Recall - Front Exhaust Pipe/Catalyst
NUMBER: WZS-43DATE: April 1991
APPLICABILITY:
1987MY 4WD California Specification 3D, 4D & SW Vehicles
SUBJECT:
Front Exhaust Pipe
Subaru of America has determined that a number of 1987 Model 4WD non-Turbo California Specification vehicles equipped with single-point injection may experience failure of the catalyst in the front exhaust pipe. These vehicles are equipped with a dual bed catalytic converter. The catalyst is a primary part of the emission control system. The catalyst failure has been associated with a crack in the inner exhaust pipe in a double-walled pipe of the original equipment EPF.
Therefore, Subaru of America will notify the potentially affected 1987 Model 4WD non-Turbo California Specification vehicle owners that they should contact their dealer who will replace the original double-walled front exhaust pipe with an improved part at no cost to the owner.
VEHICLES INVOLVED
The affected vehicles are 1987 Model 4WD non-Turbo California Specification 3-door coupes, 4-door sedans and station wagon DL and GL models. This campaign ONLY affects California models.
Potentially affected vehicles have been identified by Vehicle Identification Number computer listings. These computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to the dealers with this bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.
These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.
OWNER NOTIFICATION
SOA will prepare and mail an Owner Notification Letter and a two-part Recall Certification/Repair Order Form to the owners of all potentially affected vehicles which are equipped with the original double-walled EPF. The owner notification mailing is scheduled for April 1991. A copy of the Owner Notification Letter and a sample two-part Recall Certification/Repair Order form are included in this bulletin.
DEALER CAMPAIGN RESPONSIBILITY
Dealers are to promptly repair all affected vehicles presented for repair which are equipped with original double-walled front exhaust pipe regardless of the vehicle's age or mileage, at no charge to owners. When you are presented a two-part Recall Certification/Repair Order Form by a Subaru owner, follow the instructions presented in the Service Procedure section of this bulletin.
In accordance with the service procedure of emission campaign WZS-43, there is no reimbursement without front exhaust pipe (Y-pipe) P/N 441 01 GA600 replacement. Front exhaust pipe replacement is based on your confirmation that the vehicle is equipped with an original double-walled EPF and is included in the VIN ranges. Replacement of the front exhaust pipe for vehicles which were previously repaired with P/N 441 01 GA600 is not necessary. For further details, please refer to the sections entitled "Service Procedure" and "Recall Impact on Customer Satisfaction."
Whenever a vehicle subject to this campaign or any open campaign is taken into vehicle inventory, or is in your dealership for service in the future, you should check for the presence of a double-walled EPF. If so equipped, be sure the campaign correction has been made before selling or releasing the vehicle.
Owners of vehicles recently sold from your vehicle inventory within the VIN range listed are to be contacted by the dealer, and arrangements should be made to make the required correction according to instructions contained in this bulletin.
PARTS INFORMATION
Quantities of the front exhaust pipe assembly P/N 441 01 GA600 and replacement exhaust gaskets are available through your normal parts supply.
Parts Pricing:
SERVICE PROCEDURE - FRONT EXHAUST PIPE ASSEMBLY (EPF)
1) Verify that the vehicle has not been repaired (no "Campaign Completion Label") and the vehicle is included in the VIN Range listed.
2) Verify that the vehicle is equipped with a double-walled EPF. A double-walled EPF can be distinguished from a single-walled EPF by appearance. A double-walled EPF has no shield covers around each pipe except for the converter shell cover. In comparison, a single-walled EPF has shield covers around each pipe including the converter shield cover. The lot number for double-walled EPF is marked on the lower surface of the converter shell cover and should read *8430 or less. (The asterisk portion in the lot number is marked with either an "A" or "B"). See Figure 1 for double-walled EPF identification.
NOTE:
Further replacement of the EPF for vehicles previously repaired with single-wall EPF P/N 44101GA600 is not necessary. Under this campaign, only one EPF (P/N 441 01 GA600) replacement is allowed per VIN.
3) Lift the vehicle and, remove the existing EPF following the procedures in the applicable Service Manual Section 2-9 and retain all attachment hardware, if reusable.
4) Install a new EPF (P/N 44101GA600) using new exhaust gaskets (P/Ns 44022GA330 and 44022GA190) and the attachment hardware from Step 3.
5) Apply the Campaign Completion Label.
6) All replaced EPFs must be handled according to the current SOA Service parts return policy.
CAMPAIGN COMPLETION LABEL
Each vehicle corrected in accordance with the instructions outlined in this bulletin will require a "Campaign Completion Label." This label is to be affixed to the top surface of the radiator core support which will be visible when the vehicle is brought in for periodic servicing by the owner. Apply the "Campaign Completion Label" only on a clean dry surface.
A quantity of 25 labels are being provided to each dealer with this bulletin. Additional quantities of these labels are available through your local regional office or Distributor.
CLAIM PROCESSING INFORMATION - DEALER REIMBURSEMENT
Credit for the performance of the front exhaust pipe replacement plus applicable exhaust gaskets will be provided from the two-part Recall Certification/Repair Order Form.
All claims for reimbursement should follow the procedures outlined below.
You must complete the repairing dealer section of the two-part Recall Certification/Repair Order Form and remove and retain the first copy for your records.
Star System dealers may enter the applicable information using the Campaign Claim (RY) routine.
Non Star System dealers will be reimbursed upon submission of the remaining copy of the Recall Certification/Repair Order Form to your Distributor/Region in an envelope with postage prepaid.
Dealers will be credited with 0.7 hours at their approved warranty labor rate plus dealer cost and handling allowance for the front exhaust pipe replacement and applicable exhaust gaskets on the two-part Recall Certification/Repair order Form. Retail states will receive reimbursement at suggested retail cost.
As indicated in Step 3 of the Service Procedure, attachment hardware should be reused. However, if it is necessary to replace the attachment hardware, an MSA-400A must be submitted listing individual part numbers. The MSA-400A must be submitted through normal channels, using operation number 101-101 (0.0 hours), failure code WZS-43 and override code WZS-43.
OWNER REIMBURSEMENT
If an owner of an affected vehicle inquires about reimbursement for the front catalytic exhaust pipe plus applicable exhaust gaskets and attachment hardware repair costs which was performed prior to this campaign (WZS-43) and the owner paid for these repairs, please instruct the owner to follow the procedures listed below.
The owner must forward the original or original carbon copy of the repair invoice, which has completed information including date of repair, vehicle mileage, vehicle identification number and name, with correct address and telephone number, to the address listed below:
Subaru of America
Attention: Recall Headquarters
Subaru Plaza
P.O. Box 6000
Cherry Hill, N.J. 08034-6000
Please have the owner send original receipts only and retain a photocopy for his/her records. Please assure the owner that we will attempt to process his/her reimbursement request as quickly as possible, but it may take as long as 90-120 days for this process to be completed.
RECALL IMPACT ON CUSTOMER SATISFACTION
The recall is a positive effort on our part to satisfy our owners and should be presented as such to the customer.
If a customer has an exhaust system problem that is not directly related to Campaign WZS-43 take the extra effort to explain your findings to him/her. This may address the customer's concern in the event that additional diagnosis and/or service is required at the customer's expense. This extra effort to explain the situation will show the customer that you value him/her.
Recognize and respect the inconvenience this situation may be for the customer and thank them for their interest in keeping their Subaru properly maintained.
We recommend that you establish a service file on this recall and keep all documents relating to this recall in that file. Furthermore, we suggest that you discuss this recall with members of your staff so that they will be knowledgeable in the proper handling procedures. This will ensure that this recall runs smoothly.
RECALL CERTIFICATION/REPAIR ORDER FORM
OWNER LETTER
SUBARU OF AMERICA
P.O. Box 6000
Cherry Hill, NJ 08034-6000
April 1991
Dear Subaru Owner:
Subaru of America has determined that a number of 1987 Model 4WD Non-Turbo California specification 4-Door Sedan, 3-Door, and Station Wagon vehicles may experience failure of the catalyst in the front exhaust pipe. The catalyst is a primary part of the emission control system. Subaru will replace the original front exhaust pipe with an improved part at no cost to you regardless of your vehicle's mileage or age.
Please contact your Subaru Dealer as soon as possible to schedule for corrective action. The labor time to perform this campaign procedure is approximately 40 minutes. However, please plan to leave your Subaru vehicle at your Subaru Dealer for the full day of your scheduled appointment to allow the dealer some flexibility in scheduling other customers.
You must present the enclosed two-part Recall Certification/Repair Order Form to your Subaru Dealer at the time this determination and repair procedure is performed. If you lose this form, please contact the Customer Relations Department of the Subaru Distributor/Region responsible for your area shown on the map on the back of this letter. You will then be sent a new form. If you are no longer in possession of this vehicle, please complete the enclosed prepaid postcard and mail it to us so that we may update our records.
In the event that you paid for these repairs, you may be entitled to reimbursement for the front exhaust pipe and attachment hardware repair costs. Please send the original service repair order, which has completed information including date of repair, vehicle mileage, vehicle identification number and your name, with correct address and telephone number, to the address listed below:
Subaru of America
Attention: Recall Headquarters P.O. Box 6000 Cherry Hill, NJ 08034-6000
Please send original receipts only and retain a photocopy for your records. Please be assured that we will attempt to process your reimbursement request as quickly as possible, but it may take as long as 90 days for this process to be completed.
We regret any inconvenience this may cause you. However, we have taken this action to assure that your vehicle continues to meet California emission requirements and assure your continued satisfaction with our product.
SUBARU DISTRIBUTORS