Campaign - Alternator Inspection/Replacement
NUMBER: WXX-81DATE: 10/15/00
APPLICABILITY:
1996MY-1998MY Subaru Legacy
SUBJECT:
Alternator
Subaru of America, Inc. (SOA) has determined that some 1996 through 1998 Subaru Legacy vehicles may experience a loss of alternator charging due to a broken brush wire. On vehicles with higher mileage, an alternator brush wire may become fatigued and eventually break as a result of engine operation at high RPMs. If an alternator brush wire does break, the Charge Warning Light will illuminate steadily while the engine is running thereby providing ample time for the driver to seek repair service (depending on the battery condition, approximately one hour of vehicle operation). However, if the warning is ignored and the vehicle continues to operate under this condition, the battery will eventually lose electrical power and the engine will stop running.
The program will involve the inspection of affected vehicles for possible alternator replacement.
VEHICLES INVOLVED
The affected vehicles are 1996 through 1998 model year Subaru Legacy vehicles identified in the VIN range chart.
NOTE:
Coverage for all affected vehicles must be confirmed by using the Vehicle Coverage Inquiry in the Dealer Communication System (DCS).
Vehicles identified in the preceding chart may include VIN's that were not distributed in the U.S. market. Dealers will be provided a list of VIN's that include the owner name and address. This information will enable dealers to follow-up with owners of potentially affected vehicles.
These listings contain owners' names and addresses obtained from State Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is unlawful in some states. Accordingly, dealers are urged to limit the use of this listing only for the purpose of completion of this service program.
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).
OWNER NOTIFICATION
SOA will prepare and mail an Owner Notification Letter to owners of the affected vehicles. Because of the number of vehicles affected and parts availability, owner notification will occur in the following 3 stages:
1996MY - October 2000
1997MY - January 2001
1998MY - March 2001
DEALER PROGRAM RESPONSIBILITY
Dealers are to promptly inspect all vehicles subject to this Service Program at 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 outlined 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 a dealer's 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
NOTE:
Two alternator part numbers (23700AA34ARA & 23700AA34BRA) are available for this Service Program. Both alternators apply to all affected vehicles and are interchangeable. There may be a difference in the appearance of the alternator pulley and/or case.
Prior to the release of each stage of this program, dealers will automatically be shipped a quantity of replacement alternators equivalent to 20% of their vehicle sales for the appropriate model year. Additional quantities of the improved alternator will be available through normal parts supply after 10/5/00. In order to maintain an adequate part supply, SOA requests that Dealers only order parts necessary to supply anticipated demand for each applicable model year (MY) based on the program release date: 1996MY - October 2000; 1997MY - January 2001; and 1998MY - March 2001.
INSPECTION PROCEDURE
1. Inspect the tag on the alternator for the part number and manufacturing date-code (lot number).
2. If the part number is anything other than 23700AA211F, replacement is not necessary. Also, if the alternator part number is 23700AA211F, but does NOT fall within the indicated Lot range of 62P to 84W (as listed in the chart), replacement is not necessary. If the alternator is affected, replace it with the countermeasure part as indicated below.
If it is determined that replacement of the alternator assembly is necessary, proceed to Replacement Procedure section. If no replacement is necessary, affix a campaign identification label and submit a claim for visual inspection as described in the claims processing reimbursement information section.
REPLACEMENT PROCEDURE
As a matter of convenience for the customer record radio settings prior to disconnecting the battery. Please remember to reset the radio and clock when repairs have been completed.
1. With the ignition switch in the "off" position, disconnect the battery ground cable.
2. Disconnect the connector and terminal from the alternator.
3. Remove V-belt cover
4. Loosen the V-belt tensioning bolt and remove the V-belt.
5. Remove the remaining alternator mounting bolts and remove the alternator.
6. Reinstall the replacement alternator in reverse order of removal.
Note:
Save the original packaging for return of the removed alternator for core credit.
7. Check and adjust the V-belt tension.
Reused belt tension = 0.354 - 0.433 in. (9 - 11 mm)
8. Apply a "Service Program WXX-81" completion label. This label should be affixed to the radiator core support panel on a clean, dry surface, which will be visible, when the vehicle is brought in for periodic servicing by the owner.
IMPORTANT:
All alternators replaced under this program are subject to return for core credit and remanufacturing. Please promptly complete step #9 to ensure your core credit and future availability of replacement parts.
9. Return the removed alternator in the original packaging that contained the replacement alternator. Complete the Core Credit Request Tag and return the part to your Parts Department for shipping and core credit.
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.
STATE EMISSION TESTING ADVISORY
Federal regulations require the inspection of the On-Board Diagnostic (OBD) system as part of state emission inspections on 1996 model and newer passenger cars and light duty trucks. However, some states (such as California, Colorado, Illinois, Maine, Oregon, Utah, Vermont & Wisconsin) have started their OBD system check inspections earlier than the current January 1, 2001 regulatory deadline. Subaru believes it is extremely important that OBD systems are promoted in a positive light with the motoring public and those states choosing early OBD system check implementation.
A part of the OBD system check inspection includes the status of Readiness Codes. These codes serve as indicators whether or not a specific emission control system monitor has "completed" all of its related diagnostic tests. (The Readiness Code status does not indicate a pass/fail determination of the diagnostic, only that the monitoring process is complete) (See the November 1999 Subaru Technical Support T.I.P.S. for details.)
Since the battery is disconnected in step #1 of the replacement procedure, the Readiness Code status will indicate "incomplete". Dealers should instruct those owners whose vehicles are due for a state emission inspection (evidenced by the state inspection decal) to drive their vehicle a few days before taking them to the authorized state inspection facility. This will ensure preset readiness codes have been reset as "complete".
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES
Credit for performing this Service Program Will be based on the submission of properly completed repair order information. Dealers may enter the applicable claim information through their Dealer Communications System (DCS).
Listed below is claim entry information:
Inspection Only - Verification of the alternator part number and lot number. The original alternator part/lot number indicates replacement is not necessary. A total of 0.2 labor hours will be automatically credited upon claim submission.
Inspection and Replacement - Use the following claim submission information if the alternator was found within the affected VIN range and the part/lot number on the original alternator indicated replacement was necessary.
For alternator inspection and replacement enter labor operation 181-221 for 0.1 labor hours. The claim will automatically be credited an additional 0.2 labor hours for inspection. A total of 0.3 labor hours will be credited.
Enter applicable part number(s). Parts will be reimbursed at dealers cost plus applicable handling allowance.
REIMBURSEMENT FOR PREVIOUS REPAIR
Owners are being advised in the owner notification letter (copy attached) that if they have previously paid an authorized Subaru dealer for replacement of the alternator, they may be entitled to reimbursement. The owners are further advised that to qualify for any reimbursement, they must submit the original or original carbon copy of the repair invoice to Subaru of America, Inc. Please review the owner notification letter, which explains this procedure so that you are familiar with it, and can assist owners with any questions.
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