Recall - Fuel Tank Damage
NUMBER: WZJ-51APPLICABILITY: 1992MY, SIA Produced Legacy Station Wagon Models
SUBJECT: Fuel Tank Damage
Date: April 20, 1992
Subaru of America, Inc. (SOA) has determined that a defect which relates to motor vehicle safety exists in some 1992 SIA produced Legacy Station Wagon models manufactured during the period of July 1991 through January 13, 1992.
A minor misalignment of the rear seat cushion latching bracket reinforcement plate to the floor pan required the use of a machine tap to clear the opening for the mounting bolt. The top of the fuel tank may have been punctured when the machine tap was used. Under certain conditions when fuel is in the tank d could leak out, which could result in a fire.
To correct this condition, it is necessary to inspect and, if necessary, replace the damaged fuel tank.
VEHICLES INVOLVED
Affected vehicles involved are 1992MY SIA produced Legacy Station Wagon models within the VIN range listed. (Last eight only)
N*900468 - N*915346
*= 1, 6, 7, 9
NOTE:
MANY OF THE AFFECTED VEHICLES WITHIN THE LISTED VIN RANGE HAVE BEEN REPAIRED WHILE UNDER PLANT CONTROL AND DO NOT REQUIRE FURTHER REPAIRS. ALL DEALERS MUST VERIFY CAMPAIGN APPLICABILITY PRIOR TO REPAIR.
Involved vehicles have been identified by Vehicle Identification Number (VIN) Computer Listings. Computer listings contain the VIN, owner name and address data, and are furnished to the dealers with this bulletin. The 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. The Owner Notification mailing is scheduled for late April. 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 service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward in accordance with the instructions and the service procedure section of this bulletin, when presented a two-part Recall Certification / Repair Order Form by a Subaru owner. Dealers must also promptly service all new inventory prior to delivery to the customer in accordance with our letter TS92-004 dated 4/7/92.
Whenever a vehicle subject to this campaign or any open campaign is taken into new or used vehicle inventory, or it is in your dealership for service in the future, you should take the steps necessary to be sure the campaign correction has been made before reselling or releasing the vehicle.
Owners of vehicles, recently sold from your vehicle inventory within the VIN range listed, are to be verified for campaign applicability and contacted by the dealer and provided with a copy of the owner letter. Arrangements should be made to make the required correction according to instructions contained in this bulletin.
PARTS INFORMATION
PARTS AVAILABILITY:
Fuel tank replacement is estimated to be necessary on about 1 % of the affected vehicles. Upon inspection and determination of the need for a replacement fuel tank, contact your Regional or Distributor Expeditor with the specific Vehicle Identification Number. A replacement fuel tank and gaskets applicable to that vehicle will be shipped to your dealership by next day air.
PARTS PRICING:
LOANER CAR PROVISIONS
If you determine that a fuel tank replacement is required, the vehicle owner should be provided with a loaner car per the Subaru Owner Assistance Alternate Transportation Program.
SERVICE PROCEDURE
1. Verify that the vehicle is included in the VIN range listed on page 1 and has not been repaired (i.e., Star System, Distributor Office, etc.).
2. REMOVE REAR CUSHION STRIKER
Raise rear seat bottom cushion. Remove two (2) striker bolts. Figure 1.
3. VISUAL CHECK
Check the top surface of the fuel tank through the striker bolt body holes. Visually inspect through both body bolt holes, using a focusing flashlight (ex. Maglite) held approximately 6 inches above the holes and with eyes positioned 12 inches directly above the holes, check for any visual damage to the top surface of the tank. See figure 2.
EXAMPLES OF POSSIBLE DAMAGE TO THE TOP SURFACE OF FUEL TANK ARE AS FOLLOWS:
^ Small evidence of undercoating removed by tapping operation, thus scratching the fuel tank.
^ Undercoating removed by tapping operation resulting in a deep scratch or scoring impression or hole.
^ Rust present in the scratch or dent.
^ Any presence of strong fuel odor when removing striker bolts may indicate hole in the fuel tank.
4. If any discrepancies are detected from the "visual check", the fuel tank must be replaced. Refer to the appropriate section of the service manual for replacement of the fuel tank.
REMINDER:
At this time you should order the fuel tank in accordance with the Parts Availability information. The customer should be put in a loaner vehicle until the repairs have been completed.
5. If no discrepancies are detected, re-install striker to original position. Please make sure striker direction is correct.
^ Tighten torque for striker bolt: 100 +/- 30 KGFCM
^ Please use genuine bolt # 010106160 (16 MM length)
IF YOU DAMAGE THE THREADS DURING THIS PROCEDURE. PLEASE TAKE CARE WHEN REPAIRING NOT TO CONTACT THE FUEL TANK WITH THE TAP.
6. Apply the campaign identification label properly filled out to the radiator core support.
NOTE:
ALL FUEL TANKS WHICH HAVE BEEN REPLACED MUST BE HELD FOR INSPECTION BY YOUR DISTRICT TECHNICAL MANAGER (DTM).
CAMPAIGN IDENTIFICATION LABEL
Each vehicle corrected in accordance with the instructions outlined in this bulletin will require a "Campaign Identification Label". Each label provides a space to include the five digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.
Each "Campaign Identification Label" is to be affixed to the radiator core support panel in an area which will be visible when the vehicle is brought in for periodic servicing by the owner. Apply "Campaign Identification Label" only on a clean dry surface.
A quantity of 50 blank labels are being provided to each dealer with this bulletin.
CLAIM PROCESSING REIMBURSEMENT INFORMATION
Dealers must utilize the two-part Recall Certification / Repair Order Form to track the performance of this recall. Therefore, it is very important that all information in the form be complete and correct.
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.
Dealers will be credited 0.2 labor hours for the inspection at their warranty labor rate, based on the submission of the two-part Recall Certification/Repair Order Form.
Star System dealers may enter the applicable information using the Campaign Claim (RY) routine.
Non Star System dealers in SOA regional areas will be reimbursed upon submission of the remaining copy of the Recall Certification / Repair Order Form to your Subaru of America, Inc. Warranty Administration Section in an envelope supplied by SOA. Dealers must complete a Warranty Document Control Sheet and include this with the Recall Certification/Repair Order form. Dealers located in distributor areas must follow normal procedures issued by them.
Credit for additional repairs (i.e., fuel tank replacement as described in the Service Procedure and alternate transportation charges and towing charges) will be provided based on the submission of a standard warranty claim, MSA-400A. The operation number for the replacement of the fuel tank is A469201F. The failure code is WZJ-51 and the override code is WZJ-51. You will be credited with the additional 1.3 labor hours for 2WD or 2.4 labor hours for 4WD plus the parts and handling allowance for the fuel tank and gasket(s) replacement as identified in this campaign bulletin.
Should it be necessary to provide the vehicle owner with a loaner car per the Alternate Transportation Program, this may be claimed along with the replacement of the fuel tank, using operation number 102**7
(* indicate the number of days for loaner car), as the last operation number. The override code is WZJ-51.
In the event a vehicle needs to be towed to a Subaru Dealer for repairs under this campaign, towing charges will be reimbursed using an MSA400A and labor operation number 101 207, 0.0 hours, failure code TOW00. Towing must be in the "B" portion of the claim. The override code is WZJ-51.
All fuel tanks which have been replaced must be held for inspection by your DTM. Dealers will be debited for fuel tank replacement that is not necessary. Any claim for other consequential damages should be reviewed with your DTM prior to repair.
OWNER NOTIFICATION MATERIALS
OWNER LETTER
Subaru of America, Inc.
Recall Headquarters
Subaru Plaza
P.O. Box 6000
Cherry Hill, NJ 08034-6000
Dear Subaru Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Subaru of America, Inc. has determined that a defect which relates to motor vehicle safety exists in certain 1992MY Legacy Station Wagon vehicles.
Safety Defect:
The fuel tank may have been punctured on certain vehicles during the manufacturing process Under certain conditions when fuel is in the tank it could leak out, and could result in a vehicle tire.
Repairs:
Your Subaru Dealer will inspect and, if necessary, replace the fuel tank at no charge to you.
What you should do:
Drive cautiously until this recall repair has been made on your vehicle. Until your vehicle is inspected or repaired, do not fill the fuel tank more than half full. This may help limit fuel leakage and help the dealer if fuel tank replacement is necessary. If you notice a strong fuel odor contact your dealer for towing arrangements.
Call your dealer:
Even if you are not experiencing any problems you should call your Subaru Dealer and schedule a service date to repair your vehicle after receiving this letter.
How long will it take?
The actual time to perform the inspection is approximately 12 minutes, although additional time will be needed d component replacement is required. However, please plan to leave your vehicle at your Subaru Dealer for the full day of your scheduled appointment to allow the dealer some flexibility in scheduling other customers.
Changed address or sold your Subaru?
If you have, please fill out the enclosed prepaid postcard and mail it to us.
If you need more information or forms:
You must present the enclosed two-part Recall Certification / Repair Order Form to your Subaru Dealer at the time this repair procedure is performed. If you lose the Recall Certification / Repair Order Form provided with this notification or if the dealer doesn't make the repair promptly and without charge, you may contact the Subaru Recall Headquarters at 1-800-782-2783 or by writing to the address listed above.
If your complaint is not resolved, you may notify the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W. Washington, D.C. 20590 or call the toll free Auto Safety Hotline at 800-424-9393 (Washington, D.C. area residents may call 366-0123).
We regret any inconvenience this matter may cause you. However, we have taken this action in the interest of your safety and your continued satisfaction with our products.
WE URGE YOU TO SCHEDULE AN APPOINTMENT TO HAVE THESE REPAIR PROCEDURES PERFORMED AS OUTLINED IN THIS LETTER.