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PostPosted: Mon Apr 07, 2008 5:58 pm 
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This issue should now be resolved and all engines inspected and good to go.

updated 4/17. Turbo engine stop sale. It's my understanding Subaru will be replacing a small number of turbo engines built after early January due to a manufacturing defect that could potentially cause early bearing failure.
Joe

****
4/7/08
Subaru announced a stop sale on all of the 2008/2009 Subaru Impreza, Forester, Legacy and Outback vehicles equipped with a 2.5L Turbo Engine produced with the beginning chassis number and later as shown below "due to several reports of "Engine Knocking Noise” from other markets on vehicles produced after the production dates listed. Initial investigation confirms an internal wear issue on the failed units. In the interest of preventing any possibility of failures for our customers, we have chosen to isolate any potentially affected vehicles by ceasing sales of the potentially affected units until the root cause and correction can be identified. All the other displacement engines and the 2.5L Natural Aspirated Engine are excluded from this action".
Forester VIN 701045 or later, date 2008/01/08 or later;
Impreza sedan VIN 523363 or later, date 2008/01/08 or later; Impreza wagon VIN 825183 or later, date 2008/01/08 or later;
Legacy 2.5 GT Ltd VIN 222825 or later, date 2008/02/04 or later; 2.5GT specB VIN 222958 or later, date 2008/02/04 or later;
Ooutback 2.5XT Limited VIN 353835 or later, date 2008/02/01 or later

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PostPosted: Mon Apr 21, 2008 5:31 pm 
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Announcement April 21, 2008
(edited)
******************

Turbo Engine Stop Sale checking Procedure
On April 7, 2008 we informed you of a stop sale order on 2008 Impreza, STi and Legacy vehicles and 2009 Forester vehicles equipped with 2.5L Turbo Engines and produced with the beginning chassis number/production dates and later as shown below:

    Forester VIN 701045 or later, date 2008/01/08 or later
    Impreza sedan VIN 523363 or later, date 2008/01/08 or later;
    Impreza wagon VIN 825183 or later, date 2008/01/08 or later;
    Legacy 2.5 GT Ltd VIN 222825 or later, date 2008/02/04 or later;
    Legacy 2.5GT specB VIN 222958 or later, date 2008/02/04 or later;
    Outback 2.5XT Limited VIN 353835 or later, date 2008/02/01 or later

We took this action as a “Customer First” preventive action as we had confirmed, in other markets, that there was a small possibility of an “Engine Knocking Noise” caused by a contamination in the area of the connecting rod big end journal at very low mileage/time in service.
The action was successful in preventing the potential of failures for our customers.
Subaru has defined a screening process that you must perform to all of the affected vehicles in your inventory before delivery to a customer or putting in demonstrator service.
The screening process consists of several steps to inspect the condition of the engine oil to determine if the engine is not affected by the contamination, is already damaged, or has a potential for damage.
Both a flow chart and detailed instruction sheet of the process are included in this document. Each step must be followed exactly, no short cuts.
As soon as the engine is determined to be in proper working condition, it can be sold or put into demo service.
If you determine that the engine is damaged, immediately submit an E-QMR following this criteria:
•Vehicle Information
•Customer Description of Complaint: “Turbo Engine Check”
•Technician Finding: Where in the process was it confirmed that the engine needs
to be replaced?
•Also include contact name and phone number at the dealership for further
discussions, if necessary.
•Fail code operation AAU-25
Continued on next page...
Date: 04/21/08 Page Disclaimer: For Authorized Subaru Dealer Use Only.
You will be contacted within 2 business days with instructions and arrangements for repair parts and procedures. Please mark the E-QMR with a reference to “Turbo Engine Check”.
To perform the screening, you will need the following materials for each vehicle:
• New magnetic Oil Pan Drain Plug (1) (32103KA000 - only this P/N is acceptable)
• New Oil Drain Plug Gasket (1) (11126AA000)
• New Oil Filter (1) (15208AA100)
• Engine Oil 5w30
• Filter paper (such as a standard automotive funnel type paint filter)
• Clear plastic “wash bottle” 16oz (500ml), with angled flexible snorkel:
Please order a plastic wash bottle, 16 ounce (500ml / 500cc), translucent color for observing
the color of the oil. The cap and pick-up tube colors are not important for this test. We suggest using the following suppliers and supply houses to locate the plastic wash bottle or equivalent:
• W.W. Grainger Supply, Inc. - http://www.grainger.com/
• Fisher Scientic, Inc. - http://www.fishersci.com
• Most Medical Supply Locations
• Most Beauty Supply Locations
Note: It is important that the opening at the tip of the flexible snorkel be at least 3mm inside diameter in order to properly allow any contamination that may be present in the bottom of the oil pan to pass through into the bottle. It may be necessary to trim the flexible snorkel to obtain the 3mm opening. See picture in flowchart on page 4.
Detailed Instructions
You will need to refer to the flow chart provided to follow this written procedure and refer to the photos and graphics for examples.
Always follow all environmental and hazardous waste handling precautions to prevent any contamination or safety issues.
Engine Screening Procedure One
1) Drain the engine oil through the drain plug.
2) Using the wash bottle, insert the tip of the snorkel through the drain hole, ensuring
that the tip is between the bottom of the pick-up screen and the oil pan.
Note: The wash bottle can be re-used, but it must be thoroughly cleaned with aqueous
parts cleaner and dried. All residual oil, particles and cleaner must be removed to ensure
that no false judgments are made.
3) Siphon the remaining oil and residue from the oil pan as shown in the drawing
(approximately 100cc).
4) Observe the color and clarity of the oil in the wash bottle, and compare it to the examples
in the photo found on the flowchart on page 4.
NOTE: If the wash bottle is not clear, pour the oil and residue into a clear glass
container to make a good judgment.
Continued on next page...
Date: 04/21/08 Page Disclaimer: For Authorized Subaru Dealer Use Only.
5) If the oil is clear, the engine is okay.
A)Replace the oil filter, install a new magnetic Oil Plug and new Oil Plug Gasket,
and refill with fresh engine oil.
Engine Screening Procedure Two
6) If the oil clarity or color matches the “Needs Check” samples, strain the oil through
the filter paper and capture the material residue.
A)If there are copper particles larger that 1 mm in the material residue, the engine
is damaged. Immediately submit an E-QMR and wait for further instructions.
NOTE: It may be necessary to clean the particles to determine if they are copper. Copper
is reddish in color. There may be very small particles of other materials that are typical
of a new engine, such as silicon, aluminum and ferrous (steel or magnetic) content, that
do not indicate any failure.
B)If there are no copper particles, or they are smaller than 1 mm, proceed to step 7.
7) Install a new magnetic Oil Drain Plug, reusing the original gasket and engine oil filter,
and refill the engine with fresh oil.
8) Start the engine and let it idle for five (5) minutes to flush any residue from the
oil passages.
A)Stop the engine, drain the oil, remove and replace the oil filter, clean and reinstall the
magnetic drain pug, using the new gasket.
B)Refill with fresh oil.
9) Re-start the engine and let it idle for 5 minutes.
Note: Be sure to allow the Air Pump operation to complete its cycle. It will be
difficult to distinguish any engine noise while the pump is operating.
A)Quickly rev and release the engine to 6,000 rpm at least 10 (ten) times. Caution: Do
not exceed 6000 rpm or hold above the red line.
Note: Be sure to follow the “Reving Procedure” found on the flow chart located
on page 4.
B) Let the engine idle for a few seconds; then increase and decrease the rpm slowly
to 2500 rpm, while listening for abnormal lower end engine noise.
10) If lower end engine noise is evident, immediately stop the engine and submit an E-QMR
and wait for further instructions.
11) If no noise, the engine is okay, and the vehicle can be released for retail sale

update 4/24: Currently, supplies of magnetic oil pan drain plug part number 32103KA000, used in the screening of vehicles, are somewhat limited. Therefore, we are asking dealers to limit their orders for part number 32103KA000 to the quantity that they absolutely need to screen their population of vehicles.


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PostPosted: Wed May 14, 2008 8:29 pm 
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What hasn't been stated by Subaru is how far into the line the run this TSB/Recall will extend. It merely states that VIN# greater than some value and build date greater than a particular date. I am strongly considering one of the 2008 models, but in my research I found this issue. I would prefer to completely avoid the VIN#s involved in this problem.


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PostPosted: Wed May 14, 2008 10:45 pm 
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Location: Seattle, Wa
I haven't heard of any US or Canadian dealers finding problems... has anyone?

Joe


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PostPosted: Thu May 15, 2008 1:19 pm 
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I asked the dealer to contact Subaru on the subject of a VIN# range. I'm going to contact them myself as well. I'd prefer to buy one that is completely beyond the range.

I've seen mostly top quality from Subaru over the years and I need/want a second car. I miss handing out the occasional azz kicking with my 3rd Gen RX-7. I think I can get back to that with the STi after a tire and suspension upgrade along with, maybe, an engine kit to make it ridiculous. I'm saying this to see if anyone thinks I'm off-base in thinking that I can get it to pull a G on the skid pad without freaking out the VDC on it. I'm new to the Scoob scene and haven't found data yet. I was wondering: what are the performance limits of this car with upgrades from, say, Perrin and/or APR (not that I plan to drag race, but I may join SCCA).


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PostPosted: Thu May 15, 2008 5:30 pm 
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Joined: Mon May 22, 2006 3:59 pm
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Location: Seattle, Wa
The STI VDC has 3 settings- on, off and partial. Partial allows some slipping before activating but I'm not sure of the limits.
Joe

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