Subaru Outback II (1999–2003) BE/BH  Workshop Manual

This manual is a complete reference for repair, maintenance and diagnostics of the second generation Subaru Outback (BE/BH, 1999–2003). It covers all aspects of the vehicle, including the engine, transmission, suspension, brakes, electrical system, body and all-wheel drive (AWD) system.

🚗 Main sections:

✔️ Detailed electrical diagrams

✔️ Maintenance procedures

✔️ Troubleshooting

✔️ Engine, gearbox and chassis repair instructions

✔️ Safety systems and ABS

✔️ Body repair and anti-corrosion treatment

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Years of production: 1998–2003

🔹 Body type: sedan (BE), station wagon (BH), Outback (BK)

🔹 Engines:

2.0L EJ20 (135–280 hp)

2.5L EJ25 (156–165 hp)

3.0L EZ30 H6 (209 hp)

🔹 Transmission: 5MT, 4EAT

🔧 Engine (EJ25, EZ30)

🛠 Overheating and head gasket issues (EJ25 SOHC)

The main problem with the 2.5L EJ25 is coolant leaks due to weak cylinder head gaskets.

Symptoms: overheating, bubbles in the expansion tank, antifreeze leak.

🛠 Oil leak from the front crankshaft oil seal

Over time, the seals can become leaky, which leads to oil loss.

🛠 Oil consumption (EZ30 H6)

The 3.0-liter engine consumes oil when driving aggressively.

⚙️ Transmission (automatic and manual)

🛠 Slippage and jerks 4EAT (automatic)

The weak point is the solenoids and torque converter, which leads to jerking when changing gears.

🛠 Clutch wear on 5MT (manual)

With active driving, the clutch wears out quickly, especially when towing.

🚗 Chassis and suspension

🛠 Knocking in the front suspension

The stabilizer struts, silent blocks and ball joints wear out.

🛠 Rusting rear shock absorbers

In regions with an aggressive environment, the rear suspension shock absorbers quickly become covered with corrosion.

⚡️ Electrical

🛠 Generator malfunctions

The relay regulator often fails, which is why the battery is undercharged.

🛠 Problems with the electric windows and seats

Over time, the contacts fail, the motors work intermittently.

🔩 Body and corrosion

🛠 Rust on the sills and wheel arches

Especially in cars operated in regions with salt on the roads.

🛠 Paint peeling off the hood

Often observed on models with factory two-layer paint.