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NHTSA ID Number: 10222368
Manufacturer Communication Number: 09-74-21R
Summary
This bulletin provides updated parts information and a service procedure to follow for removing accumulated carbon deposits from fuel injectors and internal engine components.
NUMBER: 09-74-21R
DATE: 05/06/21
REVISED: 09/27/22
APPLICABILITY: | 2020-22MY Legacy and Outback 2.5L NA and 2.4L DIT 2018-22MY Crosstrek 2017-22MY Impreza 2019-22MY Forester 2.5 NA 2014-18MY Forester 2.0L DIT 2015-22MY WRX 2.0 DIT 2019-22MY Ascent |
SUBJECT: | Cleaning Procedure for Carbon Deposit Removal to Address Engine Misfire DTCs, Black Smoke from the Exhaust, Lack of Power, Knocking (Ping) and / or Rough Idle Concerns |
INTRODUCTION:
This bulletin provides updated parts information and a service procedure to follow for removing accumulated carbon deposits from fuel injectors and internal engine components (e.g. intake valves and / or manifold, and combustion chambers). Fuel quality and how the vehicle is operated are both major contributing factors which will have a direct effect on carbon deposit accumulation. This cleaning procedure for carbon deposit removal is recommended to address engine misfire DTCs, black smoke from the exhaust, lack of power, knocking (ping) and / or rough idle concerns.
The procedure outlines the use of Genuine Subaru P.E.A. (Polyether Amine) Carbon Cleaner (p.n. SOA868V9166) and the “Carbon Clean Tool” applicator tools (p.n. SOA868V9430 or SOA868V9432) which are both available through the Subaru Chemical Program.
IMPORTANT NOTES:
- The actual P.E.A. bottle may appear different than the black long-neck bottle shown in the photo below.
- When the cleaning procedure is determined to be necessary, a minimum of two bottles of the P.E.A. carbon cleaner will be required to complete it.
- An order quantity of 1 (one) SOA868V9166 will be shipped as a “case” of 12- 6.76 oz. bottles.
- There are 2 different applicator tools for use with specific bottles as specified below. These tools are not The current long-neck bottle will be replaced with the shorter versions soon.
- The new (shorter) bottle contains the same amount of P.E.A. product (6.76 oz.) but utilizes the newer version (SOA868V9432) of the applicator tool which has a shorter siphon tube designed to work in conjunction with the new bottle.
- Be sure to use the correct tool for the corresponding bottle style. The siphon tube on the original (long-style) tool is approximately 7 5/8” long while the new version for use with the shorter bottles measures 6 3/8”.
- The end of the siphon tube on the tool should not contact the bottom of the bottle. If it does, the old tool is being used with the new style bottle.
- If the tool does not extract all the contents of the bottle, the new tool may have been used with the old bottle.
- Each retailer has been automatically shipped ONE of the new (shorter siphon tube) applicator tools at no charge.
Use tool SOA868V9430 with this black, long-neck style bottle only.
New tool SOA868V9432 is to be used with these new shorter clear or black bottles only.
SERVICE PROCEDURE / INFORMATION:
VERY IMPORTANT: APPENDIX A has been added to the end of this bulletin (pg. 10) and it provides a Flow Chart for the overall Service Procedure described below. It is STRONGLY RECOMMENDED Technicians review the Flow Chart closely to ensure their understanding of the Service Procedure before proceeding further.
REMINDERS:
- Customer satisfaction and retention starts with performing quality repairs.
- ALWAYS road test the vehicle to confirm the customer’s concerns. If necessary, road test with the customer to ensure a full understanding of the condition(s) before proceeding with the procedure.
- STEP 1: Preliminary Inspection Procedure:
Step 1a) Connect the SSM4.
Step 1b) Check for any DTC(s) other than P030* (misfire). Correct any external spark plug / ignition coil concerns, poor connection, etc. before attempting this procedure. Remove the intake manifold assembly following all precautions and the service procedure supplied in the applicable Service Manual. Inspect inside the runners closely along with the cylinder head intake ports, plates and intake valves for any excessive amount of carbon / soot accumulation. Clean any readily accessible components with carburetor / throttle plate cleaner prior to re-assembly. Do not attempt to clean the intake valves at this point. Avoid allowing cleaners to enter the engine. If any other concerns are found, diagnose according to the applicable Service Manual procedure before attempting this carbon cleaning procedure.
IMPORTANT NOTES:
- ALWAYS use new intake manifold and EGR pipe gaskets along with any other one-time use parts as specified in the applicable Service Manual procedure during re-assembly.
- NOTE: The P.E.A. cleaner may worsen the conditions if other concerns exist outside of carbon / soot
Step 1c) Road test the vehicle and perform Drive Cycle A and B according to the applicable Service Manual. On STIS, go to Service Diagnostics and select the related Model Year and Model of the vehicle being repaired. Select Diagnostics then go to Engine (Diagnostics) > (Applicable Engine Type). Scroll down to Inspection Mode > Procedure > Inspection Mode A and Inspection Mode B then follow the related driving cycle patterns for each. Check if any DTC(s) other than P030* are set. If any other DTC(s) are found, diagnose and repair according to the applicable Service Manual.
Step 1d) Obtain customer authorization (if the fuel tank is not already full) to fill the fuel tank (for later P.E.A. application).
NOTE: Fueling and engine oil top-off expenses cannot be claimed.
IMPORTANT: DO NOT add P.E.A. carbon cleaner to the fuel tank before completing all of Step 2 below.
Step 1e) Inspect the ignition coils and spark plugs closely for evidence of tracking, poor electrical connection, etc.
Step 1f) Confirm the engine oil level is full. Top off if necessary.
Step 1g) For 2.5L DINA engines, proceed to Step 2. For Turbo and other engines, proceed to Step 3.
- STEP 2: Checking the Roughness Counter with SSM4 (NATURALLY ASPIRATED 2.5L MODELS (DINA) ONLY):
IMPORTANT CAUTION: Always confirm the parking brake is fully applied and the select lever is in the Park position (CVT models) or the shift lever is in the neutral position (MT models).
Step 2a) With the SSM4 connected, turn the ignition to ON and access the Data Monitor. Begin sampling data (all PIDs).
Step 2b) Start the engine and warm it up until the radiator fan cycles on. Document any unusual noises or concerns with the engine.
Step 2c) Turn the ignition OFF and allow the engine to cool down. The use of a supplemental cooling fan to circulate air and cool the engine compartment is recommended.
Step 2d) Turn the ignition and SSM4 back ON (engine OFF) access the Data Monitor again and monitor the coolant temperature until it is 60 +/- 2 deg. C (140+/- 3.6 deg. F).
Step 2e) Restart the engine, turn the A/C ON and set the system to “MAX” then allow the engine to idle for one minute.
Step 2f) Save the SSM4 data and turn the ignition OFF.
Step 2g) Confirm the data is correctly captured as listed below:
- Coolant temperature is 60 +/-2 deg. C (140+-3.6 F deg. F) at the start of measurement.
- A/C is ON at the start of measurement.
- “Flag control of Catalyst Rapid Warming-up reflect Ignition Timing” is ON at the start of measurement (it is OK if it changes to OFF during the measurement).
Step 2h) Read the roughness counter values on all cylinders by referring to FIG 1 below and record the values on the Repair Order for reference later in the procedure.
- FIG 1: How to Read the Roughness Counter:
On the SSM4, display the items listed below:
- Flag control of Catalyst Rapid Warming-up reflect Ignition Timing
- Misfire Monitoring (comp)
- Engine RPM
- Roughness Counters #1, #2, #3 and #4.
- The roughness counter rises and resets (drops sharply) repeatedly which is the reason the signals form triangles. Read the peak values of each triangle on all cylinders until the “Misfire Monitoring (comp)” changes to “0” then, add all the values to get a “total” value. A TOTAL count of 34 or less is to be considered acceptable.
If the TOTAL Roughness Counter number:
- EXCEEDS 34, proceed to the P.E.A. cleaning procedure starting with Step 3 below.
- Is 34 OR LESS, proceed to the Warranty and Claim Information and process a claim for Roughness Counter Inspection Only.
EXAMPLE 1:
EXAMPLE 2:
- STEP 3 (all models): Pour ONE full bottle of P.E.A. carbon cleaner into the vehicle’s FULL fuel tank. REMINDER: The fuel tank MUST be FULL.
- STEP 4: With the valve CLOSED as shown below, remove the cap and thread the applicator tool onto the P.E.A. bottle. During use, try to keep the bottle vertical to insure all the contents are consumed.
- STEP 5: Use the hanging hook to hold the assembled applicator tool on the hood striker as shown here.
- STEP 6: Remove the purge hose located at the top of the throttle body as shown below and connect the hose from the applicator tool. Refer to the images below for the hose locations.
- STEP 7: Application of P.E.A. Carbon Cleaner into the Intake Manifold:
IMPORTANT CAUTION: The cleaning operation MUST be performed in well-ventilated area. If performed inside, always confirm the vehicle is connected to an exhaust evacuation system before proceeding.
Step 7a) Start the engine and warm it up until the radiator fan cycles on. Keep the engine speed at 2000rpm using the SSM4.
IMPORTANT: To avoid engine overheating, keep the engine hood open. The use of a supplemental cooling fan to circulate air and cool the engine compartment is recommended.
Step 7b) Open the valve on the applicator tool carefully and adjust to approximately 22 degrees from closed. Use the illustration below for reference. At that flow rate, it should take about 1 hour to empty the 6.76 oz. bottle. IMPORTANT: This flow rate is critical. Some trial and error (e.g. put the intake supply hose into a CLEAN container and experiment as needed to determine the proper opening position of the valve to achieve the required flow rate). Return any used P.E.A. to the supply bottle.
Step 7c) When the bottle has been emptied, return the engine speed to idle, allow to idle for a few moments then switch the ignition OFF.
Step 7d) Close the valve, remove the tool from the purge hose connection and reconnect the purge hose.
- STEP 8: Burning of Carbon Deposits Off the Spark Plugs:
Step 8a) Start the engine, warm it up until the radiator fan cycles on then return the engine speed to idle.
Step 8b) Raise the engine speed to 3500 rpm, hold it there for 25 seconds then return it to idle for 5 seconds. Repeat this cycle 5 times then keep it at idle for 30 seconds to allow the engine to cool down. Repeat the above procedure 2 more times (3 times total).
REMINDER: To avoid overheating, keep the engine hood open. The use of a supplemental cooling fan to circulate air and cool the engine compartment is recommended.
- STEP 9: Verification of Cleaning Status: Follow A) or B) below depending on the engine type:
A) FOR 2.5L NATURALLY ASPIRATED 2.5L (DINA) MODELS ONLY:
Step 9a) Read the Roughness Counter again referencing Step 2 above for the procedure.
Step 9b) Verify the results of the cleaning procedure by confirming the condition below:
- Has the Roughness Counter total value become less than 34?
If YES (successful), proceed to Step 10.
B) FOR ALL MODELS OTHER THAN 2.5L DINA:
Step 9a) Verify the cleaning procedure results by confirming the 2 conditions below:
- Has the rough idle condition smoothed out?
- Have the other conditions confirmed before cleaning been successfully addressed including: engine misfire DTCs, black smoke from the exhaust, lack of power, and/or knocking (ping)?
Step 9b) If the answers to the above questions (9a / 9b) are YES (successful), proceed to Step 10.
If one or more answers to the questions above is NO (NOT successful), return to Step 4 and repeat the P.E.A. cleaning process. If the conditions above are not satisfied after the second attempt, CHANGE THE ENGINE OIL (no filter change) and perform a third attempt. If a fourth attempt is required and the result is still unsuccessful, CHANGE THE ENGINE OIL AGAIN (no filter change) and follow the SOA Escalation Process for additional support.
IMPORTANT: In a case where more than one cleaning attempt is required, it is STRONGLY recommended to change the engine oil (oil only, no filter change) after every 2 bottles of P.E.A. are consumed by the engine. Do NOT add more P.E.A. to the fuel tank.
- STEP 10: Confirmation Road Test
Step 10a) Clear the ECM memory and road test the vehicle to confirm the Check Engine light does not come back on to complete the procedure.
VERY IMPORTANT: When returning the vehicle to the customer, always advise to NOT refill the fuel tank until the gauge reads BELOW 1/4 full. This will maximize the effect of the P.E.A. poured into the fuel tank in Step 3.
Appendix A: Service Procedure Flow Chart
See PDF Bellow…
8 Affected Products
Vehicle
MAKE | MODEL | YEAR |
SUBARU | WRX | 2015-2022 |
1 Associated Document
Manufacturer Communications
NUMBER: 09-74-21R
DATE: 05/06/21
REVISED: 09/27/22
https://www.nhtsa.gov/recalls?nhtsaId=10222368
MC-10222368-0001.pdf 3312.926KB
NHTSA ID Number: 10222367
Manufacturer Communication Number: 09-74-21R
Summary
This bulletin provides updated parts information and a service procedure to follow for removing accumulated carbon deposits from fuel injectors and internal engine components.
1 Associated Document
Manufacturer Communications
NUMBER: 09-74-21R
DATE: 05/06/21
REVISED: 09/27/22
https://www.nhtsa.gov/recalls?nhtsaId=10222367
MC-10222367-0001.pdf 3312.926KB
NHTSA ID Number: 10219496
Manufacturer Communication Number: 09-74-21R
Summary
This bulletin provides updated parts information and a service procedure to follow for removing accumulated carbon deposits from fuel injectors and internal engine components (e.g. intake valves and / or manifold, and combustion chambers).
1 Associated Document
Manufacturer Communications
NUMBER: 09-74-21R
DATE: 05/06/21
REVISED: 08/26/22
https://www.nhtsa.gov/recalls?nhtsaId=10219496
MC-10219496-0001.pdf 3312.975KB
NHTSA ID Number: 10201810
Manufacturer Communication Number: 09-74-21R
Summary
This bulletin provides updated parts information and a service procedure to follow for removing accumulated carbon deposits from fuel injectors and internal engine components (e.g. intake valves and / or manifold, and combustion chambers).
1 Associated Document
Manufacturer Communications
NUMBER: 09-74-21R
DATE: 05/06/21
REVISED: 09/24/21
https://www.nhtsa.gov/recalls?nhtsaId=10201810
MC-10201810-0001.pdf 1942.718KB
NHTSA ID Number: 10201059
Manufacturer Communication Number: 09-74-21R
Summary
This bulletin provides updated parts information and a service procedure to follow for removing accumulated carbon deposits from fuel injectors and internal engine components (e.g. intake valves and / or manifold, and combustion chambers).
1 Associated Document
Manufacturer Communications
NUMBER: 09-74-21R
DATE: 05/06/21
REVISED: 08/30/21
https://www.nhtsa.gov/recalls?nhtsaId=10201059
MC-10201059-0001.pdf 1942.578KB
NHTSA ID Number: 10198768
Manufacturer Communication Number: 09-74-21R
Summary
This bulletin provides updated parts information and a service procedure to follow for removing accumulated carbon deposits from fuel injectors and internal engine components (e.g. intake valves and / or manifold, and combustion chambers).
1 Associated Document
Manufacturer Communications
NUMBER: 09-74-21R
DATE: 05/06/21
REVISED: 06/28/21
https://www.nhtsa.gov/recalls?nhtsaId=10198768
MC-10198768-0001.pdf 1547.843KB
NHTSA ID Number: 10194830
Manufacturer Communication Number: 09-74-21R
Summary
This bulletin provides updated parts information and a service procedure to follow for removing accumulated carbon deposits from fuel injectors and internal engine components.
1 Associated Document
Manufacturer Communications
NUMBER: 09-74-21R
DATE: 05/06/21
REVISED: 05/21/21
https://www.nhtsa.gov/recalls?nhtsaId=10194830
MC-10194830-0001.pdf 1543.451KB
“This site contains affiliate links for which OEMDTC may be compensated” |
- Deglaze & decoke engines
- Reduce engine blow-by & oil use
- Restore engine power and fuel economy
- Significantly reduce harmful emissions
- Prolong turbocharger life
- Non-dismantle cleaner has special handling one-way valves to seal up gas and durable pressure regulating valves
- Has anti-corrosion, anti-friction connectors for fast-connection and anti-friction oil tubes for all cleaning fluid
- Tank Capacity: 600ml; Pressure: 0-220PSI;Working Temperature: -10℃~+50℃ (14℉~122℉)
- Special handling one-way valves, able to seal up gas
- Includes many different adapters, covering almost all the EU, Asia, USA cars and light trucks(petrol 12V)
- 【Simple Operation & Efficient Cleaning】Fuel injector cleaner is fit for all petrol cars and is designed to remove carbon deposits and maintain the pipeline. It has high and low pressure cleaning function, which can be used to clean the whole fuel system, intake system and TWC converter, about 20 minutes to completely remove carbon deposits. It is easy to operate and is a no-disassembly cleaning tool, which can be used to clean the fuel system without disassembly,saving a lot of time and energy.
- 【1000ML Large Capacity Cleaner canister & 0-150PSI Adjustable Pressure Gauge】Fuel injector tester adopts a stainless steel bottle, which is anti-scratch, wear-resistant and corrosion-resistant, and adopts a downward oil discharge design, which ensures no residue during cleaning and does not corrode the cleaning equipment.The high-precision pressure gauge can clearly display the air/oil pressure, and is equipped with a pressure regulating valve to adjust the pressure to prevent bottle explosion.
- 【Automatic Pressure Relief & Multi-Function Valve】Fuel injector cleaner kit comes with a pressure relief valve, which will automatically release the pressure when the pressure in the bottle reaches 150 PSI, the whole cleaning process is safe and reliable. Fuel injector cleaner tester is designed with a special handling check valve for adding liquid and releasing gas, which has good airtightness. Pneumatic cleaning, using Japanese air quick connect joint (1/4” BSPT thread)
- 【More Humanization Design】The stainless steel oil storage bottle is designed with a portable hook,which can be hung in the car to free your hands;The shell of the pressure gauge is covered with a shockproof rubber protective sleeve,which is shockproof,drop-resistant and high pressure-resistant,and deflation can be repeated up to 10,000 times;Equipped with a heavy blow molded plastic box,which is convenient to store and easy to carry,and can withstand high-strength extrusion without deformation.
- 【Ultra-high Configuration & Wide Application】Fuel injector cleaning kit contains 40 accessories, including a 40” long oil outlet pipe (For all cleaning fluids), which helps you to realize ultra-long-distance connection.With a complete range of joints, mainly made of stainless steel and engineering plastics, which is one of the most complete joints on the market at the moment, and it's suitable for almost all cars and light trucks in the European Union, Asia, and the Americas. light trucks.
- [Function] The system is not only characteristic of high and low pressure cleaning function. At the same time put the function of the whole combustion chamber fuel system of several main functions in one product, such as cleaning throttle valve and the fuel nozzle.
- [Application] The injector clean kits include many different kinds of adapter, cover almost all the EU,Asia,USA cars and light trucks (petrol). Non-Dismantle injector Throttle and fuel system. NOTE:Clean liquid not include,work on gasoline injector only, not for diesel injector.
- [Installation] It hangs on the hood and can be used without using large tools. Non-dismantle fuel injector has anti-friction connectors for fast-connection and anti-friction oil tubes for all cleaning fluid Please wear protective glasses before operation. Observe whether the joint is leaking. If yes, please clear the fault before starting work.
- [Identify the hose] 1. Generally speaking, inlet hose is bigger, return hose is smaller; 2. There is always a filter connected in the inlet hose side, and a buffer in the return side; 3. There is arrow on the hose to show the fuel flow direction.
- [Package Included] 1x Fuel Injector Cleaner; 1x Adapter Kits; 1x Suitcase.
- Function: Used to clean the fuel injector and intake system, and the fuel system can be taken out from the cleaning system.
- Multi-function: The system is not only characteristic of high and low pressure cleaning function.
- Wide Application: The injector clean kits include many different kinds of adapters, covering almost all for EU, for Asia, for USA cars and light trucks.
- Dimension: Pressure: 0-140PSI; Tank: 600ml; Accessories Thread Size: M8x1.25, M15x1.5, M14x1.5; Oil Storage Bottle Size: 19x7.6cm/7.48"x2.99"(H*D). Please make sure your adapter size before ordering.
- Package Include: 1x Fuel Injector Cleaner, 1x Adapter Kits, 1 x Instruction. The package does not include the cleaning fluid, and only for gasoline injectors, not for diesel injectors.
- 1.【1000ML Stainless Steel Canister & 150PSI Pressure Gauge】The fuel injector cleaning tool adopts a delicate high-pressure stainless steel bottle body, which is scratch-resistant, corrosion-resistant, safe and reliable. The customized pressure gauge can display air pressure and oil pressure, and a check valve is connected in the middle, which has good air tightness. The deflation can be repeated up to 10,000 times! The pressure level can be adjusted by turning the valve so that the detergent has better spraying performance.
- 2.【Complete Adapters for Wide Compatibility】The adapters in this fuel injection cleaning kit are the most complete on the market. Its main parts and joints are made of brass, and the connecting pipes and seals are made of selected perfluoro rubber materials, which have strong toughness and corrosion resistance, are more stable, and do not leak. This fuel injector cleaner machine is compatible with various car series and can clean all kinds of carburetors, electronic/mechanical fuel injection vehicles and light trucks in Europe, America, Japan, Korea and domestically produced.
- 3.【Bottom Oil Outlet & Hook & Rubber Protective Cover & Case】The advantage of the bottom oil outlet design is that there is no residue in the cleaning, and it will not corrode the cleaning equipment. The special hook design is convenient for hanging and moving the fuel injector cleaner tool. The pressure gauge has a special shockproof rubber protective cover to prevent damage due to falling. A custom heavy-duty plastic carrying case to better protects the car fuel injector cleaner kit from shocks for easy storage, quick organization and transport.
- 4.【Efficient Cleaning & Wide Application】Pneumatic cleaning, without external power supply, avoiding the fire hazard caused by electric sparks. The fuel injection cleaner tool can be used in conjunction with a fast and efficient fuel system cleaning agent (not included), and the carbon deposits in the intake valve, fuel injector, piston ring and combustion chamber can be completely removed in about 20 minutes, and the entire fuel system can be cleaned quickly and effectively, including TWC, Intake manifold, throttle valve and exhaust pipe, etc. It can restore vehicle power and driving performance, and greatly reduce fuel consumption and exhaust emissions.
- 5.【Packing List and 3-Year Warranty】The auto fuel injector cleaning kit include 25pcs vehicle adapters, 1pc TWC cleaning joint, 1pc throttle cleaning nozzle, 1pc hose opener, 1pc funnel, 1pc return pipe clip, 4pcs universal hose quick coupling, 1pc leader air hose, 2pcs hose clamps, 3pcs hose plugs, 3pcs thread plugs, 1pc user manual. We provide a 36-month free warranty and 24-hour friendly customer service to ensure your shopping experience. If you have any questions about this fuel injector cleaner tool kit, please feel free to contact us and we will provide you with a satisfactory solution as soon as possible.
- QUALITY ASSURED
- Reduces: rough idle, engine surge, hesitation, and spark plus fouling
- 20 oz. bottle.
- Improves: cold start performance, and fuel stability for up to one year
- Keeps fuel fresh for up to 24 months during storage
- Eliminates the need to drain fuel prior to storage
- Ensures quick, easy starts after storage
- Prevents gum and varnish build-up
- Effective in all gasoline, including Ethanol blends
Last update on 2024-04-16 / Affiliate links / Images from Amazon Product Advertising API
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SEOCONTENT-START
Bulletin Number: 09-74-21R; Revised: 09/27/22 Page 1 of 11 SERVICE BULLETIN Continued… CAUTION: VEHICLE SERVICING PERFORMED BY UNTRAINED PERSONS COULD RESULT IN SERIOUS INJURY TO THOSE PERSONS OR TO OTHERS. Subaru Service Bulletins are intended for use by professional technicians ONLY. They are written to inform those technicians of conditions that may occur in some vehicles, or to provide information that could assist in the proper servicing of the vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do the job correctly and safely. If a condition is described, DO NOT assume that this Service Bulletin applies to your vehicle, or that your vehicle will have that condition. Subaru of America, Inc. is ISO 14001 Compliant ISO 14001 is the international standard for excellence in Environmental Management Systems. Please recycle or dispose of automotive products in a manner that is friendly to our environment and in accordance with all local, state and federal laws and regulations. APPLICABILITY: 2020-22MY Legacy and Outback 2.5L NA and 2.4L DIT 2018-22MY Crosstrek 2017-22MY Impreza 2019-22MY Forester 2.5 NA 2014-18MY Forester 2.0L DIT 2015-22MY WRX 2.0 DIT 2019-22MY Ascent SUBJECT: Cleaning Procedure for Carbon Deposit Removal to Address Engine Misfire DTCs, Black Smoke from the Exhaust, Lack of Power, Knocking (Ping) and / or Rough Idle Concerns INTRODUCTION: This bulletin provides updated parts information and a service procedure to follow for removing accumulated carbon deposits from fuel injectors and internal engine components (e.g. intake valves and / or manifold, and combustion chambers). Fuel quality and how the vehicle is operated are both major contributing factors which will have a direct effect on carbon deposit accumulation. This cleaning procedure for carbon deposit removal is recommended to address engine misfire DTCs, black smoke from the exhaust, lack of power, knocking (ping) and / or rough idle concerns. The procedure outlines the use of Genuine Subaru P.E.A. (Polyether Amine) Carbon Cleaner (p.n. SOA868V9166) and the “Carbon Clean Tool” applicator tools (p.n. SOA868V9430 or SOA868V9432) which are both available through the Subaru Chemical Program. IMPORTANT NOTES: • The actual P.E.A. bottle may appear different than the black long-neck bottle shown in the photo below. • When the cleaning procedure is determined to be necessary, a minimum of two bottles of the P.E.A. carbon cleaner will be required to complete it. • An order quantity of 1 (one) SOA868V9166 will be shipped as a “case” of 12- 6.76 oz. bottles. • There are 2 different applicator tools for use with specific bottles as specified below. These tools are not interchangeable. The current long-neck bottle will be replaced with the shorter versions soon. NUMBER: 09-74-21R DATE: 05/06/21 REVISED: 09/27/22 ATTENTION: GENERAL MANAGER q PARTS MANAGER q CLAIMS PERSONNEL q SERVICE MANAGER q IMPORTANT – All Service Personnel Should Read and Initial in the boxes provided, right. ©2021 Subaru of America, Inc. All rights reserved. Bulletin Number: 09-74-21R; Revised: 09/27/22 Page 2 of 11 Continued… • The new (shorter) bottle contains the same amount of P.E.A. product (6.76 oz.) but utilizes the newer version (SOA868V9432) of the applicator tool which has a shorter siphon tube designed to work in conjunction with the new bottle. • Be sure to use the correct tool for the corresponding bottle style. The siphon tube on the original (long-style) tool is approximately 7 5/8” long while the new version for use with the shorter bottles measures 6 3/8”. • The end of the siphon tube on the tool should not contact the bottom of the bottle. If it does, the old tool is being used with the new style bottle. • If the tool does not extract all the contents of the bottle, the new tool may have been used with the old bottle. • Each retailer has been automatically shipped ONE of the new (shorter siphon tube) applicator tools at no charge. • In cases where more than one (1) P.E.A. cleaning procedure is claimed, SSM4 data will be required. Use tool SOA868V9430 with this black, long-neck style bottle only. New tool SOA868V9432 is to be used with these new shorter clear or black bottles only. SERVICE PROCEDURE / INFORMATION: VERY IMPORTANT: APPENDIX A has been added to the end of this bulletin (pg. 10) and it provides a Flow Chart for the overall Service Procedure described below. It is STRONGLY RECOMMENDED Technicians review the Flow Chart closely to ensure their understanding of the Service Procedure before proceeding further. REMINDERS: • Customer satisfaction and retention starts with performing quality repairs. • ALWAYS road test the vehicle to confirm the customer’s concerns. If necessary, road test with the customer to ensure a full understanding of the condition(s) before proceeding with the procedure. • STEP 1: Preliminary Inspection Procedure: Step 1a) Connect the SSM4. Bulletin Number: 09-74-21R; Revised: 09/27/22 Page 3 of 11 Continued… Step 1b) Check for any DTC(s) other than P030* (misfire). Correct any external spark plug / ignition coil concerns, poor connection, etc. before attempting this procedure. Remove the intake manifold assembly following all precautions and the service procedure supplied in the applicable Service Manual. Inspect inside the runners closely along with the cylinder head intake ports, plates and intake valves for any excessive amount of carbon / soot accumulation. Clean any readily accessible components with carburetor / throttle plate cleaner prior to re-assembly. Do not attempt to clean the intake valves at this point. Avoid allowing cleaners to enter the engine. If any other concerns are found, diagnose according to the applicable Service Manual procedure before attempting this carbon cleaning procedure. IMPORTANT NOTES: • ALWAYS use new intake manifold and EGR pipe gaskets along with any other one-time use parts as specified in the applicable Service Manual procedure during re-assembly. • NOTE: The P.E.A. cleaner may worsen the conditions if other concerns exist outside of carbon / soot accumulation. Step 1c) Road test the vehicle and perform Drive Cycle A and B according to the applicable Service Manual. On STIS, go to Service Diagnostics and select the related Model Year and Model of the vehicle being repaired. Select Diagnostics then go to Engine (Diagnostics) > (Applicable Engine Type). Scroll down to Inspection Mode > Procedure > Inspection Mode A and Inspection Mode B then follow the related driving cycle patterns for each. Check if any DTC(s) other than P030* are set. If any other DTC(s) are found, diagnose and repair according to the applicable Service Manual. Step 1d) Obtain customer authorization (if the fuel tank is not already full) to fill the fuel tank (for later P.E.A. application). NOTE: Fueling and engine oil top-off expenses cannot be claimed. IMPORTANT: DO NOT add P.E.A. carbon cleaner to the fuel tank before completing all of Step 2 below. Step 1e) Inspect the ignition coils and spark plugs closely for evidence of tracking, poor electrical connection, etc. Step 1f) Confirm the engine oil level is full. Top off if necessary. Step 1g) For 2.5L DINA engines, proceed to Step 2. For Turbo and other engines, proceed to Step 3. • STEP 2: Checking the Roughness Counter with SSM4 (NATURALLY ASPIRATED 2.5L MODELS (DINA) ONLY): IMPORTANT CAUTION: Always confirm the parking brake is fully applied and the select lever is in the Park position (CVT models) or the shift lever is in the neutral position (MT models). Step 2a) With the SSM4 connected, turn the ignition to ON and access the Data Monitor. Begin sampling data (all PIDs). Step 2b) Start the engine and warm it up until the radiator fan cycles on. Document any unusual noises or concerns with the engine. Bulletin Number: 09-74-21R; Revised: 09/27/22 Page 4 of 11 Continued… Step 2c) Turn the ignition OFF and allow the engine to cool down. The use of a supplemental cooling fan to circulate air and cool the engine compartment is recommended. Step 2d) Turn the ignition and SSM4 back ON (engine OFF) access the Data Monitor again and monitor the coolant temperature until it is 60 +/- 2 deg. C (140+/- 3.6 deg. F). Step 2e) Restart the engine, turn the A/C ON and set the system to “MAX” then allow the engine to idle for one minute. Step 2f) Save the SSM4 data and turn the ignition OFF. Step 2g) Confirm the data is correctly captured as listed below: • Coolant temperature is 60 +/-2 deg. C (140+-3.6 F deg. F) at the start of measurement. • A/C is ON at the start of measurement. • “Flag control of Catalyst Rapid Warming-up reflect Ignition Timing” is ON at the start of measurement (it is OK if it changes to OFF during the measurement). Step 2h) Read the roughness counter values on all cylinders by referring to FIG 1 below and record the values on the Repair Order for reference later in the procedure. • FIG 1: How to Read the Roughness Counter: On the SSM4, display the items listed below: • Flag control of Catalyst Rapid Warming-up reflect Ignition Timing • Misfire Monitoring (comp) • Engine RPM • Roughness Counters #1, #2, #3 and #4. • The roughness counter rises and resets (drops sharply) repeatedly which is the reason the signals form triangles. Read the peak values of each triangle on all cylinders until the “Misfire Monitoring (comp)” changes to “0” then, add all the values to get a “total” value. A TOTAL count of 34 or less is to be considered acceptable. If the TOTAL Roughness Counter number: • EXCEEDS 34, proceed to the P.E.A. cleaning procedure starting with Step 3 below. • Is 34 OR LESS, proceed to the Warranty and Claim Information and process a claim for Roughness Counter Inspection Only. Bulletin Number: 09-74-21R; Revised: 09/27/22 Page 5 of 11 Continued… EXAMPLE 1: EXAMPLE 2: • STEP 3 (all models): Pour ONE full bottle of P.E.A. carbon cleaner into the vehicle’s FULL fuel tank. REMINDER: The fuel tank MUST be FULL. • STEP 4: With the valve CLOSED as shown below, remove the cap and thread the applicator tool onto the P.E.A. bottle. During use, try to keep the bottle vertical to insure all the contents are consumed. Bulletin Number: 09-74-21R; Revised: 09/27/22 Page 6 of 11 Continued… • STEP 5: Use the hanging hook to hold the assembled applicator tool on the hood striker as shown here. • STEP 6: Remove the purge hose and connect the hose from the applicator tool. Refer to the images below for the hose locations. 2.4 DIT 2.0 DIT FRONT FRONT FRONT FRONT Bulletin Number: 09-74-21R; Revised: 09/27/22 Page 7 of 11 Continued… 2.0L & 2.5L DINA • STEP 7: Application of P.E.A. Carbon Cleaner into the Intake Manifold: IMPORTANT CAUTION: The cleaning operation MUST be performed in well-ventilated area. If performed inside, always confirm the vehicle is connected to an exhaust evacuation system before proceeding. Step 7a) Start the engine and warm it up until the radiator fan cycles on. Keep the engine speed at 2000rpm using the SSM4. IMPORTANT: To avoid engine overheating, keep the engine hood open. The use of a supplemental cooling fan to circulate air and cool the engine compartment is recommended. Step 7b) Open the valve on the applicator tool carefully and adjust to approximately 22 degrees from closed. Use the illustration below for reference. At that flow rate, it should take about 1 hour to empty the 6.76 oz. bottle. IMPORTANT: This flow rate is critical. Some trial and error (e.g. put the intake supply hose into a CLEAN container and experiment as needed to determine the proper opening position of the valve to achieve the required flow rate). Return any used P.E.A. to the supply bottle. Bulletin Number: 09-74-21R; Revised: 09/27/22 Page 8 of 11 Continued… Step 7c) When the bottle has been emptied, return the engine speed to idle, allow to idle for a few moments then switch the ignition OFF. Step 7d) Close the valve, remove the tool from the purge hose connection and reconnect the purge hose. • STEP 8: Burning of Carbon Deposits Off the Spark Plugs: Step 8a) Start the engine, warm it up until the radiator fan cycles on then return the engine speed to idle. Step 8b) Raise the engine speed to 3500 rpm, hold it there for 25 seconds then return it to idle for 5 seconds. Repeat this cycle 5 times then keep it at idle for 30 seconds to allow the engine to cool down. Repeat the above procedure 2 more times (3 times total). REMINDER: To avoid overheating, keep the engine hood open. The use of a supplemental cooling fan to circulate air and cool the engine compartment is recommended. • STEP 9: Verification of Cleaning Status: Follow A) or B) below depending on the engine type: A) FOR 2.5L NATURALLY ASPIRATED 2.5L (DINA) MODELS ONLY: Step 9a) Read the Roughness Counter again referencing Step 2 above for the procedure. Step 9b) Verify the results of the cleaning procedure by confirming the condition below: • Has the Roughness Counter total value become less than 34? If YES (successful), proceed to Step 10. B) FOR ALL MODELS OTHER THAN 2.5L DINA: Step 9a) Verify the cleaning procedure results by confirming the 2 conditions below: • Has the rough idle condition smoothed out? • Have the other conditions confirmed before cleaning been successfully addressed including: engine misfire DTCs, black smoke from the exhaust, lack of power, and/or knocking (ping)? Step 9b) If the answers to the above questions (9a / 9b) are YES (successful), proceed to Step 10. If one or more answers to the questions above is NO (NOT successful), return to Step 4 and repeat the P.E.A. cleaning process. If the conditions above are not satisfied after the second attempt, CHANGE THE ENGINE OIL (no filter change) and perform a third attempt. If a fourth attempt is required and the result is still unsuccessful, CHANGE THE ENGINE OIL AGAIN (no filter change) and follow the SOA Escalation Process for additional support. IMPORTANT: In a case where more than one cleaning attempt is required, it is STRONGLY recommended to change the engine oil (oil only, no filter change) after every 2 bottles of P.E.A. are consumed by the engine. Do NOT add more P.E.A. to the fuel tank. Bulletin Number: 09-74-21R; Revised: 09/27/22 Page 9 of 11 Continued… • STEP 10: Confirmation Road Test Step 10a) Clear the ECM memory and road test the vehicle to confirm the Check Engine light does not come back on to complete the procedure. VERY IMPORTANT: When returning the vehicle to the customer, always advise to NOT refill the fuel tank until the gauge reads BELOW 1/4 full. This will maximize the effect of the P.E.A. poured into the fuel tank in Step 3. WARRANTY / CLAIM INFORMATION: For vehicles within the Basic New Car Limited or Powertrain Limited Warranty period, this repair may be submitted using the following claim information: IMPORTANT NOTES: • In a case where multiple cleaning attempts are required, it is STRONGLY recommended to change the engine oil after every 2 bottles of P.E.A. are consumed by the engine (oil only, no filter). • The claimable Warranty Part Number for 1 (one) bottle of the P.E.A. cleaner is SOA635328. TESTING / REPAIR OUTCOMES and CLAIM CODING INFORMATION Fail Code TEST DRIVE, DTC CHECK, SPARK PLUG, IGNITION COIL AND INTAKE MANIFOLD INSPECTIONS (TURBO AND NA MODELS), P.E.A. CLEANING PROCEDURE NOT REQUIRED A449-208 2.7 DGR-85 **NOTE: In cases where more than one (1) P.E.A. cleaning procedure is claimed, SSM4 data will be required. DIT (TURBO) MODELS ONLY P.E.A. CLEANING PROCEDURE REQUIRED Model Applicability Fail Codes Ascent, Leg / Obk WRX, Forester XT INTAKE MANIFOLD R&R & CLEAN, 1 TREATMENT REQUIRED A449-211 5.6 5.3 DGN-42 INTAKE MANIFOLD R&R & CLEAN, 2 TREATMENTS REQUIRED AND 1 ENGINE OIL CHANGE A449-212** 7.6 7.3 DGO-42 INTAKE MANIFOLD R&R & CLEAN, 3 TREATMENTS REQUIRED AND 1 ENGINE OIL CHANGE A449-213** 9.3 9.0 DGP-42 INTAKE MANIFOLD R&R & CLEAN, 4 TREATMENTS REQUIRED AND 2 ENGINE OIL CHANGES A449-214** 11.3 11.0 DGQ-42 Bulletin Number: 09-74-21R; Revised: 09/27/22 Page 10 of 11 Continued… DINA (N/A) MODELS ONLY P.E.A. CLEANING PROCEDURE REQUIRED Model Applicability Crosstrek Sport, Fail Codes Leg / Obk, Forester Impreza / Crosstrek 2.0 DINA INTAKE MANIFOLD R&R & CLEAN, 1 TREATMENT REQUIRED A449-201 7.1 6.9 DGN-42 INTAKE MANIFOLD R&R & CLEAN, 2 TREATMENTS REQUIRED AND 1 ENGINE OIL CHANGE A449-202 9.6 9.4 DGO-42 INTAKE MANIFOLD R&R & CLEAN, 3 TREATMENTS REQUIRED AND 1 ENGINE OIL CHANGE A449-203 12.1 11.9 DGP-42 INTAKE MANIFOLD R&R & CLEAN, 4 TREATMENTS REQUIRED AND 2 ENGINE OIL CHANGES A449-204 14.9 14.7 DGQ-42 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. Bulletin Number: 09-74-21R; Revised: 09/27/22 Page 11 of 11 Appendix A: Service Procedure Flow Chart Diagnose following applicable Service Manual. Perform P.E.A. Cleaning Procedure starting with Step 3. COMPLETE. Return vehicle to the customer. Follow SOA Escalation Process. DI (NA) or DIT (Turbo) engine is operating erratically Confirmation road test, Drive Cycle A or B Any DTC(s) other than P030X? Any DTC(s) other than P030X? Remove intake manifold assembly and inspect for carbon, soot or deposits inside it and / or on the intake valves. Were any deposits verified? 2.5L DINA engine with P030X? Read Roughness Counter (2.5L DINA ONLY) and record results. Confirm the fuel tank is FULL Add 1 full bottle of P.E.A to the fuel tank (Step 3). Install the cleaning tool with 1 full bottle of P.E.A. to the intake manifold Steps 4-6. Remove the cleaning tool. Perform burning of carbon deposits from the spark plugs procedure (Step 8). NOTE: NOT necessary when additional P.E.A. applications are required. Begin application of PEA into intake manifold (Step 7). Perform confirmation road test, Drive Cycle A or B. Has the symptom (rough idle, etc.) been eliminated? If NO, (on 2.5L DINA w/ P030X ONLY) has the Roughness Counter number decreased to below 34? Successful after after SECOND, THIRD or FOURTH P.E.A. application? Change the engine oil after the SECOND and FOURTH P.E.A. application. Diagnose other DTC(s) following applicable Service Manual. Check all spark plugs and ignition coils per Service Manual procedures. YES NO YES NO YES YES NO NO YES YES NO NO Free of any DTC(s)? YES Diagnose other DTC(s) following applicable Service Manual.
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