SERVICE PROGRAM BULLETIN
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1 ATTENTION: GENERAL MANAGER PARTS MANAGER CLAIMS PERSONNEL SERVICE MANAGER IMPORTANT - All Service Personnel Should Read and Initial SERVICE PROGRAM BULLETIN APPLICABILITY: SUBJECT: 2000MY Subaru Legacy and Outback 4EAT; 2000MY Impreza 2.5 RS MT5 or 4EAT; 2000/2001MY Forester MT5 or 4EAT Front Oxygen (Air/Fuel Ratio) Sensor NUMBER: WXW-80R (Revised DATE: February 01/ , 2010) DATE: 01/2001 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 2000/2001MY 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). Model From To Sedan Y Y Legacy 2000MY Wagon Y Y (*1) Outback Y Y Impreza 2000MY Sedan Y* Y* (*2) Coupe Y* Y* Forester 2000MY Y* Y* MY 1* * * Various characters may occupy this position. *1 Legacy models with manual transmissions are not affected. *2 Impreza models with 2.2 liter engines are not affected. 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). C A U T I O N: VEHICLE SERVICING PERFORMED BY UNTRAINED PERSONS COULD RESULT IN SERIOUS INJURY TO THOSE PERSONS OR TO OTHERS. Subaru Service Bulletins are intended for use by professional technicians ONLY. They are written to inform those technicians of conditions that may occur in some vehicles, or to provide information that could assist in the proper servicing of the vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do the job correctly and safely. If a condition is described, DO NOT assume that this Service Bulletin applies to your vehicle, or that your vehicle will have that condition.
2 Number: WXW-80; Date 01/2001 Page 2 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. A copy of the Owner Notification Letter is included at the end of this bulletin. 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 suppy anticipated demand. Model Description Part Number Legacy/Outback Front Oxygen 22791AA00A Impreza 2.5 RS, (A/F) Sensor Forester Note: All correct replacement parts will have a white paint mark on the harness connector.
3 Number: WXW-80; Date 01/2001 Page 3 SERVICE PROCEDURE 1. With the ignition switch in the off position, disconnect the front oxygen (A/F) sensor from the vehicle wire harness. B2M 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 22mm 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. G2M Install the applicable replacement front oxygen (A/F) sensor. Tightening torque /- 2.2 ft-lb. (21+/-3 N.m, 2.1+/- 0.3 kg-m)
4 Number: WXW-80; Date 01/2001 Page 4 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 below. Connector Front Axle Resonator 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.
5 Number: WXW-80; Date 01/2001 Page 5 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. Write in "WXW-80" here. 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.
6 Number: WXW-80; Date 01/2001 Page 6 CLAIM REIMBURSEMENT AND ENTRY PROCEDURES Credit to perform this Service Program will be be based on on the the submission of of properly completed repair repair order information. Dealers may may enter enter the applicable the applicable claim claim information information through through their Dealer Subarunet. Communications System. Replacement of the Front Oxygen (A/F) Sensor - All properly submitted claims wil receive a credit for Replacement parts and 0.4 of the labor Front hours Oxygen for installation (A/F) Sensor of the - All front properly oxygen submitted (A/F) sensor. claims Parts will receive will be an reimbursed at automatic dealer cost credit plus for the parts applicable and 0.4 labor handling hours allowance. for installation of the front oxygen (A/F) sensor. Parts will be reimbursed at dealer cost plus the applicable handling allowance. Claim Recall Labor Labor Labor Description Type Code Operation Time Claim RC Type WXW-80 B Campaign 0.4 Code hrs Recall / Campaign Labor. Multiple Recall (MR) WXW-80
7 Number: WXW-80; Date 01/2001 Page 7 Subaru of America, Inc. Subaru Plaza P.O. Box 6000 Cherry Hill, NJ Service Program WXW-80 January 2001 Dear Subaru Owner: SUBARU OF AMERICA, INC. has determined that some 2000 model year Subaru Legacy and Outback models with automatic transmission, Impreza 2.5 RS models with manual or automatic transmission and 2000 / 2001 Forester models with manual or automatic transmission may require replacement of the front oxygen (Air / Fuel Ratio) sensor. THE REASON FOR THIS NOTICE The front oxygen (Air / Fuel Ratio) sensor is part of your vehicle s emission control system and is monitored by the On-Board Diagnostic system. Should this component operate improperly prior to replacement, the CHECK ENGINE warning light / Malfunction Indicator Lamp will illuminate steadily while the engine is running, advising the driver of a malfunction and the need to seek repair service. WHAT YOU SHOULD DO You should immediately contact your Subaru Dealer for an appointment to replace the front oxygen (Air / Fuel Ratio) sensor with replacement parts at no cost to you. The approximate time to perform this repair is 30 minutes. However, it may be necessary to leave your vehicle the full day of your scheduled appointment to allow your dealer flexibility in scheduling. Please present this letter to your Subaru Dealer at the time this repair procedure is performed. RESIDENTS OF CALIFORNIA / MASSACHUSETTS The Departments of Motor Vehicles in the states of California and Massachusetts require that all emission related service program repairs be completed before a vehicle registration is renewed. They also require Subaru of America, Inc. to periodically provide a list of vehicles that have not had the service program repairs performed. The state will know that this service program may not have been completed if your vehicle is on that list.
8 Number: WXW-80; Date 01/2001 Page 8 RESIDENTS OF CALIFORNIA / MASSACHUSETTS (CONTINUED) Your dealer will provide you with a Vehicle Emission Recall Proof of Correction certificate after the service program repair has been completed. You should retain this certificate because the California / Massachusetts Department of Motor Vehicles may require you to provide proof the service program repair has been completed. These states also require that every vehicle pass an emission test (Smog Check) every two years and before it is sold. Failure to have this no-cost repair service performed may result in the vehicle failing an emission test and the vehicle may require future costly repairs. CHANGED YOUR ADDRESS OR SOLD YOUR SUBARU? If you have changed your address, or if you have sold your Subaru vehicle, please complete the enclosed prepaid postcard and mail it to us. IF YOU HAVE A PROBLEM Should you have any questions regarding this service program, please contact your nearest Subaru Dealer or Subaru of America, Inc., at (1-800-SUBARU3). Your continued satisfaction with Subaru is important to us. Please understand that we have taken this action in the interest of clean air and to assure your vehicle s proper performance. 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. Notice to Lessors Under Federal law the lessor of a vehicle who receives this letter must provide a copy of it to the vehicle lessee(s). The lessor must also keep a record of the lessee(s) to whom this letter is sent, the date sent, and the applicable vehicle identification number (VIN). (For the purposes of this section, a lessor means a person or entity that in the last twelve months prior to the date of this notification has been the owner, as referenced on the vehicle's title, of any five or more leased vehicles. A leased vehicle is a vehicle leased to another person for a term of at least four months.)
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