Subaru Legacy 2002 User Manual

2002 LEGACY SERVICE MANUAL

NEW CAR INFORMATION SECTION

QUICK REFERENCE INDEX

Specifications SPC

FOREWORD

This manual has been prepared to provide information
for the construction, operation and other technical de­tails of SUBARU vehicles.
Read this manual thoroughly and make the most of it
to give better service to your customers and improve
your knowledge of vehicle maintenance.

Fuel Injection (Fuel System) FU

Fuel Injection (Fuel System)

Emission Control
(Aux. Emission Control Devices)

Emission Control
(Aux. Emission Control Devices)EC (w/o OBD)

Intake (Induction) IN

Mechanical ME

Exhaust EX

Exhaust

Cooling CO

(w/o OBD)

(w/o OBD)

FU

EC

EX

All information, illustration and specifications con­tained in this manual are based on the latest product
information available at the time of publication ap­proval.

FUJI HEAVY INDUSTRIES LTD.

Lubrication LU

Speed Control System SP

Ignition IG

Ignition

Starting/Charging SC

Fuel Injection (Fuel System)

Emission Control
(Aux. Emission Control Devices)

Intake (Induction)

(w/o OBD)

IG

FU

(H6)

EC

(H6)

IN

(H6)

W2290GE

FOREWORD

QUICK REFERENCE INDEX

Mechanical

Exhaust

Cooling

Lubrication

Speed Control System

Ignition

Starting/Charging

Control System CS

Automatic Transmission AT

ME

(H6)

EX

(H6)

CO

(H6)

LU

(H6)

SP

(H6)

IG

(H6)

SC

(H6)

Manual Transmission and Differential MT

Clutch CL

Front Suspension FS

Rear Suspension RS

Differentials DI

Drive Shaft System DS

ABS ABS

VDC VDC

Brakes BR

FOREWORD

Parking Brake PB

QUICK REFERENCE INDEX

Power Assisted System
(Power Steering)

HVAC System
(Heater, Ventilator and A/C)

Airbag System AB

Seat Belt System SB

Wiper and Washer Systems WW

Glass/Windows/Mirrors GW

Body Structure BS

Instrumentation/Driver Info IDI

Seats SE

PS

AC

Security and Locks SL

Sunroof/T-top/Convertible Top SR

Exterior Body Panels EB

Cruise Control System CC

Exterior/Interior Trim EI

FOREWORD

All right reserved. This book may not be reproduced or
copied, in whole or in part, without the written permis­sion of FUJI HEAVY INDUSTRIES LTD., TOKYO JA­PA N

SUBARU, and are trademarks of FUJI
HEAVY INDUSTRIES LTD.

 Copyright 2001 FUJI HEAVY INDUSTRIES LTD.

SPECIFICATIONS

1. Legacy ............................................................................................................. 2

2. OUTBACK ....................................................................................................... 10

SPC

Page

LEGACY

Specifications

1. Legacy

A: DIMENSIONS

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

With catalytic
converter

Australia mm (in) 155 (6.1) 155 (6.1)

mm (in) 160 (6.3) 165 (6.5)

mm (in) 155 (6.1) 155 (6.1)

*1: With leather seat
*2: With sunroof

B: ENGINE

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

Compression ratio 10.0

Firing order 1 — 3 — 2 — 4

Idle speed at Park/Neutral
position

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

3

(cu in) 1,994 (121.67) 2,457(149.9)

rpm 700±100

SPC-2

LEGACY

C: ELECTRICAL

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

Others 12V — 27AH (34B19L)

MT: 12V — 48AH (55D23L)

AT: 12V — 52AH (65D23L)

MT: 12V — 48AH (55D23L)

AT: 12V — 52AH (75D23L)

D: TRANSMISSION

Specifications

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)

Reduction gear
(Rear 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

Tr a n sf e r
reduction

Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid

Type of gear Helical — Helical —

Gear ratio 1.000 — 1.000 —

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

Specifications

E: STEERING

LEGACY

Model Models with

185/70R14 tires

Ty pe 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)

Models with

195/60R15 tires

Models with

205/50R16 tires

F: SUSPENSION

Model Conventional suspension

Front Macpherson strut type, Independent, Coil spring

Rear Multi-link type, Independent, Coil spring

G: BRAKE

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

Rim size 14 × 5½JJ 15 × 6JJ 16 × 6½JJ

Tire size 185/70R14 195/60R15 205/50R16

Type Steel belted radial, Tubeless

I: CAPACITY

Model Sedan/Wagon

AWD

2.0 L 2.5 L

5MT4AT5MT4AT

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

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

AT differential gear oil (US qt, Imp qt) — 1.1 – 1.3

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)

(US qt, Imp qt) Approx. 4.0 (4.2, 3.5)

— 9.3 – 9.6

(8.9 – 9.2,

7.4 – 7.7)

— 1.1 – 1.3

(1.2 – 1.4,

1.0 – 1.1)

(9.8 – 10.1,

8.2 – 8.4)

(1.2 – 1.4,

1.0 – 1.1)

SPC-4

LEGACY

Specifications

J: WEIGHT

1. SEDAN

! LHD 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)

Maximum permissible
axle weight (M.P.A.W.)

Maximum permissible
weight (M.P.W.)

Option Side airbag ————

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)

Total kg (lb) 1,870

(4,125)

Air conditioner ————

Audio ————

Cruise control ——————

Cold weather pack ——————

1,415

(3,120)

1,870

(4,125)

1,385

(3,055)

1,870

(4,125)

1,410

(3,110)

1,870

(4,125)

1,400

(3,085)

1,870

(4,125)

1,425

(3,140)

1,870

(4,125)

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)

Maximum permissible
axle weight (M.P.A.W.)

Maximum permissible
weight (M.P.W.)

Option Side airbag ————

*1: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>

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)

Total kg (lb) 1,910

(4,210)

Air conditioner ——

Audio ————

Cruise control —— ——

Cold weather pack ——————

1,440

(3,175)

1,000

(2,205)

1,910

(4,210)

1,405

(3,110)

1,000

(2,205)

1,910

(4,210)

1,435

(3,165)

1,000

(2,205)

1,910

(4,210)

1,395

(3,075)

1,000

(2,205)

1,910

(4,210)

1,425

(3,140)

1,000

(2,205)

1,910

(4,210)

SPC-5

LEGACY

Specifications

! RHD 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.)

Maximum permissible
weight (M.P.W.)

Option Side airbag —

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)

Total kg (lb) 1,870 (4,125) 1,870 (4,125) 1,870 (4,125) 1,910 (4,210) 1,910 (4,210)

Air conditioner —————

Audio

Cruise control —————

Cold weather pack —————

Option code *1 KA

Model 2.0 L 2.5 L

4WD

GL (GX) GX (RX)

5MT4AT5MT4AT

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.)

Option Side airbag ————

*1: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>

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)

Air conditioner ———

Audio

Cruise control ———

Cold weather pack ————

SPC-6

LEGACY

Specifications

2. WAGON

! LHD 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

Maximum permissible
axle weight (M.P.A.W.)

Maximum permissible
weight (M.P.W.)

Option Side airbag —————

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

Total kg (lb) 1,920

Air conditioner ————

Audio ————

Cruise control ——————

Cold weather pack ——————

(3,155)

(2,270)

(4,235)

1,450

(3,195)

1,030

(2,270)

1,920

(4,235)

1,430

(3,155)

1,030

(2,270)

1,920

(4,235)

1,445

(3,185)

1,030

(2,270)

1,920

(4,235)

1,445

(3,185)

1,030

(2,270)

1,920

(4,235)

1,460

(3,220)

1,030

(2,270)

1,920

(4,235)

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

Maximum permissible
axle weight (M.P.A.W.)

Maximum permissible
weight (M.P.W.)

Option Side airbag ————

*1: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>

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

Total kg (lb) 1,980

Air conditioner ———

Audio ————

Cruise control —————

Cold weather pack —————

(3,185)

(2,315)

(4,365)

1,475

(3,250)

1,050

(2,315)

1,980

(4,365)

1,430

(3,155)

1,030

(2,270)

1,920

(4,235)

1,445

(3,185)

1,030

(2,270)

1,920

(4,235)

1,445

(3,185)

1,030

(2,270)

1,920

(4,235)

1,460

(3,220)

1,030

(2,270)

1,920

(4,235)

SPC-7

LEGACY

Specifications

! RHD Vehicle

Option code *1 K1 EK

Model 2.0 L 2.5 L

4WD

GL GX

5MT 4AT 5MT 4AT 5MT 4AT

Curb weight (C.W.) Front kg (lb) 775 (1,710) 790 (1,740) 785 (1,731) 800 (1,765) 790 (1,740) 805 (1,775)

Rear kg (lb) 655 (1,445) 655 (1,445) 650 (1,435) 650 (1,435) 655 (1,445) 655 (1,445)

Total kg (lb) 1,430

(3,155)

Maximum permissible
axle weight (M.P.A.W.)

Maximum permissible
weight (M.P.W.)

Option Side airbag ——

Front kg (lb) 960 (2,115) 960 (2,115) 960 (2,115) 960 (2,115) 995 (2,195) 995 (2,195)

Rear kg (lb) 1,030

(2,270)

Total kg (lb) 1,920

(4,235)

Air conditioner ——————

Audio

Cruise control ——————

Cold weather pack ——————

1,445

(3,185)

1,030

(2,270)

1,920

(4,235)

1,435

(3,165)

1,030

(2,270)

1,920

(4,235)

1,450

(3,195)

1,030

(2,270)

1,920

(4,235)

1,445

(3,185)

1,050

(2,315)

1,980

(4,365)

1,460

(3,220)

1,050

(2,315)

1,980

(4,365)

Option code *1 KA

Model 2.0 L 2.5 L

4WD

GL (GX) GX (RX)

5MT4AT5MT4AT

Unladen mass (U.M.) Front kg (lb) 775 (1,710) 775 (1,710) 765 (1,685) 780 (1,720)

Rear kg (lb) 635 (1,400) 635 (1,400) 645 (1,420) 645 (1,420)

Total kg (lb) 1,410 (3,110) 1,410 (3,110) 1,410 (3,110) 1,425 (3,140)

Gross vehicle mass
(G.V.M.)

Option Side airbag ————

*1: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>

Front kg (lb) 930 (2,050) 930 (2,050) 950 (2,095) 950 (2,095)

Rear kg (lb) 1,010 (2,225) 1,010 (2,225) 1,040 (2,295) 1,040 (2,295)

Total kg (lb) 1,940 (4,280) 1,940 (4,280) 1,990 (4,390) 1,990 (4,390)

Air conditioner ———

Audio

Cruise control ———

Cold weather pack ————

SPC-8

LEGACY

Specifications

NOTE:
When any of the following optional parts are installed, add the weight to the curb weight.

Weight of
optional parts

Front kg (lb) 6.5 (14.33) 2.1 (4.6) 13.9 (30.6) 10.9 (24.0) 1.8 (4.0) 2.9 (6.4)

Rear kg (lb) 0.1 (0.22) 0.3 (0.7) –0.1 (–0.2) 16.4 (36.2) 3.1 (6.8) 3.0 (6.6)

Total kg (lb) 6.6 (14.55) 2.4 (5.3) 13.8 (30.4) 27.3 (60.2) 4.9 (10.8) 5.9 (13.0)

Weight of
optional parts

Front kg (lb) 0.2 (0.44) 1.8 (4.0) –0.7 (–1.54) –1.4 (–3.09) 0.2 (0.4)

Rear kg (lb) 0.2 (0.44) 0.7 (1.5) 3.2 (7.06) –3.8 (–8.38) 4.2 (9.3)

Total kg (lb) 0.4 (0.88) 2.5 (5.5) 2.5 (5.51) –5.2 (–11.47) 4.4 (9.7)

VDC Cruise control Air conditioner Sunroof Leather interior SRS Airbag

(Side)

Cold weather pack Audio Rear spoiler Sports package Self-leveling

rear suspension

SPC-9

OUTBACK

Specifications

2. OUTBACK

A: DIMENSIONS

Model OUTBACK

AWD

Overall length mm (in) 4,720 (185.8)

Overall width mm (in) 1,745 (68.7)

Overall height (at CW) mm (in) 1,580 (62.2), 1,590 (62.6)*3

Compartment Length mm (in) 1,925 (75.8)

Width mm (in) 1,440 (56.7), 1,420 (55.9)*1

Height mm (in) 1,190 (46.9), 1,175 (46.3)*2

Wheelbase mm (in) 2,650 (104.3)

Tread Front mm (in) 1,470 (57.9)

Rear mm (in) 1,460 (57.5)*3, 1,465 (57.7)

Minimum road
clearance

Without catalytic
converter

With catalytic
converter

Australia mm (in) 200 (7.9)

mm (in) 195 (7.7)

mm (in) 190 (7.5)

*1: With leather seat
*2: With sunroof
*3: Australia spec. vehicles

B: ENGINE

Model OUTBACK

AWD

2.5 L 3.0 L

Engine type Horizontally opposed, liquid cooled,

4-cylinder, 4-stroke gasoline engine

Valve arrangement Overhead camshaft type Double overhead camshaft type

Bore × Stroke mm (in) 99.5 × 79.0 (3.917 × 3.110) 89.2 × 80.0 (3.512 × 3.150)

Displacement cm

Compression ratio 10.0 10.7

Firing order 1 — 3 — 2 — 41 — 6 — 3 — 2 — 5 — 4

Idle speed at Park/Neutral
position

Maximum output kW (HP)/rpm 115 (154)/5,600 154 (206)/6,000

Maximum torque N·m (kgf-m, ft-lb)/rpm 223 (22.7, 164.2)/3,600 282 (28.8, 208)/4,400

3

(cu in) 2,457 (149.9) 3,000 (183.06)

rpm 700±100 600±100

Horizontally opposed, liquid cooled,
6-cylinder, 4-stroke gasoline engine

SPC-10

OUTBACK

Specifications

C: ELECTRICAL

Model OUTBACK

AWD

2.5 L 3.0 L

Ignition timing at idling speed BTDC/rpm 10°±10°/700 10°±8°/600

Spark plug Type and manufacturer RC10YC4 ....... CHAMPION PLFR6A ....... NGK

Alternate RC8YC4 ....... CHAMPION

Generator 12V — 90A 12V — 100A

Battery Type and capacity (5HR) For Europe and

South America

Others 12V — 27AH (34B19L) 12V — 48H (55D23L)

BKR6E-11 ....... NGK

K20PR-U11 ....... NIPPONDENSO

MT: 12V — 48AH (55D23L)
AT: 1 2V — 52AH (75D23L)

12V — 52AH (75D23L)

D: TRANSMISSION

Model OUTBACK

AWD

2.5 L 3.0 L

Transmission type 5MT 4AT 4AT

Clutch type DSPD TCC TCC

Gear ratio 1st 3.454 2.785

2nd 2.062 1.545

3rd 1.448 1.000

4th 1.088 0.694

5th 0.825 —

Reverse 3.333 2.272

Auxiliary transmission gear ratio High 1.000 —

Low 1.196 —

Reduction gear
(Front drive)

Reduction gear
(Rear drive)

1st reduction Type of gear — Helical

Gear ratio — 1.000

Final reduction Type of gear Hypoid Hypoid

Gear ratio 3.900*1, 4.111*2 4.444 4.111

Tr a n sf e r
reduction

Final reduction Type of gear Hypoid Hypoid

Type of gear Helical —

Gear ratio 1.000 —

Gear ratio 3.900*1, 4.111*2 4.444 4.111

5MT: 5 × 2 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-11

OUTBACK

Specifications

E: STEERING

Model OUTBACK

Ty pe Rack and Pinion

Turns, lock to lock 3.0

Minimum turning circle m (ft) Curb to curb: 11.2±1.0 (36.7±3.3)

Wall to wall: 12.0±1.0 (39.4±3.3)

F: SUSPENSION

Model OUTBACK

Front Macpherson strut type, Independent, Coil spring

Rear Multi-link type, Independent, Coil spring

G: BRAKE

Model OUTBACK

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

Model OUTBACK

Rim size 16 × 6½JJ

Tire size 215/60R16

Type Steel belted radial, Tubeless

I: CAPACITY

Model OUTBACK

AWD

2.5 L 3.0 L

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) 6.8 (7.2, 6.0)

Engine oil
amount for refill

Transmission gear oil (US qt, Imp qt) 4.0 (4.2, 3.5) —

Automatic transmission fluid (US qt, Imp qt) — 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)

AWD rear differential gear oil (US qt, Imp qt) 0.8 (0.8, 0.7)

Power steering fluid (US qt, Imp qt) 0.7 (0.7, 0.6)

Engine coolant (US qt, Imp qt) 6.8 (7.2, 6.0) 6.7 (7.1, 5.9) 7.7 (8.1, 6.8)

(US qt, Imp qt) Approx. 4.0 (4.2, 3.5) Approx. 5.8 (6.1, 5.1)

SPC-12

OUTBACK

Specifications

J: WEIGHT

1. OUTBACK

! LHD Vehicle

Option code *1 K4 KS KO

Model 2.5 L

4WD

5MT 4AT 5MT 4AT

Curb weight (C.W.) Front kg (lb) 810 (1,785) 825 (1,820) 815 (1,795) 830 (1,830) 785 (1,730)

Rear kg (lb) 670 (1,475) 670 (1,475) 670 (1,475) 670 (1,475) 650 (1,435)

Total kg (lb) 1,480 (3,265) 1,495 (3,295) 1,485 (3,275) 1,500 (3,310) 1,435 (3,165)

Maximum permissible
axle weight (M.P.A.W.)

Maximum permissible
weight (M.P.W.)

Option Side airbag —————

Front kg (lb) 995 (2,195) 995 (2,195) 995 (2,195) 995 (2,195) 960 (2,115)

Rear kg (lb) 1,050 (2,315) 1,050 (2,315) 1,050 (2,315) 1,050 (2,315) 1,030 (2,270)

Total kg (lb) 2,000 (4,410) 2,000 (4,410) 2,000 (4,410) 2,000 (4,410) 1,920 (4,235)

Air conditioner

Audio ——

Cruise control

Cold weather pack —————

Leather interior ————

Sunroof ————

Option code *1 EC

Model 2.5 L 3.0 L

4WD

5MT 4AT

Curb weight (C.W.) Front kg (lb) 815 (1,795) 830 (1,830) 915 (2,020)

Rear kg (lb) 675 (1,490) 675 (1,490) 695 (1,530)

Total kg (lb) 1,490 (3,285) 1,505 (3,320) 1,610 (3,550)

Maximum permissible
axle weight (M.P.A.W.)

Maximum permissible
weight (M.P.W.)

Option Side airbag

*1: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>

Front kg (lb) 1,010 (2,225) 1,010 (2,225) 1,040 (2,295)

Rear kg (lb) 1,060 (2,335) 1,060 (2,335) 1,060 (2,335)

Total kg (lb) 2,015 (4,445) 2,015 (4,445) 2,085 (4,595)

Air conditioner

Audio ——

Cruise control ——

Cold weather pack ——

Leather interior ——

Sunroof ——

SPC-13

OUTBACK

Specifications

! RHD Vehicle

Option code *1 EK

Model 2.5 L 3.0 L

4WD

5MT 4AT

Curb weight (C.W.) Front kg (lb) 800 (1,765) 815 (1,795) 915 (2,020)

Rear kg (lb) 670 (1,475) 670 (1,475) 695 (1,530)

Total kg (lb) 1,470 (3,240) 1,485 (3,275) 1,610 (3,550)

Maximum permissible
axle weight (M.P.A.W.)

Maximum permissible
weight (M.P.W.)

Option Side airbag ——

Front kg (lb) 1,010 (2,225) 1,010 (2,225) 1,040 (2,295)

Rear kg (lb) 1,060 (2,335) 1,060 (2,335) 1,060 (2,335)

Total kg (lb) 2,015 (4,445) 2,015 (4,445) 2,085 (4,595)

Air conditioner ——

Audio

Cruise control ——

Cold weather pack ——

Leather interior ——

Sunroof ——

Option code *1 KA

Model 2.5 L 3.0 L

4WD

5MT 4AT

Unladen mass (U.M.) Front kg (lb) 790 (1,740) 800 (1,765) 900 (1,985)

Rear kg (lb) 650 (1,435) 650 (1,435) 690 (1,520)

Total kg (lb) 1,440 (3,175) 1,410 (3,110) 1,590 (3,505)

Gross vehicle mass
(G.V.M.)

Option Side airbag ——

*1: For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>

Front kg (lb) 970 (2,140) 970 (2,140) 1,035 (2,280)

Rear kg (lb) 1,050 (2,315) 1,050 (2,315) 1,050 (2,315)

Total kg (lb) 2,020 (4,455) 2,020 (4,455) 2,085 (4,595)

Air conditioner ——

Audio

Cruise control ——

Cold weather pack ——

SPC-14

OUTBACK

Specifications

NOTE:
When any of the following optional parts are installed, add the weight to the curb weight.

Weight of
optional parts

Front kg (lb) 2.1 (4.6) 0.2 (0.4) 13.9 (30.6) 10.9 (24.0) 1.8 (4.0)

Rear kg (lb) 0.3 (0.7) 4.2 (9.3) –0.1 (–0.2) 16.4 (36.2) 3.1 (6.8)

Total kg (lb) 2.4 (5.3) 4.4 (9.7) 13.8 (30.4) 27.3 (60.2) 4.9 (10.8)

Weight of
optional parts

Front kg (lb) 2.9 (6.4) 0.2 (0.44) 1.8 (4.0) –0.7 (–1.54) –1.4 (–3.09)

Rear kg (lb) 3.0 (6.6) 0.2 (0.44) 0.7 (1.5) 3.2 (7.06) –3.8 (–8.38)

Total kg (lb) 5.9 (13.0) 0.4 (0.88) 2.5 (5.5) 2.5 (5.51) –5.2 (–11.47)

Cruise control Self

levelizer

SRS Airbag (Side) Cold weather pack Audio Rear spoiler Sports package

Air conditioner Sunroof Leather interior

SPC-15

Specifications

MEMO

OUTBACK

SPC-16

FUEL INJECTION (FUEL SYSTEM) FU

Page

1. General ............................................................................................................ 2

2. Air Line ............................................................................................................ 3

3. Fuel Line .......................................................................................................... 8

4. Sensors and Switches .....................................................................................19

5. Control System ................................................................................................ 30

6. On-board Diagnosis System ...........................................................................38

GENERAL

Fuel Injection (Fuel System)

1. General

! The Multipoint Fuel Injection (MFI) system supplies optimum air-fuel mixture under every engine

operating condition through the use of the latest electronic control technology.

This system pressurizes the fuel to a constant pressure and injects it into each intake air port in
the cylinder head. The injection quantity of fuel is controlled by an intermittent injection system
where an electro-magnetic injection valve or injector opens for a short period that is precisely con­trolled depending on the quantity of air appropriate for each condition of operation. In actual con­trol, an optimum fuel injection quantity is achieved by varying the duration of an electric pulse
applied to the injector. This way of control enables simple, yet highly precise metering of the fuel.

! The engine control module (ECM) that controls the fuel injection system corrects the fuel injec-

tion amount depending on the vehicle speed, throttle opening, coolant temperature and other ve­hicle-operation-related information. The ECM receives the information in the form of electric
signals from the corresponding sensors and switches.

The MFI system also has the following features:

! Reduced exhaust emissions

! Reduced fuel consumption

! Increased engine output

! Quick response to accelerator and brake pedal operation

! Superior startability and warm-up performance in cold weather due to corrective controls made

according to coolant and intake air temperatures

FU-2

AIR LINE

Fuel Injection (Fuel System)

2. Air Line

A: GENERAL

The air filtered by the air cleaner enters the throttle body where it is regulated in the volume by the
throttle valve and then enters the intake manifold. It is then distributed to each cylinder where the
air is mixed with fuel injected by the injector. During idling operation, air flows into the cylinder
through the idle air control solenoid valve, bypassing the throttle valve. This enables controlling the
engine idling speed properly.

B: INTAKE MANIFOLD PRESSURE AND AIR TEMPERATURE SENSORS

The intake manifold pressure sensor and the intake air temperature sensor are integrated into a
single unit. The unit is mounted on the intake manifold and measures the absolute air pressure in
the intake manifold as well as the temperature of the intake air.
The measured pressure and temperature are converted into electrical signals and sent to the
ECM. The ECM uses these signals to control injection and ignition timing as well as the fuel injec­tion amount.

(1) Pressure sensor

(2) Intake air temperature sensor

H2H2825B

FU-3

AIR LINE

Fuel Injection (Fuel System)

C: ATMOSPHERIC PRESSURE SENSOR

The atmospheric pressure sensor converts pressure values into electric signals, and sends the
signals to the ECM.

H2H1869B

(1) Sensor unit (6) Terminal

(2) O-ring (7) Inner lead

(3) Case (8) Resin

(4) Pipe (9) Metal lid

(5) Through capacity

D: THROTTLE BODY

In response to operation of the accelerator pedal, the throttle valve in the throttle body opens/clos­es to regulate the volume of the air drawn into the combustion chamber.

During idling, the throttle valve is almost fully closed and the volume of air passing through the
throttle body is less than that passing through the idle air control solenoid valve.

More than half of the air necessary for idling is supplied to the intake manifold via the idle air con­trol solenoid valve which controls properly the engine idling speed, so the idling speed needs not
be adjusted.

FU-4

AIR LINE

Fuel Injection (Fuel System)

E: THROTTLE POSITION SENSOR

! The throttle position sensor is mounted in the throttle body and linked to the throttle valve.

! The throttle position sensor sends the ECM voltage signal corresponding to the opening of the

throttle valve. When the sensor’s output voltage exceeds a predetermined level, the ECM inter­prets it as complete closure of the throttle valve. When the output voltage is at another predeter­mined level, the ECM recognizes that the throttle valve is at a wide open position. Since the output
characteristics of the sensor change over years, the ECM is provided with a learning function to
be able to interpret signals into throttle valve angles always correctly.

(1) Lever

(2) Terminal

B2H2004B

FU-5

AIR LINE

Fuel Injection (Fuel System)

F: IDLE AIR CONTROL SOLENOID VALVE

! The idle air control solenoid valve is located in the throttle body and regulates the amount of

intake air that flows bypassing the throttle valve into the intake manifold during engine idling. It is
activated by a signal from the ECM in order to maintain the engine idling speed at a target speed.

! The idle air control solenoid valve is a stepping motor type solenoid-actuated valve which con-

sists of coils, a shaft, a permanent magnet, a spring and a housing. The housing is an integral part
of the throttle body.

! The stepping motor consists of two paired coils, the coils of each pair being arranged face to

face with a shaft in between.

! The shaft has a screw at the end around which the permanent magnets are arranged.

! As current flows in the form of pulses through the paired coils sequentially while alternating the

polarity, the N and S poles of the permanent magnets around the shaft are repelled by the same
poles of the magnetism generated by the coils. This causes a nut externally fixed to the magnets
and internally engaging with the screw of the shaft to turn.
The shaft then goes upward or downward.

! This upward and downward motions of the shaft open or close the valve port, adjusting the

amount of bypass air.

(1) Connector

(2) Permanent magnet

(3) Shaft

(4) Coil

(5) Spring

B2H2005B

FU-6

AIR LINE

Fuel Injection (Fuel System)

G: AIR ASSIST INJECTOR SOLENOID VALVE

The air assist injector solenoid valve is located in the piping between the throttle body and the in­jector and secured to the intake manifold.
This solenoid valve is opened or closed by the signals from the ECM, adjusting the flow rate of air
supplied to the injector.

(1) Valve seat A: From idle air control solenoid valve

(2) Solenoid B: To inj ec to r

(3) Plunger and valve

(4) Spring

(5) Connector

FU-7

B2H3447B

FUEL LINE

Fuel Injection (Fuel System)

3. Fuel Line

A: GENERAL

! The fuel pressurized by the fuel tank inside pump is delivered to each fuel injector by way of the

fuel pipe and fuel filter. Fuel injection pressure is regulated to an optimum level by the pressure
regulator.

! Each injector injects fuel into the intake port of the corresponding cylinder where the fuel is

mixed with air. The mixture then enters the cylinder.

Fuel injection amount and timing are regulated by the ECM.

(1) Purge control solenoid valve (10) Air vent pipe

(2) Pressure regulator (11) Fuel filter

(3) Fuel injector (12) Jet pump

(4) Throttle body (13) Fuel pump

(5) Intake manifold (14) Fuel cut valve

(6) Two-way valve (15) Fuel tank

(7) Canister (16) Fuel return line

(8) Filler cap (17) Fuel delivery line

(9) Filler pipe (18) Fuel evaporation line

FU-8

B2H2907B

FUEL LINE

Fuel Injection (Fuel System)

B: PRESSURE REGULATOR

The pressure regulator is installed at the injector end of the fuel supply line. It has a fuel chamber
and spring chamber separated by a diaphragm. Fuel chamber is connected to the fuel supply line
and the spring chamber is connected to the intake manifold. Fuel chamber also has a relief valve
connected to the fuel return line through which fuel returns to the fuel tank. When the intake man­ifold vacuum increases, the diaphragm is pulled and the relief valve opens to decrease the fuel
supply line pressure (or fuel injection pressure). When the intake manifold vacuum decreases, the
diaphragm is pushed by the spring to increase the fuel supply line pressure. Thus, the difference
between the fuel injection pressure and the intake manifold vacuum is kept at a constant level of
294 kPa (3.00 kgf/cm
hicles to precisely control the amount of injected fuel.

2

, 43.0 psi) for MT vehicles or 299.1 kPa (3.05 kgf/cm2, 43.4 psi) for AT ve-

A

B

(1)

(2)

(1) Relief valve A: To intake manifold

(2) Diaphragm B: Fuel IN

C: Fuel OUT

C

S2H0623C

FU-9

FUEL LINE

Fuel Injection (Fuel System)

C: FUEL INJECTORS

! The MFI system employs top feed type fuel injectors with an air assist feature.

! Each injector is installed in the fuel pipe in such a way that the injector is cooled by fuel.

! The features of this type of fuel injector are as follows:

1) High heat resistance

2) Low driving noise

3) Easy to service

4) Small size

! The injector injects fuel according to the valve open signal from the ECM. The needle valve is

lifted by the solenoid which is energized on arrival of the valve open signal.

! Since the injector’s nozzle hole area, the lift of valve and the fuel pressure are kept constant,

the amount of fuel injected is controlled only by varying the duration of the valve open signal from
the ECM.

! Fuel atomization is enhanced using assist air supplied from the idle air control solenoid valve

passing through the passage formed in the intake manifold at the area in which each injector is
installed. This contributes not only to higher combustion efficiency and higher output but also to
cleaner exhaust emissions.

FU-10