Turbo Oil Supply Pipe (WVF-16)
Publication date: 2008-10-01Reference number: WVF-16
TURBO OIL SUPPLY PIPE
SERVICE CAMPAIGN BULLETIN
| SUBARU: | 2007 & 2008 Legacy/Outback; 2008 Impreza; 2009 Forester |
INTRODUCTION
Subaru of America, Inc. has determined that certain 2007 & 2008 Turbo Legacy/Outback, 2008 Impreza WRX (except STI) and 2009 Turbo Forester models may have been produced with the turbo charger oil supply pipe deformed due to misalignment during the assembly process. If the pipe is deformed, vibration experienced during normal driving could result in a crack developing over time, causing an engine oil leak.
There is a potential safety risk associated with this condition. If leaking oil contacts components operating at high temperatures, an engine compartment fire could result.
This recall will involve inspection of the turbo charger oil supply pipe for proper alignment. If the pipe is found to be properly aligned, a support bracket must be installed as a precautionary measure to increase rigidity of the pipe. If the pipe is found to be deformed, a new replacement pipe must be installed. Please refer to the Service Procedure section of this bulletin for more details.
AFFECTED VEHICLES
- 2007-2008MY Subaru Legacy Sedan/Wagon 2.5GT & Outback Wagon 2.5XT.
- 2008 Subaru Impreza WRX (except STI)
- 2009 Subaru Forester 2.5XT
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 in the Dealer Communication System (DCS).
| YEAR | MODEL | FROM | TO |
|---|---|---|---|
| 2007MY | Legacy Sedan 2.5GT | 7*200020 | 7*215147 |
| 2007MY | Legacy Wagon 2.5GT/Outback Wagon 2.5XT | 7*300013 | 7*346075 |
| 2008MY | Legacy Sedan 2.5GT | 8*200004 | 8*222000 |
| 2008MY | Outback Wagon 2.5GT | 8*300006 | 8*351020 |
| 2008MY | Impreza WRX 4 Door | 8*500002 | 8*522433 |
| 2008MY | Impreza WRX 5 Door | 8*800005 | 8*823185 |
| 2009MY | Forester 2.5XT | 9*700001 | 9*700139 |
OWNER NOTIFICATION
SOA will prepare and mail Owner Notification Letters to owners of affected vehicles on or around October 21, 2008.
A copy of the Owner Notification Letter is included at the end of this bulletin.
DEALER PROGRAM RESPONSIBILITY
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 recall is taken into dealer new or used inventory, or is in the dealership for service, necessary steps should be taken to ensure the recall correction has been made before selling or releasing the vehicle.
New or used vehicles listed in a recall/campaign that are in dealer stock must be:
- Immediately identified.
- Tagged or otherwise marked to prevent their delivery or use prior to inspection and/or repair.
- Repaired in accordance with the repair procedures outlined in this Product Campaign Bulletin.
Please be advised that it is a violation of Federal law for a dealer to deliver a new motor vehicle covered by a recall under a sale or lease until the defect is remedied. Therefore, any Authorized Subaru Dealer failing to perform the applicable service procedures defined in this bulletin to correct all affected vehicles in their inventory (new, used, demo) prior to the vehicle being placed in service may be subject to civil penalties of up to $5,000 per violation (i.e., for each vehicle), as provided in 49 USC 30165(a) of the Safety Act, and will also be in breach of the Subaru Dealer Agreement.
PARTS INFORMATION
Each effected vehicle will initially require installation of a "Stay Set" which includes a turbo oil supply pipe bracket with plastic pipe clip and rocker cover bolt. Each dealer will initially be sent one stay set for each affected vehicle in new car inventory on or around October 2, 2008. Also, SOA will automatically pre-order and ship each dealer a supply of stay sets equivalent to 50% of their affected sold list during the week of October 6, 2008. Following receipt of that shipment, dealers will need to order any additional supply through normal part ordering procedures.
There is only a small possibility that replacement of the turbo charger oil supply pipe will be necessary. Replacement of the pipe is only necessary when indicated by the inspection results described in the Service Procedure section of this bulletin. Replacement pipes should only be ordered for those vehicles requiring repair. If needed, the part should be ordered VOR by calling the Parts Information Coordinators (PIC's) at 1-888-742-7278. It will be necessary to provide the following information in order for the order to be processed:
- The VIN of the affected vehicle.
- Confirm the vehicle has been inspected using the Stay Set as a template.
- Identify where the clearance was found that indicates the need for a pipe replacement (see inspection procedure).
If applicable, the additional airfreight charges may be included with the Recall/Campaign claim submission.
| DESCRIPTION | PART NUMBER |
|---|---|
| Stay Set | 24012AA010 |
| Pipe Kit - Oil | 15192AA512KAI |
SERVICE PROCEDURE
This recall will involve inspection of the turbo charger oil supply pipe for proper alignment including checking for possible stress cracks and/or oil leaks. If the pipe is found to be properly aligned and there are no signs of cracks or oil leaks, a pipe stay bracket used to check pipe alignment will remain installed as a precautionary measure to increase rigidity of the pipe. If the pipe is found to be misaligned, cracked or leaking oil, a new replacement pipe must be installed.
The number of affected vehicles produced with a misaligned and deformed turbo charger oil supply pipe is expected to be low. Replacement of the oil supply pipe will only be necessary when indicated by the inspection results described in the following Inspection Procedure.
Inspection Procedure
- Identify the location of the applicable turbo charger oil supply pipe as illustrated in Fig 1, below.
- Visually check the pipe for signs of cracking and/or oil leakage in the area of the pipe identified in Fig 2, below.
- If the pipe shows signs of cracking and/or oil leakage, replace the pipe and related parts using part number 15192AA512KAI - Pipe Kit - Oil. Skip Step 3, and proceed to the "Turbo Charger Oil Supply Pipe Replacement Procedure" found on page 9 of this bulletin.
- If there are no signs of cracking and/or leakage, proceed to Step 3.
- In order to determine alignment of the turbo charger oil supply pipe, it will be necessary to install a pipe stay bracket with clip and rocker cover bolt. Part number 24012AA010 - Stay Set.CAUTION: The pipe stay bracket must be installed correctly as instructed in the following steps "a" through "d". Otherwise, it will not be possible to determine the correct measurements.
- Remove the original rocker cover bolt which is located at the upper rear of the RH side of engine. (See Fig 3)
- With the plastic clip attached to the pipe stay bracket, insert the plastic clip firmly onto the pipe beneath the pipe flare nut as illustrated in Fig 4.
- Be sure to use the new rocker cover bolt contained in the "stay set" kit when installing the stay bracket. The new style bolt is longer then the original and has no carved seal on the head of the bolt.CAUTION: Do Not Reuse The Original Bolt. However, do not discard the bolt at this time. (See Fig 5)
- Attach the pipe stay bracket to the engine using the new rocker cover bolt as illustrated in Fig 6. Tightening torque: 6.4 +/- 0.5N-m (0.65 kgf-m, 4.7 ft-lb)
- Referring to the measurements defined in Fig 7 below, make a visual inspection to determine if the pipe is properly seated in the pipe stay bracket clip.
Check the 4 reference points "A" through "D". Refer to the corresponding photographs that follow Fig 7 for visual confirmation. During this process, a "GO" or "NG" (No Go) condition will be determined for each of the 4 reference points ("A" through "D").
- If all 4 reference points are within the "GO" range, the inspection is complete and no further action is required.
- If any of the reference points are found to be in the "NG" range, replace the pipe. Refer to the Turbo Charger Oil Supply Pipe Replacement Procedure , found on page 9 of this bulletin.
"A" Interference between Flare Nut and Stay.
< GO >
A gap exists between the pipe flare nut and the stay with no interference.
< NG >
The pipe flare nut interferes with the stay body.
"B" Dislocation between Pipe and Clip (Mirror might be used to check beneath the clip).
< GO >
The pipe is inserted into the clip firmly.
< NG >
A gap exists between the pipe and the clip.
"C" Dislocation of Clip Anchor
< GO >
The clip anchor is completely inserted into the stay hole.
< NG >
The clip anchor is dislocated from the stay hole.
"D" Loose Clip Pedestal
< GO >
A gap is 2.0mm or less between the plastic clip pedestal and the stay surface.
< NG >
A gap is more than 2.0mm between the plastic clip pedestal and the stay surface.
"D" Loose Clip Pedestal
< GO >
A gap is 2.0mm or less between the plastic clip pedestal and the stay surface.
< NG >
A gap is more than 2.0mm between the plastic clip pedestal and the stay surface.
Turbo Charger Oil Supply Pipe Replacement Procedure
If it has been determined that the turbo charger oil supply pipe requires replacement, replace the pipe and related parts using part number 15192AA512KAI - Pipe Kit - Oil. This part is a kit and contains all necessary gaskets and seals to perform the repair. Although no specific instructions for replacement of the turbo charger oil supply pipe are listed in the Service Manuals, follow the procedure for removal and reinstallation of the intake manifold found in the applicable Service Manual. After removal of the intake manifold, replace the oil supply pipe. Note: For vehicles that have been in service, prior to installing the oil pipe banjo bolt, inspect the mesh screen for debris. Clean or replace as necessary. Use the following torque specifications for proper pipe installation.
Tightening Torque: Nm(kgf-m, ft-lb)
T1: 8(0.8, 5.9)
T2: 20(2.0, 14.8)
T3: 29(3.0, 21.4)
CAR RENTAL
For retail customers, SOA will pay the cost of a car rental when an affected vehicle requires replacement of the Turbo Charger Oil Supply Pipe provided the part is ordered VOR. Car rental charges are limited to 1 to 2 days provided the part is ordered VOR the same day the vehicle is in for service and the repair is completed the same day the VOR order arrives.
The car rental charge may be included with the recall/campaign claim submission. See the Claim Submission section of this bulletin for claim entry instructions.
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) at 1-866-782-2782.
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES
Credit to perform this recall will be based on the submission of properly completed repair order information. Dealers may enter the applicable claim information through their Dealer Communications System.
| CLAIM TYPE | CAMPAIGN CODE | LABOR | LABOR DESCRIPTION | PART NUMBER |
|---|---|---|---|---|
| RC | WVF-16 | B 124-701 0.5 hrs. | Inspect and install turbo charger oil supply pipe stay bracket. | Stay Set 24012AA010 |
| C 124-708 2.4 hrs. | Inspect and Replace the turbo charger oil supply pipe. | Pipe Kit - Oil 15192AA512KAI |
For vehicles requiring Turbo Charger Oil Supply Pipe replacement only:
Rental Car Charges: If applicable, rental car charges should be entered on the RC claim in the Rental field.
VOR Freight: If applicable, VOR freight charges should be submitted on the RC claim as a sublet. Freight charges must not exceed actual dealer cost - 5% of dealer cost for the part.
OWNER NOTIFICATION LETTER
Important Safety Recall Notice
Subaru Recall Campaign WVF-16
NHTSA Recall No. 08V-460
October 2008
Dear Subaru Owner:
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. SUBARU OF AMERICA, INC. has decided that a defect which relates to motor vehicle safety exists in certain 2007 & 2008 Legacy 2.5GT/Outback 2.5XT, 2008 Impreza WRX (except STI) and 2009 Forester 2.5XT models.
DESCRIPTION OF THE SAFETY DEFECT
Subaru has determined that the turbo charger oil supply pipe located on your vehicle's engine may have been deformed due to misalignment during the assembly process. As a result, the pipe could crack causing an engine oil leak and potential fire.
DESCRIPTION OF THE SAFETY HAZARD
The turbo charger oil supply pipe is located on the right (passenger) side of the engine. If the pipe is deformed, vibration experienced during normal driving could result in a crack developing over time, causing an engine oil leak. If leaking oil contacts components operating at high temperatures, an engine compartment fire could result.
REPAIRS
To correct this condition, Subaru will inspect the turbo charger oil supply pipe for proper alignment. If the pipe is found to be properly aligned, a support bracket will be installed as a precautionary measure to increase rigidity of the pipe. If the pipe is found to be deformed a new replacement pipe will be installed.
WHAT YOU SHOULD DO
You should immediately contact your Subaru Dealer for an appointment to have this repair performed at no cost to you.
There are two important precautions you should take until this recall has been performed:
- It is highly recommended that you not park your vehicle in a garage, car port or other structure.
- If you notice an oil leak or burning odor, do not operate the vehicle. Immediately contact you Subaru dealer for assistance.
HOW LONG WILL THE REPAIR TAKE?
The actual time to inspect the turbo charger oil supply pipe and install a support bracket is approximately 30 minutes. It will take an additional 2 1/2 hours if the turbo charger oil supply pipe is found to be deformed and requires replacement. However, it may be necessary to leave your vehicle for a longer period of time on the day of your scheduled appointment to allow your dealer flexibility in scheduling. Additionally, if it is determined that the pipe requires replacement, it may be necessary for your dealer to order the part. The part will be ordered for 2nd day delivery. If the part is not immediately available, Subaru will provide you with a free rental car for the time it takes to complete repairs.
Please present this letter to your Subaru Dealer at the time this repair procedure is performed.
CHANGED YOUR ADDRESS OR SOLD YOUR SUBARU?
If you have moved or sold your vehicle, please complete the enclosed prepaid postcard and mail it to us.
IF YOU NEED FURTHER ASSISTANCE:
To locate the nearest Subaru Dealer you can access our website at www.Subaru.com and select "Find a Dealer". Or, you may call us at 1-800-SUBARU3 (1-800-782-2783) during normal business hours for assistance. Please call us immediately if the dealer fails or is unable to make the necessary repairs free of charge or write to the address listed on the first page of this letter.
You may also contact the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave. SE, West Building, Washington, DC 20590 or call the toll free Auto Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153) or go to http://www.safercar.gov if you believe the dealer has failed or is unable to remedy your vehicle without charge within a reasonable amount of time.
Your continued satisfaction with your Subaru is important to us. Please understand that we have taken this action in the interest of your safety and your vehicle's proper operation. We sincerely apologize for any inconvenience this matter may cause and urge you to schedule an appointment as soon as possible to have this repair performed.
Sincerely,
Subaru of America, Inc.