working Precautions
Super Multiple Junction (SMJ)
Power Supply Routing
Ground Distribution
Airbag System
Air Conditioning System
Anti-lock Brake System
A/T Control System
Audio System
Charging System
Combination Meter
Cruise Control System
Door Lock System
Engine Coolant Temperature Gauge System
Engine Electrical System
Fuel Gauge System
Full-Time Dual-Range System
Front Accessory Power Supply System
Headlight Beam Leveler System
Horn System
Immobilizer System
Keyless Entry System
Back-up Light System
Clearance Light and Illumination Light System
Front Fog Light System
Headlight System
In Compartment Light System
Stop Light System
Turn Signal Light and Hazard Light System
Oil Pressure Warning Light System
Outside Temperature Display System
Parking Brake and Brake Fluid Level Warning System
Power Seat System
Power Window System
Radiator Fan System
Rear Accessory Power Supply System
Rear Fog Light System
Rear Window Defogger System
Remote Controlled Rearview Mirror System
Seat Belt Warning System
Seat Heater System
Starter System
Sunroof System
Vehicle Dynamic Control System
Wiper and Washer System (Front)
Wiper and Washer System (Rear)
Wiper Deicer System
Overall Systems
Front Wiring Harness
Bulkhead Wiring Harness (In Engine Room)
Bulkhead Wiring Harness (In Compartment)
Engine Wiring Harness and Transmission Cord
Instrument Panel Wiring Harness
Rear Wiring Harness
Door Cord
Rear Wiring Harness and Trunk Lid Cord
Rear Wiring Harness and Rear Gate Cord