Engine - Reman Short Block Information
NUMBER: 02-121-11DATE: 10/10/11
APPLICABILITY:
2005~09MY Forester, Impreza, & Legacy/Outback
SUBJECT:
2.5L Remanufactured SOHC Short Block Release
INTRODUCTION
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 vehicles 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 Subam 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 greater.
PARTS INFORMATION
REPAIR PROCEDURES/INFORMATION
Gasket kits are available to speed the installation process Refer to SUBARU-FAST to obtain the appropriate part number for your application These kits include all gaskets required for a basic short block replacement, including rocker cover gaskets. ThreeBond(R) sealers are not included Oil filler duct and oil level gauge (dipstick) o-rings are not included and should 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.
Due to the shape of the thermostat housing, some remanufactured short blocks will ship with the thermostat gasket, thermostat, thermostat housing, and two bolts in a plastic bag on top of the block. These short blocks are SOA478HT TO0RT~ SOA478H~2O0Ri, and SOA478H1300R1. An example is shown.
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 remanufactured short block. Any transferred parts should always be inspected, cleaned thoroughly or replaced if needed. New oil cooler o~ring and thermostat gaskets are part of the gasket kits. The metal gasket for the oil cooler nipple should be reused. Apply ThreeBond(R) 1215 (SOA Part Number 004403007) or equivalent to the threads
of the oil cooler nipple to prevent coolant leakage. See Service Bulletin 01-167-08 for more information regarding equivalent adhesives. 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 (required if repair is being paid under any Subaru claim type). 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 Remanufactured SOHC Short Block has been tested at the factory, it needs to be treated as a dry engine on initial start up. Afier 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 any time Subaru of America, Inc. pays for the repair, with the exception of any repair to a new (in-stock) unsold vehicle.
Remanufactured short blocks can be easily identified due to a yellow label on the unit's bell housing. This label contains the part number and the remanufactured engine serial number.
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 DPSM 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.
CORE RETURN PROCEDURE
Dealers are to refer to the Returns Shipping site located on Subarunet to return remanufactured short block cores. The site is located in the Fixed Operations section of Subarunet: Subarunet / Fixed Operations Returns Shipping.
In order to receive core credit, all engine short block cores must be returned using YRC Reverse Logistics.
The Engine Diagnosis / Inspection form will need to be completed when the core is being returned for a warranty claim. Technicians must record the required information on the form. It is important that all fluids be drained from the blocks. Don't forget to install the transit cap on the thermostat housing to prevent coolant loss during shipment. The blocks are to be placed in the original shipping bag or equivalent substitute and properly secured in the original shipping container. The shipper is responsible for any fluid leakage during return shipment.
If the core is left 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. In order to obtain full credit, the core cannot be left disassembled. If the removed engine was disassembled for diagnosis, it will need to be loosely re-assembled before returning as a core.
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 DPSM authorization and must include the serial number of the unit installed (as shown on the yellow remanufactured short block label on the bell housing) The serial number must be placed in the "Misc Detail" field of the claim entry.
Any parts warranty claims for repair or replacement of external components of a remanufactured short block requires DPSM; authorization. The claim must include the repaired units serial number in the Exch/Serial/Inv # field of the claim entry
The following information is supplied for use during this programs initial release Always refer to the Subaru Warranty Wizard application for the most current information.
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