NHTSA ID Number: 10092533
Manufacturer Communication Number: WQP-51R
TSB/Document Date: 2017-02-22
Summary
SUBARU
IS CONDUCTING THIS LIMITED REGIONAL RECALL TO REPLACE THE FRONT PASSENGER AIR BAG INFLATORS PRODUCED BY TK HOLDINGS, INC. (TAKATA) IN CERTAIN 2003-2005 MODEL YEAR LEGACY, OUTBACK, AND BAJA VEHICLES AND CERTAIN 2004-2005 MODEL YEAR IMPREZA (INCLUDING WRX/STI) VEHICLES CURRENTLY OR PREVIOUSLY REGISTERED IN THE FOLLOWING AREAS OF HIGH ABSOLUTE HUMIDITY.
•
Disconnect the airbag module harness connector (A) and release it from the support
beam bracket.
Continued...
Bulletin Number: WQP-51R; Revised: August 24, 2015
Page 7
•
Remove the 3 retaining bolts and CAREFULLY remove the airbag module from
the vehicle and place it on a clean cloth to protect the dash trim outer surface portion
from damage.
IMPORTANT: DO NOT destroy or damage the Kit Box as it MUST be used for the
original inflator’s return shipping.
•
Open the Kit Box and confirm all the necessary components are included:
4 Self-Locking nuts
New Inflator (yellow tape applied to one end to identify it as the replacement part)
New Inflator Harness
Electro-Tap (red shorting crimp connector)
Shipping Declaration document, FedEx document pouch and return shipping label
Continued...
Bulletin Number: WQP-51R; Revised: August 24, 2015
Page 8
•
IMPORTANT: The removed airbag module must be mounted to the Airbag
Deployment Fixture (part number J-39401-B) as shown in the photo below to
better secure it during the inflator and wiring harness component replacement
procedures. When mounting the module to the fixture, pay close attention to the
harness routing as shown in the photo below. Always perform this work in an area
away from others to reduce chances of inadvertent injury should any deployment
occur. Take your surroundings into account to avoid possible hazards should
inadvertent deployment occur or sources of static or other electricity that could
potentially induce such a deployment.
STEP 2- Remove the harness clip from the retainer bracket by rotating the harness / clip 90
degrees then releasing it from the bracket with needle-nose pliers.
STEP 3- CAREFULLY cut the yellow harness cover (approximately 1 1/2 inches) enough
to expose the 2 yellow wires inside and provide enough room to install the Electro-Tap
(shorting) connector using a scissor or wire cutter (no knives or razors). TAKE YOUR
TIME AND BE CAREFUL TO NOT CUT THE 2 YELLOW WIRES!
Continued...
Bulletin Number: WQP-51R; Revised: August 24, 2015
Page 9
STEP 4- Short the 2 yellow wires together by installing the Electro-Tap connector. The
connector creates a short circuit which acts as a safeguard to prevent against static discharge
that may deploy the removed inflator. The tab portion of the Electro-Tap connector MUST
be cut off prior to use to insure a good short-circuit is made as shown in the illustration below.
Follow the sequence below for installing the Electro-Tap connector. Use pliers to squeeze
closed the two sections of the connector together, one section at a time.
This tab MUST
be cut off
Insert 1 wire in
the Electro-Tap
Fold
1
2
3
Place the other
wire in the
Electro-Tap,
fold then crimp
closed with pliers
Crimp closed
with pliers
4
5
STEP 5- Once the Electro-Tap connector is fully crimped in place, cut the 2 yellow wires on
the body harness connector side of the Electro-Tap connector.
CUT
Continued...
Bulletin Number: WQP-51R; Revised: August 24, 2015
Page 10
STEP 6- Remove the two 8mm self-locking nuts securing the stopper plate. Loosen but do
not remove the other two nuts on the mounting bracket as leaving them in place will help
keep the airbag assembly together.
NEVER ATTEMPT TO REMOVE THE HARNESS CONNECTORS FROM THE
INFLATOR!
Stopper Plate
STEP 7- With the stopper plate removed and the other 2 self-locking nuts loosened, unseat
the inflator off the mounting bracket end plate then rotate it slightly CLOCKWISE to make it
easier to remove as shown below. Slide the original inflator out of the mounting bracket while
feeding the cut off portion of the wiring harness through the “D-Shaped” hole in the end plate.
NEVER ATTEMPT TO REMOVE THE HARNESS CONNECTORS FROM THE
INFLATOR! Place the removed original air bag inflator in the “cradle” of the Kit Box insert.
Continued...
Bulletin Number: WQP-51R; Revised: August 24, 2015
Page 11
STEP 8- VERY IMPORTANT: Record the FedEx Shipper Receipt Number (located at
the top of the return shipping label included with the new inflator) and the 11-digit alphanumeric serial number for both the new and the removed inflators on the hard copy of
the Repair Order. This information will be required for completion of the Part Return Notice
which will be forwarded by the retailer to the PCC.
STEP 9- Install the new inflator into the mounting bracket so the yellow taped end aligns with
the removed stopper plate. Make sure the “D-shaped” portion of the inflator harness connector
boss aligns with the “D-shaped” portion of the hole in the end of the mounting bracket as
shown below. When properly installed, the end of the inflator will be seated tight against the
mounting bracket. Do not peel the white harness connection dust cover at this time.
Inflator properly
seated against
mounting bracket
(NO GAP)
STEP 10- As shown below, install but do not fully tighten 2 of the NEW self-locking nuts
while holding the stopper plate tight against the inflator. Remove the nuts still installed on
the mounting bracket and replace them with 2 NEW self-locking nuts. Once all 4 NEW nuts
are in place, torque to 31 - 38 inch pounds in the sequence shown below. Use a marker to
mark the nuts after torquing to indicate they have been fully tightened.
3
1
2
4
Continued...
Bulletin Number: WQP-51R; Revised: August 24, 2015
Page 12
STEP 11- The new inflator wiring harness has a “long side” and a “short side” with round 2-pin
connectors on both ends. The short side with red wires will connect to the end of the inflator
with the round wiring harness connector boss, yellow tape and removable stopper plate. VERY
IMPORTANT: When connecting the new harness to the inflator, both sides of the harness
MUST be routed toward the module’s mounting brackets as shown in the photos below.
Peel off the white dust cover from the round connector boss end of the inflator ONLY.
CAREFULLY align the pins with the female terminals of the harness connector (2 red
wires) as shown in the sequence below. IMPORTANT: NEVER PEEL BOTH THE
WHITE DUST COVERS OFF AT THE SAME TIME! Once pin alignment is confirmed,
push down firmly to engage the connector’s 3 locking tangs into the locking groove inside
the connector boss. Confirm the connector is locked by prying up LIGHTLY with a small
flat-blade screwdriver. Repeat the procedure on the D-shaped connector boss end (2 yellow
wires). Reinstall the black wiring harness retaining clip into the mounting bracket to
complete the airbag reassembly.
Locking Groove
STEP 12- Reinstall the airbag assembly into the vehicle in reverse order of disassembly.
Before installing the glove box assembly, reconnect the negative battery cable. Turn the
ignition key “ON” and confirm the AIRBAG warning light comes on then cycles off properly.
Once proper warning light operation is confirmed, reinstall the glove box assembly to
complete the procedure.
STEP 13- Place the removed original air bag inflator in the “cradle” of the Kit Box insert,
with a completed SOA warranty parts tag (MSA5W402A) attached to it. The tag must
contain the following information: Claim Number, Repair Date, 17-digit VIN, and vehicle
mileage. Refer to the “PARTS RETURN PROCEDURES” section of this bulletin (page
4) for further return shipping instructions and information. Ensure both the removed and
installed inflator serial numbers along with the FedEx Shipper Receipt number have
been recorded correctly as previously instructed on the repair order hard copy before
returning the removed part to your Parts Department.
IMPORTANT: UNDER NO CIRCUMSTANCES SHOULD ANY AIR BAG
INFLATORS BE RETURNED TO SUBARU OF AMERICA, INC.
• Refer to Page 29 for instructions on completing and installing the Recall
Identification Label.
Continued...
Bulletin Number: WQP-51R; Revised: August 24, 2015
Page 13
*SERVICE PROCEDURE FOR 2004-05MY IMPREZA, WRX and STI MODELS*
CAUTION: Refer to the “CAUTION” section in the General Description portion
of Airbag System AB in the Body Section of the Service Manual before handling or
servicing the airbag module!
STEP 1- PREPARATION:
•
•
•
Turn the ignition “OFF”.
Disconnect the Negative (ground) cable from the battery and wait at least 20 seconds
before proceeding further.
Remove the glove box assembly following the procedure in the applicable Service
Manual.
IMPORTANT: Whenever beginning to remove (or install) the airbag assembly, and
periodically while performing the procedure or after stepping away, remove any possible
static charge from your body by momentarily touching a clean, bare metal ground point
on the vehicle (e.g. the door striker). Remove from your person all electronic devices
including cellphones before proceeding.
•
Disconnect the airbag module harness connector
from the support beam bracket.
•
Remove the 3 retaining bolts and CAREFULLY
remove the airbag module from the vehicle and
place it on a clean cloth to protect the dash trim
surface portion from damage.
NOTE: There may be a Security Module secured
with the lower airbag module mounting bolt on some
models.
IMPORTANT: DO NOT destroy or damage the kit box as it MUST be used for the
original inflator’s return shipping.
•
Open the Kit Box and confirm all the necessary components are included:
4 Self-Locking nuts
New Inflator (yellow tape applied to one end to identify it as the replacement part)
New Inflator Harness
Electro-Tap (red shorting crimp connector)
1 ½” X 2 ¼” piece of self-adhesive Sponge Tape
Shipping Declaration document, FedEx document pouch and return shipping label
Continued...
Bulletin Number: WQP-51R; Revised: August 24, 2015
Page 14
•
IMPORTANT: The removed airbag module must be mounted to the Airbag
Deployment Fixture (part number J-39401-B) as shown in the photo below to
better secure it during the inflator and wiring harness component replacement
procedures. Always perform this work in an area away from others to reduce chances
of inadvertent injury should any deployment occur. Take your surroundings into
account to avoid possible hazards should inadvertent deployment occur or sources of
static or other electricity that could potentially induce such a deployment.
STEP 2- Peel the Sponge Tape and remove the harness clip from the retainer bracket by
pushing the tangs inward with a flat-blade screwdriver as shown below. Always remove any
Sponge Tape adhesive residue from the airbag mounting bracket using mild solvent on a clean
shop cloth. CAUTION: Never use any silicone-based products for this purpose.
STEP 3- CAREFULLY cut the yellow harness cover enough (approximately 2 inches) to
expose the 2 red or yellow wires inside and provide enough room to install the Electro-Tap
(shorting) connector using a wire cutter or scissor (no knives or razors). TAKE YOUR
TIME AND BE CAREFUL TO NOT CUT THE 2 WIRES!
Red Wires
Yellow Wires
Continued...
Bulletin Number: WQP-51R; Revised: August 24, 2015
Page 15
STEP 4- Short the 2 wires together by installing the Electro-Tap connector. The connector
creates a short circuit which acts as a safeguard to prevent against static discharge that may
deploy the removed inflator. The tab portion of the Electro-Tap connector MUST be cut off
prior to use to insure a good short-circuit is made as shown in the illustration below. Follow
the sequence below for installing the Electro-Tap connector. Use pliers to squeeze closed the
two sections of the connector together, one section at a time.
This tab MUST
be cut off
Insert 1 wire in
the Electro-Tap
Fold
2
3
Place the other
wire in the
Electro-Tap,
fold then crimp
closed with pliers
Crimp closed
with pliers
4
5
STEP 5- Once the Electro-Tap connector is fully crimped in place, cut the 2 wires on the
body harness connector side of the Electro-Tap connector.
CUT
STEP 6- Remove the two 8mm self-locking nuts securing the stopper plate. Loosen but do
not remove the other two nuts on the mounting bracket as leaving them in place will help
keep the airbag assembly together.
Remove
Continued...
Bulletin Number: WQP-51R; Revised: August 24, 2015
Page 16
STEP 7- With the stopper plate removed and
the other 2 self-locking nuts loosened, unseat
the inflator off the mounting bracket end
plate then rotate it slightly CLOCKWISE
to make it easier to remove as shown in the
photo to the right. Slide the inflator out of its
mounting while feeding the cut off portion of
the wiring harness through the “D-Shaped”
hole in the end of the mounting bracket.
NEVER ATTEMPT TO REMOVE THE
HARNESS FROM THE INFLATOR!
Place the removed original air bag inflator in
the “cradle” of the Kit Box insert.
STEP 8- VERY IMPORTANT: Record the FedEx Shipper Receipt Number (located at
the top of the return shipping label included with the new inflator) and the 11-digit alphanumeric serial number for both the new and the removed inflators on the hard copy
of the Repair Order. This information will be required for completion of the Part Return
Notice which will be forwarded by the retailer to the PCC. The new serial number is also a
requirement for claim entry.
STEP 9- Install the new inflator into the mounting bracket with the harness connector end going
in first toward the mounting bracket. Make sure the “D-shaped” portion of the inflator harness
connector boss aligns with the “D-shaped” portion of the hole in the end of the mounting
bracket as shown below. When properly installed, the end of the inflator will be seated tight
against the mounting bracket. Do not peel the white harness connection dust cover at this time.
Inflator properly
seated against
mounting bracket
(NO GAP)
Continued...
Bulletin Number: WQP-51R; Revised: August 24, 2015
Page 17
STEP 10- As shown below, install but do not fully tighten 2 of the NEW self-locking nuts
while holding the stopper plate tight against the inflator. Remove the nuts still installed on the
mounting bracket and replace them with 2 NEW self-locking nuts. Once all 4 NEW nuts are
in place, torque to 31 - 38 inch pounds in the sequence shown below. Use a marker to mark
the nuts after torquing indicating they have been fully tightened.
STEP 11- VERY IMPORTANT: When connecting the new harness to the inflator,
the harness MUST be routed toward the module’s mounting brackets as shown in the
photo below. Peel off the white dust cover and CAREFULLY align the 2 inflator pins with
the female terminals of the harness connector as shown in the sequence below. Once pin
alignment is confirmed, push down firmly to engage the connector’s 2 locking tangs into the
locking groove of the connector boss. Confirm the connector is fully locked by prying up
LIGHTLY with a small flat-blade screwdriver.
Locking Groove
STEP 12- Reinstall the wiring harness retaining clip into its position on the mounting bracket.
Continued...
Bulletin Number: WQP-51R; Revised: August 24, 2015
Page 18
STEP 13- Peel the adhesive backing and install the new Sponge Tape onto the yellow harness
tube first then adhere it to the airbag mounting bracket as shown in the illustrations below.
IMPORTANT: The
Sponge tape must be
installed more than
half-way around the
yellow harness tube.
Harness
Sponge Tape
STEP 14- Reinstall the airbag assembly into the vehicle in reverse order of disassembly.
NOTE: If the accessory security module is installed to one of the airbag module mounting
bolts, torque that specific bolt to 7.5 +/-1ft. lb. rather than the normal 5.4 ft. lb. specified in
the Service Manual. Before installing the glove box assembly, reconnect the negative battery
cable. Turn the ignition key “ON” and confirm the AIRBAG warning light comes on then
cycles off properly. Once proper warning light operation is confirmed, reinstall the glove
box assembly while making sure the cord loop for the opening dampener (if equipped) stays
connected to complete the procedure.
STEP 15- Place the removed air bag inflator in the “cradle” of the Kit Box insert, with a
completed SOA warranty parts tag (MSA5W402A) attached to it. The tag must contain the
following information: Claim Number, Repair Date, 17-digit VIN, and vehicle mileage.
Refer to the “PARTS RETURN PROCEDURES” section of this bulletin (page 4) for further
return shipping instructions and information.
IMPORTANT: UNDER NO CIRCUMSTANCES SHOULD ANY AIR BAG
INFLATORS BE RETURNED TO SUBARU OF AMERICA, INC.
•
Refer to Page 29 for instructions on completing and installing the Recall
Identification Label.
Continued...
Bulletin Number: WQP-51R; Revised: August 24, 2015
Page 19
*SERVICE PROCEDURE FOR 2005MY LEGACY / OUTBACK MODELS*
CAUTION: Refer to the “CAUTION” section in the General Description portion
of Airbag System AB in the Body Section of the Service Manual before handling or
servicing any airbag module!
STEP 1- PREPARATION:
•
•
•
•
•
Turn the ignition “OFF”.
Disconnect the Negative (ground) cable from the battery and wait at least 20 seconds
before proceeding further.
Follow the procedures in the applicable Service Manual for removing the instrument
panel assembly as required to access the passenger side airbag module.
Disconnect the wiring harness and remove the airbag module.
Secure the airbag module to the Airbag Deployment Fixture (part number J-39401-B)
as shown in the photo below.
IMPORTANT: Whenever beginning to remove (or install) the airbag assembly, and
periodically while performing the procedure or after stepping away, remove any possible
static charge from your body by momentarily touching a clean, bare metal ground point
on the vehicle (e.g. the door striker). Remove from your person all electronic devices
including cell phones before proceeding.
IMPORTANT: DO NOT destroy or damage the Kit Box as it MUST be used for the
original inflator’s return shipping.
Open the Kit Box and confirm all the necessary components are included
•
•
•
•
•
•
•
4 Self-Locking nuts
New Inflator (yellow tape applied to one end to identify it as the replacement part)
New Inflator Harness
Electro-Tap (red shorting crimp connector)
New Stopper Plate with D-Shaped hole
Self-Adhesive Foam Protector
Shipping Declaration document, FedEx document pouch and return shipping label
Continued...
Bulletin Number: WQP-51R; Revised: August 24, 2015
Page 20
To access the passenger’s airbag module, the complete instrument panel assembly must
be removed. Follow the procedures in the applicable Service Manual for removing the
instrument panel assembly in addition to the necessary related interior trim components.
NOTE: When removing the “A” pillar trim, be VERY CAREFUL not to damage the upper
metal retaining clip. The clip is located just below where the trim panel meets the head liner.
If the metal retaining clip becomes damaged or separated from the trim panel, the trim panel
MUST be replaced as the clip is not available separately. Use a plastic trim tool to push
and release the upper portion of the metal clip from the body. Be careful to not pull the trim
panel open any further than necessary to gain access for releasing the clip. There is a plastic
retaining clip in the lower portion of the trim panel which will release easily once the upper
retaining clip is loose. At reassembly and using a plastic trim tool, make sure the inner lip of
the door weatherstrip overlaps the outer fabric edge of the trim panel to help secure it.
1
Insert Trim Tool
2
Push to
Release
3
4
Lip of Door
Weatherstrip
Overlaps Fabric
Edge of Trim Panel
Continued...
Bulletin Number: WQP-51R; Revised: August 24, 2015
Page 21
Once the instrument panel assembly has been removed from the vehicle, CAREFULLY
separate the airbag module from it.
IMPORTANT: The removed airbag module must be mounted to the Airbag Deployment
Fixture (part number J-39401-B) as shown in the photo below to better secure it during
the inflator and wiring harness component replacement procedures. When mounting the
module to the fixture, pay close attention to the harness routing as shown in the photo below.
Always perform this work in an area away from others to reduce chances of inadvertent
injury should any deployment occur. Take your surroundings into account to avoid possible
hazards should inadvertent deployment occur or sources of static or other electricity that could
potentially induce such a deployment.
STEP 2- Remove both sides of the harness from the retainer bracket holders.
Continued...
Bulletin Number: WQP-51R; Revised: August 24, 2015
Page 22
STEP 3- CAREFULLY cut the yellow harness cover (approximately 1 1/2 inches) enough to
expose the 2 yellow and red wires inside and provide enough room to install the Electro-Tap
(shorting) connector using a scissor or wire cutter (no knives or razors).
TAKE YOUR TIME AND BE CAREFUL TO NOT CUT THE 2 WIRES!
STEP 4- Short the yellow and red wires together by installing the Electro-Tap connector. The
connector creates a short circuit which acts as a safeguard to prevent against static discharge
that may deploy the removed inflator. The tab portion of the Electro-Tap connector MUST be
cut off prior to use to insure a good short-circuit is made as shown in the illustration below.
Follow the sequence below for installing the Electro-Tap connector. Use pliers to squeeze
closed the two sections of the connector together, one section at a time.
This tab MUST
be cut off
Insert 1 wire in
the Electro-Tap
Fold
1
2
3
Place the other
wire in the
Electro-Tap,
fold then crimp
closed with pliers
Crimp closed
with pliers
4
5
Continued...
Bulletin Number: WQP-51R; Revised: August 24, 2015
Page 23
STEP 5- Once the Electro-Tap connector is fully crimped in place, cut the yellow and red
wires on the body harness connector side of the Electro-Tap connector as shown below.
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TSB/Document ID: WQP-51R
Replacement Service Bulletin Number:
MFR Communication Date: 2015-08-24
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: AIR BAGS
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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