Campaign - Cooling System Flush And Refill: Overview
NUMBER: WWY-09DATE: June 2006
APPLICABILITY:
2006MY Baja, Legacy, Outback, and B9 Tribeca
SUBJECT:
Engine Cooling System Flush and Refill
INTRODUCTION
Subaru of America, Inc. (SOA) has determined that vehicles affected by this Service Program require the engine cooling system to be drained, thoroughly flushed and refilled with new engine coolant. During a quality review; it was discovered that the coolant mixture used during production may contain a high level of chlorine. With a high chlorine content, the coolant can adversely react with aluminum components and quickly cause premature corrosion to occur within the cooling system. If left uncorrected, this condition will diminish the effectiveness of the heater core resulting in poor performance.
This service program will involve thoroughly flushing & refilling the engine cooling system.
AFFECTED VEHICLES
^ 2006 MY Subaru BAJA, Legacy, Outback and B-9 Tribeca
Affected vehicles are identified in the VIN range chart shown.
NOTE:
Not all vehicles found within the VIN range are affected. Prior to performing repairs, confirm coverage for potentially affected vehicles by using the Vehicle Coverage Inquiry in the Dealer Communication System (DCS).
OWNER NOTIFICATION
SOA will prepare and mail an Owner Notification Letter to owners of affected vehicles on or around June 14, 2006.
A copy of the Owner Notification Letter is shown in this bulletin.
DEALER PROGRAM RESPONSIBILITY
Dealers are to promptly service 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 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
SPECIAL TOOLS
Special Equipment Needed: 5/8" Garden Hose (25-50 feet), 1 (5/8") Hose couplet; 2 (5/8") Hose Clamps
SERVICE PROCEDURE
Caution:
The engine cooling system is under pressure and may be extremely hot. To prevent personal injury or vehicle damage, be sure to take appropriate precautions while preforming the following procedures.
Completing the following coolant flush procedure has been confirmed to effectively clean and remove any contaminates or corrosion, as well as eliminate the chlorine from the cooling system. A flush machine or flushing agents/chemicals must NOT be used in this procedure.
Note:
The following procedure should be performed at or near a water source (i.e., garden hose) which should be free of contamination from sediment, chlorine and sulfides.
Coolant Flush Procedure:
NOTE:
All drained and flushed coolant should be recycled or disposed of in accordance with applicable Federal/State/Local/Environmental Protection regulations.
1) Drain Engine Coolant
^ Remove the Radiator Cap and Reservoir Tank. (Use extreme caution when removing the radiator cap.)
^ Raise the vehicle.
^ Remove the engine under cover.
^ Remove the drain plug to drain the engine coolant.
NOTE:
While coolant is draining, wash out the reservoir tank. Fill the tank about 1/3 of the way with water and shake vigorously. If needed, use a soap solution to ensure all sediment is removed.
^ When coolant is fully drained, reinstall the drain plug in the radiator.
2) Create a heater core bypass loop
^ Remove Engine top cover (All except H4 SOHC).
^ Remove both coolant hoses from the heater core.
^ Using a hose connector (5/8"x 5/8"), connect the two heater hoses, creating a heater core bypass loop.
3) Fill cooling system with water
^ Pour water into the radiator up to the filler neck.
^ Install the radiator cap.
4) Flush the heater core (at least 4 times)
^ Move the vehicle to a water supply if away from one.
^ Install garden hose from water supply to heater core (upper inlet).
^ Install garden hose on lower heater core tube for draining.
^ Flush the heater core using a pail (at least 4 times).
^ Remove both garden hoses from the heater core.
5) Water flushing of the cooling system
^ Warm up the engine completely for more than five minutes at 2,000 to 3,000 RPM.
6) Drain flushing water
^ Raise the vehicle on a lift.
^ Drain flushing water from the cooling system.
^ Reinstall the engine under cover.
7) Restore cooling system
^ Remove hose connector from the heater bypass loop.
^ Connect heater hoses to the original positions.
^ Reinstall the reservoir tank.
^ Reinstall the engine top cover (All except H4 SOHC).
8) Fill the engine coolant/Instructions.
Note:
Add Subaru Cooling System Conditioner through the filler neck of the radiator prior to adding coolant and water.
INSPECTION
Relationship of SUBARU coolant concentration and freezing temperature: Concentration and safe operating temperature of SUBARU coolant is shown in the diagram. Measuring the temperature and specific gravity of the coolant will provide this information.
Based on the chart above, after the second drain, approximately 3.5-4Qts. of non-diluted coolant should be added along with 1.2-1.7Qts. of water to attain the 50% mixture of each.
Note:
Use coolant with 50% density when reservoir tank is filled up to the "FULL" Level.
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 has been sent each dealer along with their affected VIN list. 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 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.
Each dealer performing this Service Program should submit a "one time only" sublet charge for $20.00 on the first submitted claim. The sublet charge will serve as compensation for the equipment needed to perform this Service Program and may only be claimed on the first submitted claim. Subsequent claims should not include this charge.
Flush & Refill Engine Cooling System - Enter labor operation information as shown.
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