Campaign - Fuel Tank One Way Valve Removal: Overview
NUMBER: WVL-22DATE: October 2009
APPLICABILITY:
2005~08MY Subaru Forester & Impreza
SUBJECT:
Fuel Tank One-way Fuel Valve
Introduction
Subaru of America, Inc. has determined that certain 2005~2008 Forester and 2005~2007 Impreza models require permanent removal of the one-way fuel valve located in the fuel tank.
The one-way fuel valve is located at the base of a small sub-chamber contained in the fuel tank. When the tank's fuel level drops below 1-1/2 gallons, the sub-chamber is intended to provide a fuel reserve for the fuel pump during vehicle cornering. However, the one-way valve may inadvertently act in such a way as to prevent fuel from refilling the sub-chamber, failing to provide the intended reserve. If this were to happen, the fuel pump could momentarily draw air causing the engine to experience a sporadic misfire condition resulting in possible damage
to the vehicle's catalytic converter. (The "Check Engine" light will illuminate alerting the driver that the catalytic converter efficiency has degraded beyond an acceptable level and may be releasing air pollutants that exceed emission standards.)
This Service Program will involve permanently removing the one-way valve located in the fuel tank.
AFFECTED VEHICLES
2005~2008 Subaru Forester 2.5L NA models and 2005~2007 Impreza 2.5L NA models.
^ Turbo models are not affected.
^ Forester models with CA PZEV Emission System are not affected.
Potentially affected vehicles are identified in the VIN range chart below. Prior to performing repairs, confirm coverage for potentially affected vehicles by using the Vehicle Coverage Inquiry function on Subarunet.com.
OWNER NOTIFICATION
SOA will prepare and mail an Owner Notification Letter to owners of the affected vehicles. Because of the number of vehicles affected and parts availability, owner notification will occur in three (3) phases. Phase one (1) will begin in mid-October 2009. Once available, a final schedule for all phases will be posted on Subarunet.com.
A copy of the Owner Notification Letter is included at the end of this bulletin.
DEALER PROGRAM RESPONSIBILITY
Dealers are 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.
New or used vehicles listed in a Service Program that are in dealer stock must be:
^ Immediately identified.
^ Tagged or otherwise marked to prevent their delivery or use prior to repair.
^ Repaired in accordance with the repair procedures outlined in this
Service Program Bulletin.
PARTS INFORMATION
Each affected vehicle will require replacement of the fuel pump assembly gasket. SOA will automatically pre-order and ship each dealer a supply of repair parts equivalent to 50% of their first phase affected vehicle count. Dealers will need to order any additional supply through normal parts ordering procedures.
Note:
Prior to release of this Service Program, each dealer will be sent a count of the number of affected vehicles for each of the three phases. This count can be used to order parts in advance of anticipated demand.
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.
Additional labels are available through the Customer Dealer Services Department (CDS).
CALIFORNIA "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 state of California a completed "Vehicle Emission Recall - Proof of Correction" certificate. Vehicle owners should be advised to retain this certificate because the California 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 submit claims through Vehicle Claim Entry on Subarunet.
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