Upper Oil Pan Assembly-Design Changes (02-166-17R)

UPPER OIL PAN ASSEMBLY-DESIGN CHANGES

TECHNICAL SERVICE BULLETIN

APPLICABILITY

2013-2017MY Legacy and Outback 2.5L

2013-2017MY Impreza

2013-2017MY Crosstrek

2012-2017MY Forester, NA and Turbo

2015-2017MY WRX

2013-2017MY BRZ

INTRODUCTION

This bulletin outlines design changes made to the upper oil pan assembly on FA and FB engines used on the models listed above. There have been isolated cases where the sealer used between the upper oil pan and the crankcase has become displaced resulting in engine oil seepage.

Revisions made to the upper oil pan casting:

• The mating flange thickness of the casting in the area identified as the cause for the seepage has been increased by 5.5mm. (See images provided in the Parts Information section below.) This thickness increase creates the need for a longer bolt to provide proper tightening and retention.
• An additional mounting point has been added to the ribbing inside the casting to increase retention of the steel baffle plate and eliminate vibration.

PRODUCTION CHANGE INFORMATION

The new upper oil pan castings were incorporated into production per the table below:

Vehicle/Model	Starting VIN	Notes
Legacy and Outback	From 7/2016 Production*
Impreza 4-Door	GH006075	All
Impreza 5-Door and Crosstrek	G8224566
Forester	GG517171	2.5 NA w/MT
	GH487762	2.5 NA w/CVT
	GH493445	2.0 Turbo
WRX	G9823080	MT
	G8823385	CVT
BRZ	G9602083	MT
	G8601948	6AT

*Additional baffle mounting point only 

Design Changes incorporated into production by model:

Model	Design Change Made
	Shape Change	Bolt Change	Added Mounting Point
Legacy/Outback	NO	NO	YES
Impreza/Crosstrek	YES	YES	YES
WRX	YES	YES	YES
Forester	YES	YES	YES
BRZ	YES	YES	Already Incorporated

PART INFORMATION

Description	Part Number	Quantity
OIL PAN COMPLETE-UPPER	VIN-specific	1
BOLT (socket-head cap screw)	800408250	1
BOLT (hex-head for baffle plate)	808206010	1

REMINDER:  O-rings used between the upper oil pan and crankcase, on top of the oil pick-up tube and to seal the thermostat housing are all one-time use items and must always be replaced.

The new-style upper oil pan castings can be identified by:

• An underscore  has been added to the identification letter found on the front face next to the water pump cavity and QR code box.

  IMPORTANT NOTE:  If the identification letter is a "N", the casting is a p.n. 11120AA250 which is NOT affected by this TSB.

• Thicker casting and an additional mounting point for the baffle plate added to the internal ribbing.

SERVICE PROCEDURE/INFORMATION

If oil seepage is confirmed and replacement of the upper oil pan assembly is determined necessary, follow the service procedure in the applicable Service Manual. Both of the new bolt's torque specifications are unchanged.

WARRANTY/CLAIM INFORMATION

For vehicles within the Basic New Car Limited or Powertrain Limited Warranty period or covered by an active Subaru Added Security Powertrain, Classic or Gold plan, this repair may be submitted using the following claim information:

Labor Description	Applicability	Labor Operation #	Transmission		Fail Code
			MT	CVT/AT
UPPER OIL PAN ASSEMBLY LEAK-REPLACE	2013-2014MY Legacy/Outback	A295-025	6.2	6.7	AEZ-48
	2015-2017MY Legacy/Outback		-	6.8
	2013-2016MY Impreza		5.5	5.8
	2017MY Impreza		6.4	6.7
	2013-2017MY Crosstrek		5.5	5.8
	2012-2017MY Forester		6.2	6.7
	2015-2017MY WRX		6.6	7.1
	2013-2017MY BRZ		5.6	5.9

IMPORTANT REMINDERS: 

• SOA strongly discourages the printing and/or local storage of service information as previously released information and electronic publications may be updated at any time.
• Always check for any open recalls or campaigns anytime a vehicle is in for servicing.
• Always refer to STIS for the latest service information before performing any repairs.