NHTSA ID Number: 10153623
Manufacturer Communication Number: WVJ-20R
TSB/Document Date: 2019-02-25
Summary
Subaru
of America, Inc. has determined that certain 2005 & 2006 Baja models may have been produced with a fuel pump plastic outlet pipe that may develop cracks and potentially cause a fuel leak. There is a potential safety risk associated with this condition. If cracks at the outlet pipe were to develop, a fuel leak could occur and pose a risk of a fire. This recall will involve replacement of the fuel pump assembly housing.
ATTENTION:
GENERAL MANAGER q
PARTS MANAGER
q
CLAIMS PERSONNEL q
SERVICE MANAGER
IMPORTANT - All
Service Personnel
Should Read and
Initial in the boxes
provided, right.
q
PRODUCT CAMPAIGN BULLETIN
APPLICABILITY:
SUBJECT:
2005~06MY Subaru
Baja
Fuel Pump Outlet Pipe
NUMBER: WVJ-20R
DATE: October 2009
REVISED: 12/21/18
INTRODUCTION
Subaru
of America, Inc. has determined that certain 2005 & 2006 Baja models may have been
produced with a fuel pump plastic outlet pipe that may develop cracks and potentially cause a
fuel leak.
There is a potential safety risk associated with this condition. If cracks at the outlet pipe were
to develop, a fuel leak could occur and pose a risk of a fire.
This recall will involve replacement of the fuel pump assembly housing.
AFFECTED VEHICLES
• All 2005 & 2006 Subaru
Baja models
Affected vehicles are identified in the VIN range chart below. Prior to performing repairs,
confirm coverage for potentially affected vehicles by using the Vehicle Coverage Inquiry
function at Subarunet.com.
MODEL
2005MY
Baja
2006MY
Baja
FROM
5*100002
6*100001
TO
5*108382
6*107749
* Various Characters may occupy this position
OWNER NOTIFICATION
SOA will prepare and mail Owner Notification Letters to owners of affected vehicles on or
around October 14, 2009.
A copy of the Owner Notification Letter is included at the end of this 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.
Bulletin Number: WVJ-20R; Revised: 12/21/18
SUBARU
OF AMERICA, INC. IS “ISO
14001 COMPLIANT”
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.
Page 1
DEALER PROGRAM RESPONSIBILITY
Dealers are 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 recall is taken into dealer new or used inventory, or is in the dealership
for service, necessary steps should be taken to ensure the recall correction has been made
before selling or releasing the vehicle.
New or used vehicles listed in a recall/campaign that are in dealer stock must be:
• Immediately identified.
• Tagged or otherwise marked to prevent their delivery or use prior to repair.
• Repaired in accordance with the repair procedures outlined in this Product
Campaign Bulletin.
Please be advised that it is a violation of Federal law for a dealer to deliver a new motor
vehicle covered by a recall under a sale or lease until the defect is remedied. Therefore, any
Authorized Subaru
Dealer failing to perform the applicable service procedures defined in
this bulletin to correct all affected vehicles in their inventory (new, used, demo) prior to the
vehicle being placed in service may be subject to civil penalties of up to $6,000 per violation
(i.e., for each vehicle), as provided in 49 USC §30165(a) of the Safety Act, and will also be in
breach of the Subaru
Dealer Agreement.
PARTS INFORMATION
Each affected vehicle will require replacement of the fuel pump housing. SOA will automatically pre-order and ship each dealer a supply of repair parts equivalent to 25% of their
affected owner list. Dealers will need to order any additional supply through normal part
ordering procedures.
DESCRIPTION
Fuel Pump Housing Kit*
Retainer Clamp
PART NUMBER
42029AE02A
42037AE110
*The Fuel Pump Housing Kit contains the following components:
BRKT Pump 42052AE76B (1 piece); Gasket / Large O Ring
42025AE020(1 piece); Gasket Pump 42025AE110 (1 piece).
SPECIAL TOOL INFORMATION
DESCRIPTION
Fuel Line Retaining Clamp
Removal Tool
PART NUMBER
42099AE000
Continued...
Bulletin Number: WVJ-20R; Revised: 12/21/18
Page 2
SERVICE PROCEDURE
This service procedure will involve replacement of the fuel pump housing and includes
transferring the fuel pump, fuel level sensor, and fuel filter from the original housing to the
new housing.
Fuel Pump Housing Replacement
WARNING:
• Place “Caution” signs near the work area indicating “No Fire” or “No Smoking”.
• Be careful not to spill fuel on the floor.
• Make sure there is no more than half a tank of fuel in fuel tank.
Fuel Pump Housing Removal
CAUTION: Use extreme care while performing the following steps. Gasoline contained
in the fuel tank is extremely flammable.
• Do not use electrical devices, such as drop lights, or other items that could
cause a spark.
• Do not allow smoking or other activities in the work area that could
result in ignition of fuel vapors.
• Be sure the vehicle’s battery is disconnected as indicated in these instructions.
1) Raise rear seat and turn floor mat up.
2) Remove the fuel pump access cover.
Continued...
Bulletin Number: WVJ-20R; Revised: 12/21/18
Page 3
3) Release fuel pressure:
• Disconnect the electrical connector from fuel pump.
• Start the engine and run it until it stalls.
• After the engine stalls, crank it for five more seconds.
• Turn ignition switch to OFF.
NOTE: Record radio pre-set stations.
4) Disconnect battery ground cable.
5)
Please use caution and observe the following instructions when separating the fuel pump
line connections. Note: The larger fuel line retainer clamp used on line “A” will be
replaced during reassembly. However, the smaller retainer clamps used on lines “B” and
“C” will be reused so use care not to cause damage during disassembly.
Delivery Sub (C)
Return (B)
Delivery (A)
Continued...
Bulletin Number: WVJ-20R; Revised: 12/21/18
Page 4
Separation of the Quick Connector on the Fuel Pump Delivery Line (A) Only
(1) Hold the connector and pick up the retainer clamp using your fingers.
Claws
Retainer Clamp
Pipe
Connector
(2) Pull out the connector from the retainer clamp.
Points to Notice
(A) Sticking is expected between the Connector and the Pipe. Prior to separation, push and
pull the connector in the pipe axis direction while holding up the retainer clamp with
your fingers. Pull out the connector in the pipe axis direction after the connector becomes
free. Never wiggle or add force to the pipe from the top and bottom or right and left.
Push In
Push In
(B) Follow the procedure below if the retainer clamp can not be lifted up using your fingers.
Pick up the retainer clamp with a thin tip tool like a pair of needle nose pliers. Since the
pipe must not be damaged, take care to pick up on the retainer clamp only.
Never damage
the pipe.
Only the retainer clamp
should be lifted up.
Continued...
Bulletin Number: WVJ-20R; Revised: 12/21/18
Page 5
Separation of the Quick Connector on the Fuel Pump Return
Line (B) and Delivery Sub (C)
Special Tool: 42099AE000
The special tool: 42099AE000, which is set up to separate fuel hoses with quick connectors in
the engine compartment, can also be used for return and delivery sub hoses. The quick connector can be unlocked by inserting the special tool around the pipe and pushing it forward as
shown. Pull out and separate the connector.
2) Pull out connector.
1) Insert and Push In.
6) Remove nuts which secure fuel pump assembly onto fuel tank
7) Carefully remove fuel pump assembly from fuel tank. To ease removal, lift up on the
float while removing. Do not attempt to force the pump assembly from the tank.
Continued...
Bulletin Number: WVJ-20R; Revised: 12/21/18
Page 6
Fuel Pump Housing Component Removal & Transfer
Gasket / O-Ring
Fuel pump
housing plate
Fuel Filter Housing
Gasket / O-Ring*
Fuel pump housing*
Fuel Filter
Fuel Filter
Housing
Fuel pump
housing gasket*
Fuel pump
Lower bracket
Fuel level
sensor
(*) Indicates replacement part contained in Fuel Pump Housing Kit P/N 42029AE02A
Fuel Pump
1) Remove fuel pump and pump holder from the housing by carefully spreading the two
adjacent plastic pawls with just enough pressure to release the tabs. Note: It is not
necessary to remove the pump holder or pick-up tube and sock from the fuel pump.
Damage to these components could occur if attempted.
2) Disconnect the electrical connector from fuel pump.
Continued...
Bulletin Number: WVJ-20R; Revised: 12/21/18
Page 7
Fuel Level Sensor
1) Disconnect the electrical connector from fuel pump bracket.
2) While pushing the pawls found on the back side of the fuel level sensor with a screw
driver, remove the sensor by pulling it downwards. Caution: Do not attempt to pry on
the clips found at the top and bottom of the sensor as this will cause permanent
damage to the sensor.
Fuel Filter and Housing
1) Disconnect the ground cable from filter holder.
2) Remove the filter holder by turning it to the left from the body pawls, and then
remove the filter.
Continued...
Bulletin Number: WVJ-20R; Revised: 12/21/18
Page 8
Ejector Pump
Remove the Ejector Pump from the Fuel Pump Bracket.
1) Hold the Pump Bracket Flange.
Ejector Pump
2) Put three fingers on the Ejector Pump, as indicated in the photo and illustration (this
should be done with the assistance of another person.)
Put three fingers on the Ejector
Pump as indicated and pull it out
while rotating. It is easier to do
if the pump bracket body is held
tightly by another person.
Continued...
Bulletin Number: WVJ-20R; Revised: 12/21/18
Page 9
3) Pull the Ejector Pump away from the Pump Bracket Flange pipes, while another person
holds the Pump Bracket Flange.
Pipes
Transfer all components to the new fuel pump housing, including the Ejector Pump as
follows:
Note: Be sure to use the new fuel filter housing large o-ring / gasket contained in the repair kit
when installing the filter.
Reinstallation Procedure of the Ejector Pump
1) Align the Ejector Pump holes with the Bracket Flange Pipes. Put your thumb on the
Ejector Pump as shown (below) and hold the Pump Bracket Flange with your fingers.
2) Push the Ejector Pump firmly toward the Pump Bracket Flange pipes.
Continued...
Bulletin Number: WVJ-20R; Revised: 12/21/18
Page 10
Install The New Fuel Pump Housing
IMPORTANT:
• Always use the new gaskets provided in the fuel pump housing kit.
• Ensure the sealing portion is free from fuel or foreign particles before installation.
1)
2)
Carefully reinstall the fuel pump housing into the fuel tank using caution while inserting
the fuel level float through the fuel tank opening. It will be necessary to hold the float up
to avoid interference with the inner tank fuel reservoir.
Tighten nuts in alphabetical sequence as shown to specified torque.
Tightening torque: 5.9 N•m (0.6 kgf-m, 4.3 ft-lb)
(K)
(L)
(M)
3) Reattach the fuel lines using a new retainer clamp on the fuel delivery line (K); part
number 42037AE110. Reuse the retainer clamps previously removed on lines (L) and
(M). NOTE: If any retainer clamps were damaged during removal replace with
new ones.
• When the connector is reconnected, be careful not to force, bend, or twist the pipe.
When the retainer was separated using the special tool or the retainer was replaced
with a new part:
Hold the connector body with your fingers, align the axis of the pipe and the
connector and then push in the pipe until the retainer clicks.
Continued...
Bulletin Number: WVJ-20R; Revised: 12/21/18
Page 11
•
When the retainer was separated by hand:
Hold the connector body with your fingers, align the axis of the pipe, fit the retainer
claw in the connector groove and push in the pipe until the retainer clicks.
Push and pull the connector lightly several times to ensure the pipe is fully engaged
with the connector. Also, visually check if the retainer claws are engaged with the
connector groove at both of the two points.
Push and pull to confirm
full engagement.
Visually check if the
retainer claws are
engaged with the
connector groove.
4) Reattach the fuel pump electrical connector.
5) Reconnect the battery.
6) Start vehicle and confirm there are no fuel leaks.
• Raise fuel pressure in the high pressure fuel lines and check for leakage at each
of the connectors, tubes and pipes.
7) Reinstall the fuel pump access cover and remaining components to their
original condition.
8) Reprogram radio pre-set stations.
Continued...
Bulletin Number: WVJ-20R; Revised: 12/21/18
Page 12
RECALL IDENTIFICATION LABEL
Type or print the necessary information on a recall 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) at
1-866- 782-2782.
W V J - 20
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES
Credit to perform this recall will be based on the submission of properly completed repair
order information. Dealers may submit claims through Vehicle Claim Entry on Subarunet.
CLAIM
TYPE
RC
CAMPAIGN
CODE
WVJ-20
LABOR
OPERATION
A 186-901
0.6 hrs.
LABOR
DESCRIPTION
Replace Fuel Pump
Assembly Housing
PART NUMBERS
Fuel Pump Housing Kit: 42029AE02A
Clamp Retainer: 42037AE110
Continued...
Bulletin Number: WVJ-20R; Revised: 12/21/18
Page 13
OWNER NOTIFICATION LETTER
Important Safety Recall Notice
Subaru
Recall Campaign WVJ-20
NHTSA Recall No. 09V-277
October 2009
Dear Subaru
Owner:
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety
Act. Subaru
of America, Inc. has decided that a defect which relates to motor vehicle safety
exists in 2005 & 2006 model year Subaru
Baja vehicles.
DESCRIPTION OF THE SAFETY DEFECT
Subaru
has determined that the plastic outlet pipe on your vehicle’s fuel pump may develop
cracks and potentially cause a fuel leak.
DESCRIPTION OF THE SAFETY HAZARD
The fuel pump is positioned at the top of the fuel tank which is located under the rear passenger seat. If cracks at the outlet pipe were to develop, a fuel leak could occur and pose a risk
of a fire.
REPAIRS
To correct this condition, Subaru
will replace the fuel pump bracket which contains the outlet
pipe. This repair will be performed at no cost to you.
WHAT YOU SHOULD DO
You should immediately contact your Subaru
Dealer for an appointment to have the fuel pump
bracket replaced. Even if your vehicle was previously repaired for this condition, it is still
necessary to make an appointment with your dealer to have the fuel pump bracket replaced to
insure that your vehicle is equipped with the new, modified part.
Since it will be necessary for your dealer to remove the fuel pump from your vehicle’s fuel
tank, it would be helpful if the tank were less than half full at the time of service.
There are two important precautions you should take until this repair has been performed:
• It is highly recommended that you not park your vehicle in a garage, car port
or other structure.
• If you notice the smell of gasoline, do not operate the vehicle. Immediately contact
your Subaru
dealer for assistance.
HOW LONG WILL THE REPAIR TAKE?
The actual time to replace the fuel pump bracket is approximately 36 minutes. However, it
may be necessary to leave your vehicle for a longer period of time on the day of your scheduled appointment to allow your dealer flexibility in scheduling.
Please present this letter to your Subaru
Dealer at the time this repair procedure is performed.
Continued...
Bulletin Number: WVJ-20R; Revised: 12/21/18
Page 14
IF YOU HAVE PREVIOUSLY PAID FOR A REPAIR
In the event that you have already paid for repairs associated with this condition, you may
be eligible for reimbursement. The actual sum reimbursed will be equivalent to the amount
Subaru
of America would reimburse an authorized Subaru
dealer in your area for replacement
of the fuel pump bracket.
Please send the original service repair order, which has complete information including the
name of the repair facility, date of repair, mileage at the time of repair, complete vehicle
identification number (17 digits), and your name, with correct mailing address and telephone
number to the address listed below.
Subaru
of America, Inc.
Customer Dealer Services Department
Attention: WVJ-20 Recall
P.O. Box 6000
Cherry Hill, NJ 08034-6000
Please send original receipts only and retain a photocopy for your records. Please be assured
that we will attempt to process your reimbursement request as quickly as possible, but may
take up to 60 days for this process to be completed.
CHANGED YOUR ADDRESS OR SOLD YOUR SUBARU
?
If you have moved or sold your vehicle, please complete the enclosed prepaid postcard and
mail it to us.
IF YOU NEED FURTHER ASSISTANCE
To locate the nearest Subaru
Dealer you can access our website at www.Subaru.com and
select “Find a Dealer”. Or, you may call us at 1-800-SUBARU3 (1-800-782-2783) during
normal business hours for assistance. Please call us immediately if the dealer fails or is unable
to make the necessary repairs free of charge or write to the address listed on the first page of
this letter.
You may also contact the Administrator, National Highway Traffic Safety Administration,
1200 New Jersey Ave. SE, West Building, Washington, DC 20590 or call the toll free Auto
Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153) or go to http://www.safercar.gov if
you believe the dealer has failed or is unable to remedy your vehicle without charge within a
reasonable amount of time.
Your continued satisfaction with your Subaru
is important to us. Please understand that we
have taken this action in the interest of your safety and your vehicle’s proper operation. We
sincerely apologize for any inconvenience this matter may cause and urge you to schedule an
appointment as soon as possible to have this repair performed.
Sincerely,
Subaru
of America, Inc.
Notice to Lessors
Under Federal law the lessor of a vehicle who receives this letter must provide a copy of it to the vehicle lessee(s) within 10
business days from receipt. The lessor must also keep a record of the lessee(s) to whom this letter is sent, the date sent, and
the applicable vehicle identification number (VIN). (For the purposes of this section, a lessor means a person or entity that in
the last twelve months prior to the date of this notification has been the owner, as referenced on the vehicle’s title, of any five
or more leased vehicles. A leased vehicle is a vehicle leased to another person for a term of at least four months.)
A subsidiary of Fuji Heavy Industries Ltd.
Bulletin Number: WVJ-20R; Revised: 12/21/18
Page 15
- Restores fuel economy
- Stabilizes ethanol
- Maximizes horsepower
- Improves responsiveness
- For use in both gasoline and diesel engines
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If the TSB PDF does not show, download or view it on the NHTSA Website.
Click on the (+) Plus Sign
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TSB/Document ID: WVJ-20R
Replacement Service Bulletin Number:
MFR Communication Date: 2018-12-21
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, GASOLINE
MFR Component System:
MFR Component Subsystem:
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