NHTSA ID Number: 10174539
Manufacturer Communication Number: WRD-20R
TSB/Document Date: 2020-05-04
Summary
Subaru
of America, Inc. (Subaru) is initiating a new safety recall for certain 2019 model year Ascent, Impreza, Legacy, and Outback vehicles in which the fuel pump may become inoperative.
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TSB/Document ID: WRD-20R
Replacement Service Bulletin Number:
MFR Communication Date: 2020-04-29
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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ATTENTION:
GENERAL MANAGER
q
PARTS MANAGER
q
CLAIMS PERSONNEL
q
IMPORTANT - All
Service Personnel
Should Read and
Initial in the boxes
provided, right.
SERVICE MANAGER
q
© 2020 Subaru of America, Inc. All rights reserved.
PRODUCT CAMPAIGN BULLETIN
APPLICABILITY:
SUBJECT:
2019MY Legacy and Outback 2.5 and 3.6L
2019MY Impreza
2019MY Ascent
Fuel Pump Impeller Failure
NUMBER: WRD-20R
DATE: 04/23/20
NHTSA: 20V-218
REVISED: 04/29/20
INTRODUCTION:
Subaru of America, Inc. (Subaru) is initiating a new safety recall for certain 2019 model year Ascent,
Impreza, Legacy, and Outback vehicles in which the fuel pump may become inoperative.
DESCRIPTION OF THE DEFECT AND SAFETY RISK:
The affected vehicles may be equipped with a low pressure fuel pump which includes an impeller
that was manufactured with a lower density. If the surface of the lower density impeller is exposed
to solvent drying for longer periods of time, it may develop fine cracks. Those cracks may lead to
excessive fuel absorption, resulting in impeller deformation. Over time, the impeller may become
deformed enough to interfere with the body of the fuel pump, potentially causing the low pressure
fuel pump to become inoperative.
If the low pressure fuel pump becomes inoperative, the check engine warning light or malfunction
indicator light may illuminate, and/or the engine may run rough. In the worst case, an inoperative
fuel pump may result in the engine stalling without the ability to restart the vehicle, increasing the
risk of a crash.
AFFECTED VEHICLES:
A total of 188,207 U.S. vehicles will be affected by this recall, as listed below:
Model Year
Carline
Production Date Range
Affected Vehicle Count
2019
Ascent
June 26, 2018 - January 18,2019
40,950
2019
Impreza
June 18, 2018 – February 25, 2019
40,797
2019
Legacy
June 29, 2018 – February 19, 2019
20,182
2019
Outback
June 29, 2018 – February 19, 2019
86,278
Not all vehicles in the production ranges listed above are affected by this recall. Coverage must be
confirmed by using the Vehicle Coverage Inquiry function on Subarunet.com prior to repair. The
status of this recall will display as “Open - Remedy Not Yet Available” until parts are available to
support this recall.
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.
Continued...
Bulletin Number: WRD-20R; Revised: 04/29/20
Page 1 of 43
SERVICE, PARTS, AND CLAIM INSTRUCTIONS:
The remedy parts for this recall will begin to arrive later this month. Once there is a limited supply
available, the status of this recall will be changed to “Open – Limited Parts Available” to allow
repairs to begin if affected vehicles are presented for other services prior to owner notification.
Sufficient remedy parts supply is expected to be available prior to owner notification. Once available,
the remedy parts must be ordered through PRIME. Please refer to ‘Recalls & Campaigns/PRIME
Max Quantities’ on Subarunet for the orderable quantities.
RETAILER RESPONSIBILITY:
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 Retailer failing to perform the applicable service procedures to correct all
affected vehicles in their inventory prior to the vehicle being placed in service may be subject
to civil penalties of up to $21,000 per violation (i.e., for each vehicle), as provided in 49 CFR
§578.6 and will also be in breach of the Subaru Dealer Agreement.
Any vehicles listed in any recall/campaign that are in retailer 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 the Product Campaign Bulletin
When parts are available, retailers are to promptly perform the applicable service procedures, to
correct all affected (EXCEPT Stop Sale) vehicles in their inventory (used, demo & SSLP).
STOP SALE vehicles may be repaired with existing replacement complete fuel pump assemblies
until the remedy kits specific to this recall become available. If necessary, the applicable fuel pump
assembly (and the necessary one-time use parts required for fuel pump assembly replacement) should
be ordered through normal parts ordering channels. Due to limited supply, complete fuel pump
assemblies are on hold and will only be released for STOP SALE vehicles. Therefore, please contact
the PICs with the affected STOP SALE VIN after the order is placed so the fuel pump assembly can
be released for the specific vehicle.
Once the remedy kits specific to this recall are available, whenever a vehicle subject to this recall is
taken into retailer inventory necessary steps should be taken to ensure the recall correction has been
made before selling or releasing the vehicle.
OWNER NOTIFICATION:
Subaru will notify affected vehicle owners by first class mail within 60 days. Retailers will be advised
when the notification is scheduled.
PARTS INFORMATION:
INTRODUCTION: Please Read Carefully
In order to expedite repairs to new, in-stock, sellable units, the limited use of existing inspected
and confirmed complete fuel pump assembly parts has been authorized.
Continued...
Bulletin Number: WRD-20R; Revised: 04/29/20
Page 2 of 43
As a result, this bulletin will include two sets of procedures:
•
The first addresses performing these repairs using available complete fuel pump
assemblies. These repairs are limited to new, in-stock inventory vehicles only.
•
The second covers the installation of recall fuel pump kits to the vehicle’s existing fuel
pump assembly.
Always confirm the vehicle being repaired and follow the related repair procedure as outlined
above.
VERY IMPORTANT NOTES:
•
Included in this campaign are a small number (44) of Stop Sale vehicles. To expedite the
repair and marketability of these Stop Sale vehicles ONLY, the complete fuel pump
assembly will be replaced. IMPORTANT: Additional one-time use parts will also be
required to install along with the new fuel pump assembly. See the Parts Information table
below.
•
The new complete fuel pump assemblies for these Stop Sale vehicles have all been inspected
and assembled with the new campaign fuel pump component part.
•
The shipping boxes for these fuel pump assemblies will have a special identification label
affixed to identify them as shown below. In addition, the fuel pump assembly itself will
have a Green dot / paint mark applied to the top flange adjacent to the fuel delivery pipe
connection.
PARTS APPLICABILITY TABLE FOR STOP SALE VEHICLES ONLY:
Description
Part Number
Application
Required 1-Time Use Parts:
42021AL02C
Legacy / Outback 2.5L
42021AL03C**
Legacy / Outback 3.6L
42025AL040 O-Ring
42043AL000 Cushion
42021FL02B
Impreza
42025FL01A O-Ring
PUMP ASSY FUEL
42025FL000 O-Ring
42021XC00A
Ascent
42057FL000 Cushion Plate
14497AA080 and 21896AA130
Intercooler Gaskets
** 42021AL03C inventory may be limited. If inventory is exhausted, repairs will switch to using the
Fuel Pump Kit p.n. X4202AL010.
VERY IMPORTANT: ONLY those parts with the bright-colored labels as shown here are to be used
for completing WRD-20 Stop Sale repairs.
Continued...
Bulletin Number: WRD-20R; Revised: 04/29/20
Page 3 of 43
For the remaining vehicles included in this campaign, the parts required to perform these repairs have
been assembled into kits, numbered for each model as follows and labeled accordingly as shown
below to help insure installation of the proper kit into the applicable model.
Description
WRD-20 Fuel
Pump Kit
Kit Part Number
Model Application
X4202AL000
Legacy / Outback 2.5L
X4202AL010
Legacy / Outback 3.6L
X4202FL000
Impreza
X4202XC000
Ascent
The illustrations below list the component part content breakdowns for each of the four kits:
X4202FLOOO/PUMP IMPREZA
Part Number
42029FL020**
42025FL01A
42032FL01A
42056FL000
Part Name
KIT FUEL PUMP: Contains fuel pump, filter sock, fuel
pump o-rings, and c-clip.
GASKET FUEL PUMP
RING NUT
PLUG TEMPORARY
Qty
Part Number
1
42029XC000**
1
1
1
42025FL000
42032FL000
42057FL000
42056FL000
X4202ALOOO/PUMP LEGACY/OBK 2.5L
Part Number
42029AL000**
42025AL040
42056FL000
Part Name
KIT FUEL PUMP: Contains fuel pump, filter sock, fuel
pump o-rings, c-clip, and fuel pump cushions (3).
GASKET FUEL PUMP
PLUG TEMPORARY
X4202XCOOO/PUMP ASCENT
Part Name
KIT FUEL PUMP: Contains fuel pump, filter
sock, fuel pump o-rings, and c-clip.
GASKET FUEL PUMP
RING NUT
PLATE RING NUT
PLUG TEMPORARY
Qty
1
1
1
1
1
X4202ALO1O/PUMP LEGACY/OBK 3.6L
Qty
Part Number
1
42029AL010**
1
2
42025AL030
42056FL000
Part Name
KIT FUEL PUMP: Contains fuel pump, filter sock, fuel pump
o-rings, c-clip, and fuel pump cushions (3).
GASKET FUEL PUMP
PLUG TEMPORARY
Qty
1
1
2
** NOTE: The “KIT FUEL PUMP” part numbers supplied are for reference only and cannot be
ordered separately.
Continued...
Bulletin Number: WRD-20R; Revised: 04/29/20
Page 4 of 43
ADDITIONAL REQUIRED MATERIALS / SPECIAL TOOLS:
•
42099FL030 Fuel Pipe Adapter: Connects directly to the
fuel pump outlet pipe at the fuel tank. Each retailer will be
receiving two (2) of these automatically when they become
available. NOTE: This tool is NOT required to repair Stop
Sale vehicles. Remove & discard the temporary plug before
use.
•
42075FG480 Hose Fuel: This is a commonly
available service part which can be used on all
the affected vehicles. This adapts the incoming
fuel supply pipe and a section of bulk rubber fuel
line. Each retailer will be receiving two (2) of
these automatically when they become available.
NOTE: These tools are NOT required to repair
Stop Sale vehicles. An additional fuel draining
procedure will be added to this bulletin once
these parts are available at retailers.
•
42099CA010 (for Legacy and Outback) and
42099FL020 (for Ascent and Impreza) Fuel
Tank Caps: To be put back into the fuel
pump opening in the fuel tank after pump
removal. These caps will help contain fuel
odors and prevent contamination from
entering the tank while the pump assembly
is removed. NOTE: Not required to repair
Stop Sale vehicles. Each retailer will be
receiving two (2) of each part number
automatically when they become available.
•
42099FL000 Ring Nut Wrench: Used to remove and install
the fuel pump assembly locking rings on Ascent
and Impreza. This is already a required essential Subaru
Special Service Tool.
•
18471AA000 Fuel Pipe Adapter: Used to drain fuel by
connecting one end to the supply pipe connector at the fuel
rail in the engine compartment and a length of bulk fuel hose
going to a safety gasoline container on the other. This tool is
already a required essential Subaru Special Service Tool and
will be only be needed when performing repairs if fuel
draining is required.
•
42099AE000 Release Tool: Used to disengage the fuel
pipe connector in the engine bay. This is already a required
essential Subaru Special Service Tool.
Continued...
Bulletin Number: WRD-20R; Revised: 04/29/20
Page 5 of 43
NOTE: These adapters are only necessary when there is a need to lower the fuel level in the fuel
tank:
• To drain fuel directly from the fuel pump outlet, use adapter 42099FL030.
•
To drain fuel from the fuel pipe hard line in the engine compartment, use adapter
42075FG480.
•
To drain fuel from the fuel rail connection in the engine compartment, use adapter
18471AA000.
In addition, some or all of the following 3) three items are needed to
facilitate draining the fuel tank when required.:
• A readily available 5/16” barbed hose connecting nipple
•
A 5-foot section of bulk 5/16” rubber fuel hose
•
Two (2) small fuel line hose clamps.
IMPORTANT: A length of door edge guard, flexible tubing or heavy duty electrical tape to apply
around the fuel pump access opening to avoid cuts / abrasions from sharp edges is required for all
fuel pump replacement repairs.
SERVICE PROCEDURES / TABLE OF CONTENTS:
VERY IMPORTANT NOTES:
•
It is CRITICAL to read and understand this bulletin completely BEFORE proceeding with
any repairs.
•
Currently, due to parts and special tool availability, this bulletin will concentrate on the
Service Procedures to address the 44 Stop Sale vehicles referenced above. The bulletin will
be revised once repairs to these vehicles have been completed.
•
The Stop Sale vehicles (ONLY) will be repaired by replacing the complete fuel pump
assembly.
•
The applicable complete fuel pump assembly part numbers are on HOLD and MUST be
released after ordering by contacting the Parts PICs group. A corresponding VIN applicable
to this campaign is required before the complete pump assembly order will be released.
ALWAYS refer to the parts table supplied above to order the additional one-time use part(s)
required to complete the repair.
Carline
Begins on Page
Legacy / Outback
9
Impreza & Ascent TIPS
17
Impreza
21
Ascent
30
Service Procedure Information for ALL MODELS:
NOTE: The following information is intended to SUPPLEMENT the following and Service Manual
procedures.
VERY IMPORTANT: To avoid gasoline spillage, THIS PROCEDURE MUST BE
PERFORMED WHEN THE FUEL LEVEL IN THE TANK IS AT OR BELOW 2/3 FULL. If
over 2/3 full, the tank will need to be drained to 2/3 or less before attempting to remove the complete
fuel pump assembly.
Continued...
Bulletin Number: WRD-20R; Revised: 04/29/20
Page 6 of 43
ALWAYS follow ALL the CAUTIONS and procedures for safely releasing fuel pressure and
draining fuel from the fuel tank as supplied in the applicable Service Manual.
ALWAYS remove the fuel filler cap to release any accumulated vapor pressure as a first step.
If draining fuel from the fuel tank is necessary, follow the applicable procedure this bulletin along
with “USING THE SELECT MONITOR” procedure in the applicable Service Manual.
When removing the rear seat cushion (all models
except Ascent), if the plastic retaining clips (a) (p.n.
64396KA010 for Legacy / Outback and 64333FJ000
for Impreza) in the floor come out, they become
one-time use items and MUST be replaced during
reassembly. When installing the seat cushion, always
confirm the seat belt buckles are returned to the proper
positions.
When removing the fuel pump access cover, there is a foam seal between the cover and the vehicle
body. Use CAUTION when removing the cover to not damage the foam seal. If found to be or if it
becomes damaged, the replacement seal part numbers are: 96077AJ00A for Legacy / Outback and
96077FL00A for Impreza and Ascent.
It cannot be stressed enough to have plenty of clean shop cloths and / or
absorbent pads available to use when removing the fuel line(s) from the fuel
pump. A small drip tray or pan is also recommended to use for catching any
dripping fuel when removing the fuel pump assembly from the tank.
IMPORTANT: When performing these procedures, shop cloths contaminated
with gasoline will be created. It is CRITICAL they be handled safely and
following proper disposal guidelines. Always store contaminated shop cloths in
an approved safety can as shown here.
After removing the rear seat cushion assembly and
the (main) fuel pump access cover, use a length
of small hose (sliced lengthwise), vinyl door edge
guard as shown here or electrical tape to cover the
edge of the access opening in the floor panel. This
will protect any removed fuel line(s) and Technician
hands from cuts or abrasions resulting from sharp
edges. The photo here shows the power harness
unplugged and shop cloths in place to absorb
residual fuel that may remain in the lines after
removal from the pump assembly. CAREFULLY
release the retaining clip(s) with a small flat-blade screwdriver, put a cloth over the connection and
remove the line(s). Immediately install the plug(s) provided in the replacement fuel pump kits into
the removed line(s) to avoid any spillage. This will help reduce the chances of post-repair customer
concerns of fuel odor inside the cabin.
On Legacy and Outback models, use a small container or magnetic dish to keep all the retaining ring
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