Engine - Remanufactured Engine Availability
NUMBER: 02-96-05DATE: 09/09/05
APPLICABILITY:
00-03MY Legacy/Outback;
04MY Legacy/Outback Fed Spec only;
03-05MY Baja;
99-05MY Forester;
99-04MY Impreza with 2.5L SOHC engines
SUBJECT:
2.5L Remanufactured SOHC Short Block Release
INTRODUCTION
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Subaru of America, Inc, is making available remanufactured SOHC short Blocks for use in engine repairs when the original equipment short block must be replaced, with the exception of new (in-stock) unsold vehicle. These remanufactured short blocks include oil pans, water pumps, thermostats, thermostat housings, and oil pumps, when compared with conventional repairs using an original equipment replacement short block, a new water pump, and new oil pump, these remanufactured short blocks provide significant savings to customers. These replacement assemblies are factory tested for peak performance. Each remanufactured SOHC short block is covered by the Genuine Subaru Remanufactured Engine Limited Warranty for 3-year or 36,000 mile from the date and mileage of installation (whichever occurs first), the Limited Warranty for Genuine Subaru Replacement Parts, or the balance of the Subaru New Vehicle Limited Warranties (when installed by a Subaru dealer) whichever is applicable.
PARTS INFORMATION
REPAIR PROCEDURES/INFORMATION
A gasket kit has been made available to speed the installation process. The kit (SOA Part Number 10105AA930) includes all the gaskets required for a basic short block replacement, including rocker cover gaskets. Three Bond sealers are not included. Oil filler duct and oil level gauge (dipstick) 0-rings are not included and will need to be ordered separately if needed. The configuration of the remanufactured SOHC short block requires some component transfer depending upon the existing engine configuration. Any transferred components should be inspected and replaced if necessary.
Be sure to remove the three plastic transit plugs (shown) prior to installation. One is located in the oil pressure switch plug. The others are in the main oil gallery ports that feed each head.
If the engine being replaced has an oil cooler installed, the oil cooler assembly, oil cooler pipe, hoses, nipple, thermostat housing, and connector will need to be transferred from the existing block to the replacement hybrid block. Any transferred parts should always be inspected and replaced if needed. New oil cooler 0-ring and thermostat gaskets are part of the gasket kit (10105AA930). The metal gasket for the oil cooler nipple should be re-used. Apply Threebond 1215 (SOA Part Number 004403007) to the threads of the oil cooler nipple to prevent coolant leakage. This transfer of components will require removal of the remanufactured short block's factory installed oil filter. In this case, the oil filter should be replaced. In the case of those engines without an oil cooler, there is no need to replace the oil filter that comes with the remanufactured short block. The water pump installation on the remanufactured short block already includes a thermostat and housing.
A small amount of oil will remain in the oil filter and pan following factory testing. There is no need to attempt to remove this oil. Oil will need to be added as part of the installation process, as the remaining oil in the engine is insufficient for engine operation. Always use oil of specified viscosity and grade as listed in the appropriate Subaru Service Manual.
As with any engine repair where the coolant is replaced, Genuine Subaru Coolant and Genuine Subaru Cooling System Conditioner must be used when re-filling the system for any repairs paid for by Subaru of America, Inc. Genuine Subaru Coolant and Genuine Subaru Cooling System Conditioner are recommended for usage in all repairs to maintain peak performance and inhibit corrosion, when installing cooling system conditioner be sure to follow the installation guidelines in the April 2004 Tech Tips (available on STIS) to ensure maximum performance.
Even though the Subaru Reman SOHC Short Block has been tested at the factory, it needs to be treated as a dry engine on initial start up. After installing the engine and filling it with the appropriate amount of engine oil and coolant, it should be cranked with no compression to allow oil circulation and the development of normal oil pressure. During this process the spark plugs should be removed, the fuel pump disabled, and ignition system disabled. Please see the appropriate Subaru Service Manual for these procedures. The engine should be cranked for no more than 3 consecutive 15 second cycles to prevent starter damage. The oil pressure level can be confirmed through observation of the vehicle's oil pressure indicator lamp or in more detail through use of an approved oil pressure gauge.
Customers should be instructed to follow new vehicle break-in driving procedures as described in the owner's manual.
A remanufactured short block must be used when replacing an original equipment short block anytime Subaru of America, Inc pays for the repair, with the exception of any repair to a new (in-stock) unsold vehicles.
Remanufactured short blocks can be easily identified due to a yellow RDOT tag on the unit's bell housing.
Repairs may be performed under warranty for manufacturing defects relating to the listed external component parts of the remanufactured short block.
These items include:
^ The water pump and water pump gasket
^ Thermostat, Thermostat housing, or gasket (as supplied with the unit)
^ Oil pump, oil pump 0-ring, sealer, and crankshaft seal
^ Rear main seal
^ Oil pan, oil pan sealer, and oil return seal
^ Rear separator cover and sealer
^ Piston pin access plug and seal
^ Coolant production plugs
A DSOM authorization is required prior to replacing or repairing a remanufactured short block.
If there is damage to the internal block components due to the failure of external component(s), the unit should be replaced with another remanufactured short block. If there is an internal failure of a remanufactured short block including but not limited to: crankshaft, connecting rods, pistons, piston rings, bearings, or case the unit should be replaced with another remanufactured short block.
To ensure full core credit, dealers should follow all instructions contained in the Subaru Engine Core Document Packet. This packet contains a core return checklist; credit request and diagnosis form, core return procedures, and shipping labels. All items must be completed legibly and the packet attached to the core as indicated. The copy of the Credit Request and Diagnosis Form marked, as the "DEALER FILE COPY" should be kept as part of the vehicle record.
All engine short block cores must be returned using Roadway Reverse Logistics in order to receive core credit. All fluids must be drained from the core and the core properly packaged in the return container to prevent residual leakage or shipping damage during transit. This includes installing the three plastic transit plugs from the supplied unit. In addition, place the return unit in the original shipping bag or an equivalent substitute and seal it in a manner similar to the supplied unit. The shipper is responsible for any fluid leakage during return shipment.
If the core has been partially or fully disassembled, externally damaged, or a junkyard core substituted, no credit will be issued. A complete core consists of the complete short block assembly, oil pump, water pump, thermostat housing, and oil pan as a complete unit. The core should not be disassembled, in order to obtain full credit.
CLAIM REIMBURSEMENT/WARRANTY INFORMATION
2.5L remanufactured SOHC short blocks cannot be used for repairs to new (in-stock) unsold vehicles.
For vehicles within the New Vehicle Limited Warranty period, the Genuine Subaru Remanufactured Engine Limited Warranty, or under the terms of the Limited Warranty for Genuine Subaru Parts, repairs may be claimed using the following labor operations and failure coding information. Assembly installation or replacement claims require a DSOM authorization and must include the serial number of the unit installed (as listed on the yellow RDOT tag). The serial number must be placed in the Exch/Serial/Inv # field of the claim entry. Repair claims for external components require a DSOM authorization and must include the repaired unit's serial number in the Exch/Serial/Inv # field of the claim entry.
This information is supplied for use during this program's initial release. Always refer to the Subaru Warranty Wizard application for the most current information.
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