Recall - O2 Sensor Replacement
NUMBER: WXW-80DATE: 01/2001
APPLICABILITY:
2000MY Subaru Legacy and Outback 4EAT
2000MY Impreza 2.5 RS MT5 or 4EAT
2000/2001 MY Forester MT5 or 4EAT
SUBJECT:
Front Oxygen (Air/Fuel Ratio) Sensor
Subaru of America, Inc. (SOA) has determined that the affected vehicles listed below may experience front oxygen Air/Fuel (A/F) sensor element cracking. Should this occur 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 program will involve replacement of the front oxygen (A/F) sensor on affected vehicles.
Please Note:
Because of the number of affected vehicles and part availability, this program will be released in phases determined by geographic location. Dealers will be notified of the release schedule when available.
AFFECTED VEHICLES
^ 2000MY Subaru Legacy and Outback with 4EAT only
^ 2000MY Impreza 2.5 RS with MT5 or 4EAT
^ 2000/2001 MY Forester with MT5 or 4EAT
Affected vehicles are identified in the VIN range chart below
NOTE:
Coverage for all affected vehicles must be confirmed by using the Vehicle Coverage Inquiry in the Dealer Communication System (DCS).
Owners of affected vehicles that have been previously repaired, according to SOA claim records, will not be notified of this program. Their names and VINs will not appear on the dealer's affected VIN list and the program will show completed on Vehicle Coverage Inquiry in the Dealer Communication System (DCS).
OWNER NOTIFICATION
SOA will prepare and mail an Owner Notification Letter to owners of the affected vehicles in phases determined by geographic location. The program release schedule will be sent to dealers separately when available. Dealers will be advised of the owner notification schedule prior to the mailing.
DEALER PROGRAM RESPONSIBILITY
Dealers are to promptly service all vehicles subject to this service program. There is 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.
PARTS INFORMATION
Prior to the release of each phase of this program, affected dealers will automatically be shipped a quantity of replacement parts equivalent to 25% of their affected vehicle sales. 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 supply anticipated demand.
Note:
All correct replacement parts will have a white paint mark on the harness connector.
SERVICE PROCEDURE
1. With the ignition switch in the "off" position, disconnect the front oxygen (A/F) sensor from the vehicle wire harness.
2. Raise the vehicle on a lift.
Caution:
The catalytic converter and front oxygen (A/F) sensor may be extremely hot. Attempting to remove the sensor while hot may cause personal injury and will damage the threaded portion of the catalytic converter. Be sure they have adequately cooled before proceeding.
3. Apply penetrating lubricant at the thread portion of the front oxygen (A/F) sensor. Wait several minutes. Using a 22 mm open-end wrench, loosen and remove the sensor from the catalytic converter.
Note:
If during removal the sensor threads are stripped, in most cases, the threaded portion of the converter will not be damaged. It will be possible to install the new sensor without replacing the converter.
4. Install the applicable replacement front oxygen (A/F) sensor. Tightening torque 15.2 ± 2.2 ft-lb. (21 +/- 3 N-m, 2.1 +/- 0.3 kg-m)
5. Lower the vehicle and connect the front oxygen (A/F) sensor to the vehicle wire harness.
Forester and Impreza Models Only: The replacement front oxygen (air/fuel ratio) sensor has a longer wire lead than the original equipment part. It is important that the wire lead does not contact the front axle or the connector does not contact the air intake duct resonator. Using the supplied tie-wrap, secure the sensor wire lead to the body wire harness as shown.
6. Use the Select Monitor to remove any stored trouble codes.
Note:
If trouble codes other then P0130 or P1133 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 Office.
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 Front Oxygen (A/F) Sensor - All properly submitted claims will receive an automatic credit for parts and 0.4 labor hours for installation of the front oxygen (A/F) sensor. Parts will be reimbursed at dealer cost plus the applicable handling allowance.
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