Recall - Air Flow Meter Contamination
NUMBER: WWG-90DATE: 05/2002
APPLICABILITY:
1999MY 2.2L Legacy (Except Outback); 2.2L & 2.5L Impreza; 2.5L Forester
SUBJECT:
Air Flow Meter Sensor
INTRODUCTION
Subaru of America, Inc. (SOA) has determined that the affected vehicles listed below may experience an Air Flow Meter Sensor malfunction. This can occur if the sensor element is contaminated by seeping silicon oil contained in the silicon gel sealing material at the sensor base. The malfunction may occur after carbon and dust in the atmosphere combine with the silicon oil and accumulate on the sensor element.
Should the air flow meter sensor malfunction prior to replacement, the CHECK ENGINE warning light / Malfunction Indicator Lamp (MIL) will illuminate steadily while the engine is running advising the driver of a malfunction and the need to seek repair service.
This service program will involve replacement of the air flow meter sensor on affected vehicles.
AFFECTED VEHICLES
^ 1999 MY 2.2L Subaru Legacy (except Outback) - Federal Spec. only
^ 1999 MY 2.2L & 2.5L Impreza - Federal & California Spec.
^ 1999 MY 2.5L Forester - Federal & California Spec.
Affected vehicles are identified in the VIN range chart.
NOTE:
Prior to performing repairs, confirm coverage for potentially affected vehicles by using the Vehicle Coverage Inquiry in the Dealer Communication System (DCS).
Vehicles identified in the chart may include VIN's that were not distributed in the US. market.
OWNER INFORMATION
SOA will provide dealers with a list of affected VIN's that includes owner name and address information obtained from State Motor Vehicle Registration Records. This information is considered confidential and may only lawfully be used to follow-up with owners of affected vehicles in order to complete this service program. It is unlawful to use this information for any other purpose such as advertising or marketing. Dealers may not use this information to update their owner database.
OWNER NOTIFICATION
SOA will prepare and mail an Owner Notification Letter to owners of affected vehicles in early June, 2002.
DEALER PROGRAM RESPONSIBILITY
Dealers are to promptly service all vehicles subject to this service program at no charge to the vehicle owner regardless of mileage, age of the vehicle, or ownership.
For affected vehicles sold after the date on the dealer's computer list, dealers are to contact those owners and provide them with a copy of the owner notification letter. They should also arrange to make the required correction according to the instructions in the service procedure section of this bulletin.
Dealers are also to promptly perform the applicable service procedures defined in this bulletin to correct all affected vehicles in their inventory (new, used, demo). Additionally, whenever a vehicle subject to this service program is taken into dealer new or used inventory, or is in the dealership for service, necessary steps should be taken to ensure the service program correction has been made before selling or releasing the vehicle.
If the service program correction is performed when the vehicle is in for other service, the vehicle owner should be made aware that the campaign has been completed. For vehicles serviced in the states of California and Massachusetts, a "VEHICLE EMISSION RECALL - PROOF OF CORRECTION" Certificate should be provided to the vehicle owner along with an explanation of the purpose of that form. See this bulletin for further details.
PARTS INFORMATION
Prior to the release of this program, affected dealers will automatically be shipped a quantity of replacement parts equivalent to about 50% of their affected vehicle list. Additional quantities of the replacement part will be available through normal parts supply. In order to maintain an adequate part supply, SOA requests that Dealers only order parts necessary to meet anticipated demand.
SERVICE PROCEDURE
Replacement procedure of the Air Flow Meter Sensing Unit.
1) With the ignition switch in the "off" position, disconnect the air flow meter sensing unit from the vehicle wire harness.
2) Loosen the air intake clamp.
3) Loosen clamps for the air cleaner housing.
4) Remove the air intake housing from the engine compartment.
5) Clean the area around the Air Flow Meter Sensing Unit to ensure no dirt enters the air flow meter housing. Remove the two tamper resistant TORX head screws (TR20) securing the sensor to the air flow meter body.
Caution:
Only use tools designed for tamper resistant TORX head screws.
6) Remove the Air Flow Meter Sensing Unit from the air flow meter body.
Installation of the new Air Flow Meter Sensing Unit.
1) Install the new Air Flow Meter Sensing Unit. Make sure the "O" ring is seated properly during installation of the Air Flow Meter Sensing Unit. (Failure to seat the "O" ring will cause a vacuum leak)
2) Tighten the TORX head screws (TR20) to 31-40 lb.in, 3.53-4.61 Nm (0.36-0.47 kgf/m).
Caution:
Only use tools designed for tamper resistant TORX head screws.
3) Reinstall the air intake housing back into the engine compartment. Ensure clamps are tightened properly; failure to do so will cause a vacuum leak.
4) Reconnect the vehicle wire harness to the air flow meter sensing unit.
Note:
If the "Check Engine" light is illuminated when the vehicle arrives for service, use the Select Monitor to recover stored trouble codes. If trouble code P0170 is found, replacing the Air Flow Meter Sensing Unit should correct the condition. Clear the ECM memory. If any other codes are found, refer to the applicable service manual for trouble code diagnostic procedures.
SERVICE PROGRAM IDENTIFICATION LABEL
Type or print the necessary information on a Service Program identification label. The completed label should be attached to the vehicle's upper radiator support.
A quantity of labels is provided to each dealer with this bulletin. Additional labels are available through your Area/Distributor Service 0ffice.
CALIFORNIA/MASSACHUSETTS "VEHICLE EMISSION RECALL - PROOF OF CORRECTION" CERTIFICATE
The California Air Resources Board and the Department of Motor Vehicles Registration/Recall Program requires that all emission related Recall/Campaign or Service Program repairs be completed before a vehicle registration is renewed. Please provide owners of vehicles registered in the states of California and Massachusetts a completed "Vehicle Emission Recall - Proof of Correction" certificate. Vehicle owners should be advised to retain this certificate because the California/Massachusetts Department of Motor Vehicles may require they provide proof this service program repair has been completed.
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES
Credit to perform this Service Program will be based on the submission of properly completed repair order information. Dealers may enter the applicable claim information through their Dealer Communications System.
Replacement of the Air Flow Meter Sensor - Use the claim submission information for replacement of the Air Flow Meter Sensor.
For Air Flow Meter Sensor replacement enter labor operation 145-501 for 0.3 labor hours.
Enter part number 22794AA000. The part will be reimbursed at dealer cost plus applicable handling allowance.
REIMBURSEMENT FOR PREVIOUS REPAIRS
Owners are being advised in the owner notification letter that if they have previously paid an authorized Subaru dealer for replacement of the air fuel meter sensor, they may be entitled to reimbursement. The owners are further advised that to qualify for any reimbursement they must submit the original or original carbon copy of the repair invoice to Subaru of America, Inc. Please review the owner notification letter, which explains this procedure so that you are familiar with it, and can assist owners with any questions.
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