Campaign - Radiator Cooling Fan Relay Replacement: Overview
NUMBER: WVB-12DATE: February 2007
APPLICABILITY: 2005 - 2006 MY Subaru Legacy/Outback 2.5L M/T Turbo
SUBJECT:
Radiator Cooling Fan Relay # 2
INTRODUCTION
Subaru of America, Inc. (SOA) has determined that certain 2005-06 MY Subaru Legacy / Outback 2.5L M/T Turbo models require Radiator Cooling Fan Relay # 2 replacement.
The original Radiator Cooling Fan Relay #2 installed on affected vehicles may create an electrical surge to the radiator cooling fan circuit within the Engine Control Module (ECM). The electrical surge may damage the ECM cooling fan circuit and cause the radiator cooling fan to run continuously whenever the engine is running.
This service program will involve replacement of the Radiator Cooling Fan Relay 2. It will also involve checking the ECM radiator cooling fan circuit for proper operation. If it is determined that the ECM radiator cooling fan circuit has been damaged~ replacement of the ECM will also be necessary.
AFFECTED VEHICLES
2005~2006MY Subaru 2.5L M/T Turbo Legacy & Outback
Potentially affected vehicles are identified in the VIN range chart below. Not all vehicles 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 Owner Notification Letters to owners of affected vehicles on or around March 2, 2007.
A copy of the Owner Notification Letter is included at the end of 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
Radiator Cooling Fan Relay # 2
Engine Control Module (ECM)
Note:
ECM replacement is only necessary when it has been confirmed that the radiator cooling fan circuit is damaged. See the Service Procedure below for more details.
For vehicles requiring ECM replacement, the ECM should be ordered VOR 1-2 days. VOR freight charges may be submitted for reimbursement. See the Claims Submission section of this bulletin for claim entry instructions.
SERVICE PROCEDURE
Service Campaign Procedure
There are two (2) steps involved in this Service Program repair procedure. Step 1 will involve replacement of the Radiator Cooling Fan Relay # 2. Step 2 will involve checking the cooling fan circuit of the ECM for proper operation.
STEP 1
Replace the Radiator Cooling Fan Relay # 2 as follows:
1) Turn the ignition switch to the "Off" position.
2) Open the hood and locate the main fuse box. Remove the fuse box cover.
3) Locate the "Radiator Cooling Fan Relay # 2" as pictured below.
4) Carefully remove the relay.
5) Install a new Radiator Cooling Fan Relay # 2.
6) Replace the main fuse box cover.
STEP 2
Verify the cooling fan circuit of the ECM is operating properly as follows:
1) Ensure the HVAC system is turned to the "OFF" position.
2) Ensure the engine coolant temperature is below 196°F. This can be done by checking the engine temperature gauge on the vehicle's instrument cluster. Confirm the temperature gauge reading is below normal operating temperature - the needle should be between the "C" (cold) and the first gauge mark.
^ If the temperature is above the first gauge mark, allow the engine to cool until it reaches at or below the first gauge mark.
^ If the temperature is below the first gauge mark, proceed to step 3.
3) Start vehicle. Verify the radiator cooling fan does not turn on and stay on.
^ If the fan does not turn on~ the ECM is operating properly and no further action is necessary.
^ If the fan is on, the ECM will require replacement. See the applicable service manual for details. For vehicles requiring ECM replacement, the ECM should be ordered VOR standard 1-2 days. VOR freight charges may be submitted for reimbursement. See the Claims Submission section of this bulletin for claim entry instructions.
NOTE:
The ECM is only to be changed when the radiator cooling fan is verified as running all of the time when the engine is running. Otherwise only radiator cooling fan relay # 2 replacement is required.
Updated Radiator Cooling Fan Relay # 2 (Above) - The updated relay has a gray dot for easy identification; also the reference # has been changed to read, "RC-5101". The original relay has a different reference # and no gray dot.
RENTAL CAR
For retail customers, SOA will pay the cost of a one-day car rental when an affected vehicle requires ECM replacement provided the part is ordered VOR Standard 1-2 days.
The one-day car rental charges may be included with the Recall/Campaign claim submission. See the Claim Submission section of this bulletin for claim entry instructions.
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.
Additional labels are available through the Customer Dealer Services Department (CDS).
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.
For vehicles requiring ECM replacement only:
Rental Car Charges:
If applicable, rental car charges should be entered on the RC claim in the rental field.
VOR Freight:
If applicable, VOR standard 1-2 days freight charges should be submitted on the RC claim as a sublet. Freight charges must not exceed actual dealer cost which is 5% of dealer cost for the part.
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