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IMMEDIATE STOP SALE ORDER
TO: GLR-- MAR-- NWR-- SCR-- SDC-- SWR Dealers
FROM: Subaru of America, Inc.
DEPARTMENT: Service
DATE: 04/07/2008


Legacy vehicles have been added to the Stop Sale

We regret to inform you that we must place an immediate stop sale order on all of the 2008/2009 Subaru Impreza, Forester and Legacy vehicles equipped with a 2.5L Turbo Engine produced with the beginning chassis number and later as shown below.

Model
Body Type
Chassis Number
Production Date

Forester Wagon 701045 or later 2008/01/08 or later

Legacy 2.5GT-LTD 222825 or later 2008/02/04 or later
2.5GT-B 222958 or later 2008/02/04 or later
OBK 2.5XT-LTD 353835 or later 2008/02/01 or later

Impreza Sedan 523363 or later 2008/01/08 or later
Wagon 825183 or later 2008/01/08 or later


The reason for this immediate Quality Assurance action is that there have been 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.

Your region/distributor will be contacting you with a detailed list of affected vehicles assigned to your dealership. However, dealer trades cannot be tracked so please be aware of the affected VIN range.

If you have a vehicle in inventory that falls into the affected vehicle range, please ensure that your sales and service staff are immediately notified that the unit is un-saleable until further notice from SOA or your region/distributor.

If any of those vehicles has an unusual engine noise, please notify the SOA Technical Helpline immediately with all of the details and submit an E-QMR.

Should a customer bring an affected vehicle into your service department for an unusual engine noise, please immediately arrange that they are given the use of a clean SSLP vehicle and notify the Technical Helpline and submit an E-QMR.

You will be contacted shortly thereafter on how to proceed.

Source: Subaru
Tokyo, Japan
http://www.subaru.com/

==============================

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:

Model Body Type Chassis Number Production Date
Forester Wagon 701045 or later 2008/01/08 or later
Legacy 2.5GT-LTD 222825 or later 2008/02/04 or later
2.5GT-B 222958 or later
OBK 2.5XT-LTD 353835 or later 2008/02/01 or later
Impreza Sedan 523363 or later 2008/01/08 or later
Wagon 825183 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.

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. - Grainger Industrial Supply
• Fisher Scientic, Inc. - Fisher Scientific - Welcome
• 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.

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.



This next one is from my Subaru dealership in melbourne australia and is another official document i have received from my salesperson outlining the process in OZ.

Subaru (Aust) Pty. Limited
4 Burbank Place, Baulkham Hills NSW 2153
Postal Address: PO Box 8311, Baulkham Hills NSW 2153
Phone: (02) 98289111 Fax: (02) 9828 9131
ABN: 95000312792
Subaru New Cars - Subaru Australia
Service Information

SUBARU
ALL-WHEEL ORIVE
Category:
Date:
Reference:
Subject:
General
18 April 2008
510045
Turbo Engine Update
The Subaru Technical Department is now testing the factory's diagnostic procedure, which
identifies 2.5 litre turbo engine cars with symptoms that can result in engine knocking noise.
Subaru Australia technicians are now being trained on the procedure, which we will begin to roll
out in our compounds and the network this week.
The Subaru Technical Department will also start visiting retailers in metropolitan and provincial
centres as soon as possible, to begin assessing vehicles in stock, The Technical Department will
advise the process for rural locations.
First priority is being given to retailed vehicles. This will enable the resumption of customer
deliveries at the earliest opportunity.
Subaru's Customer Relations department will this week begin phoning customers with
potentially affected vehicles. A follow-up letter will also be sent. Their car will be booked into a
dealership for a precautionary check, at Subaru Austral ia' s expense.
As an act of goodwill, these customers are being given a five-year extended warranty.
As per our previous communications, any customers whose vehicle produces engine knocking
noise should be offered a loan car until their vehicles can be checked and, where necessary,
fixed.
Delivery of 2.5 litre turbo cars to the network will resume later this week. Please await our advice.
Production has now resumed at the factory.
Please advise all your customer-facing staff so they are equipped to respond proactively.