NHTSA ID Number: 10175966
Manufacturer Communication Number: WRD-20R
TSB/Document Date: 2020-06-02
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.
assembly, and separate the fuel filter assembly and fuel chamber
assembly as shown below.
Continued...
Bulletin Number: WRD-20R; Revised: 05/07/20
Page 34 of 47
•
After separating the fuel filter from the fuel chamber assembly,
inspect the fuel chamber to confirm the o-ring is not still in the
bore as shown here. If the o-ring remains, use a rubber -tipped
or plastic (non-marring) pick tool to CAREFULLY remove it
without scratching the fuel chamber bore.
•
Remove the fuel pump holder then
disengage the 3 claws securing the fuel
pump to the filter assembly.
•
Using the flat tip screwdriver (or equivalent) wrapped with a
protective tape, press on the fuel pump and remove the fuel pump
from the fuel filter assembly.
•
IMPORTANT: Confirm the o-ring is not stuck in the fuel filter
bore after removing the fuel pump. If needed, use a rubber-tipped
or plastic (non-marring) pick tool to CAREFULLY remove it
without scratching the filter assembly bore.
Plastic
Non-Marring
Pick Tool
•
IMPORTANT: Remove the
o-ring and spacer from
the original fuel pump.
The spacer is reused.
Put the removed pump
in a vise and crush it as
shown above to eliminate
any chance of it being
reused.
Transfer the white plastic spacer (B) to the new pump and install the new o-ring (A) from the
kit to hold the spacer in place. Always lubricate the new o-rings with gasoline.
Continued...
Bulletin Number: WRD-20R; Revised: 05/07/20
Page 35 of 47
8. Install the new fuel pump into the fuel filter assembly. Confirm all 3 retaining claws are fully
engaged.
•
Install the fuel filter assembly to the fuel chamber
assembly. Position tube (A) and spring (B) for the fuel
filter assembly as shown in the figure.
•
Confirm the fuel tube routing and make sure all the claws securing the fuel chamber to the
fuel filter assembly are fully engaged as shown in the photos shown below.
NOTE: In the images below, a section of the fuel chamber has been cut away to make the fuel pipe
routing visible for reference. Normally, these fuel pipes are inside the chamber and not visible except
at the top.
ALWAYS inspect closely for any seepage or leaks around ALL fuel delivery tube connections removed
as part of this repair (including those under the hood if fuel was drained) and around the ring nut.
•
Secure the fuel tube to the outside of the fuel chamber and
reconnect it at the bottom.
•
Push the fuel filter assembly in the direction of the arrow to
compress, and install the new clip supplied in the kit.
Continued...
Bulletin Number: WRD-20R; Revised: 05/07/20
Page 36 of 47
9. CAREFULLY refit the fuel level sensor assembly to the fuel chamber. Put the (thinner) fuel
lever sensor wires into the 2 retaining clips first followed by the fuel pump wires IN THAT
ORDER.
10. IMPORTANT: Wipe clean and thoroughly dry the red circled areas (gasket / ring nut contact
surfaces) as described and shown below: fuel tank rim (A) pump flange top face (B) and the
underside of the pump flange (C).
(A) Fuel Tank Rim
•
(B) Pump Flange Top Face
(C) Underside of Pump Flange
Use CAUTION to keep the fuel level sensor arm from contacting the fuel tank opening. If
the arm were to become bent, the fuel gauge may not read properly.
11. CAREFULLY reinstall the fuel pump assembly into the tank using the new gasket included in
the kit.
•
CRITICAL: DO NOT OVERLOOK RECONNECTING THE JET PUMP FUEL TUBE AT
THE BOTTOM OF THE FUEL CHAMBER.
•
After connecting the jet pump fuel tube, CAREFULLY lower the fuel pump assembly into
the tank and in the orientation shown in the photo below.
Continued...
Bulletin Number: WRD-20R; Revised: 05/07/20
Page 37 of 47
Pump
Indexing
Arrow
IMPORTANT: This photo shows
the NEW ring nut and (Blue) seal
plate included in the kit already
in place. The ASCENT ring nut
thread starting point is identified
by the 3 “teeth” close together
(RED circled). Align the center
(Green) tooth (position mark) with
the triangle ∆ mark between the
molded-in hash marks on the tank
(Blue arrows).
•
IMPORTANT: ALWAYS use the new gasket and blue ring nut seal plate included in the kit.
•
The photo above shows the thread STARTING POINTS for the ring plate and fuel tank.
There is a second set of molded-in hash marks 90 degrees CLOCKWISE from the starting
point hash marks which are the FINISHING POINT (End Range) hash marks shown as (c) in
the illustration below.
•
IMPORTANT: Before tightening the ring nut:
▪ Make sure the fuel delivery tube is ON TOP of the tool and not pinched under it
▪ Make sure the tool fits down fully and squarely onto the ring nut.
•
Using the ring nut tool, and the illustrations below as a guide, SLOWLY tighten the ring nut
ONE FULL TURN then continue until (b) is within the range of the End Range hash marks
(c).
•
CRITICAL: While tightening the ring nut, make sure the fuel pump does not rotate with
the ring nut otherwise, the fuel level sensor and the jet pump fuel tube may become damaged.
Always keep the Pump Indexing Arrow; (e) below and the fuel tank ring nut start mark (a)
below aligned.
STARTING POINT MARKS
END RANGE MARKS
Front of Vehicle
Continued...
Bulletin Number: WRD-20R; Revised: 05/07/20
Page 38 of 47
Fuel Tube on TOP of Tool
LEGEND FOR THE ABOVE ILLUSTRATIONS:
(a)
(b)
(c)
(d)
(e)
(f)
Front of Vehicle
Ring nut installation position start mark (on fuel tank)
Position mark (on ring nut)
Ring nut installation position end range hash marks (on fuel tank)
Fuel pump installation position range hash marks (on fuel tank)
Position (Index) mark (for fuel pump)
Toward FRONT of vehicle
•
NOTE: In a case where there is difficulty getting the ring nut threads started onto the fuel
tank threads, align the starting points, install the ring nut wrench then press down firmly
by hand on the ring nut wrench to “jump” the ring nut thread past the interference point. A
“pop” sound wil occur, the ring nut should now be parallel to the top of the fuel tank and able
to be tightened normally.
•
Using a caliper with depth gauge, measure the dimension in 3 positions between the top of
the ring nut and the top of fuel tank as shown in the illustration below. Confirm the measured
values of dimensions (D) are 23.8 ± 2.5 mm (0.937±0.098 in.).
LEGEND:
(A)
(B)
(C)
(D)
Caliper with depth gauge
Ring nut
Fuel tank
Dimension of ring nut and
top of fuel tank
(E) Measuring point
(F) Toward FRONT of
vehicle
CAUTION:
•
If the difference between any of the three measurements exceeds ±1.5mm or .060 inch, loosen
and re-tighten the ring nut to correct any cross-threading.
•
If the ring nut or fuel pump gasket are deformed, cracked or damaged, they MUST be replaced.
Continued...
Bulletin Number: WRD-20R; Revised: 05/07/20
Page 39 of 47
•
Remove and discard the plastic temporary plug from the fuel delivery pipe and re-connect the
pipe to the fuel pump outlet tube. Make sure the connector is all the way onto the outlet tube
then lock the slider. Tug on the fuel delivery pipe to be sure it is fully locked in place.
IMPORTANT REMINDERS: Discard the removed temporary fuel line plug as it is a one-time use
item. Reusing the plug may damage the connector’s internal o-ring and cause a fuel leak.
•
Ensure both the pipe and tube are clean and dry
•
If the slider does not move easily, confirm the pipe is engaged on the tube
•
ALWAYS confirm the pipe is fully engaged after connecting and check for any leaks
12. Reconnect the harness connector to the fuel pump.
13. Reconnect the ground cable and harness connector to the battery sensor. While supporting the
sensor with one hand, torque the 12mm ground cable nut to 7.5 Nm (5.5 ft. lbs.).
14. Turn on the ignition switch to run the fuel pump. The engine does not need to be started. Check
closely for any leaks around ALL fuel delivery tube connections removed as part of this repair
(including those under the hood if fuel was drained) and around the ring nut.
15. Reinstall the inspection cover.
16. Reinstall the r/rear second row seat and trim in reverse order of removal. Torque the retaining
bolts to 53 Nm (39 ft. lbs.) Make sure the seat belt buckles are properly positioned.
17. Return any removed fuel back to the vehicle.
18. Deodorize the vehicle interior as necessary.
END OF ASCENT SERVICE PROCEDURE
Continued...
Bulletin Number: WRD-20R; Revised: 05/07/20
Page 40 of 47
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES:
Credit to perform this recall will be based on properly completed repair order information. Retailers
may submit claims through Subarunet.com.
Labor Description
Labor
Operation #
WRD-20 Complete Fuel Pump Assembly
Replacement
B186-943
WRD-20 Fuel Pump Kit Replacement
B186-941
Drain Fuel Tank To 2/3 (if required)
Drain Fuel Tank To 2/3 (if required), Includes
Intercooler R&R
Applicability
Labor
Time
Legacy, Outback, Impreza
0.7
Ascent
0.9
Legacy, Outback, Impreza
0.9
Ascent
1.1
Legacy, Outback, Impreza
0.2
Ascent
0.5**
C186-945
Fail
Code
Claim
Type
WRD-20
RC
**NOTE: .5 can be claimed on Ascent only when intercooler R&R is required to use the 18471AA000 fuel pipe adapter for
draining the fuel tank. Once the 42089FL030 adapter is available to drain the tank by connection at the fuel pump, the
Labor Time will be reduced to .2 hrs.
IMPORTANT NOTES:
•
Each retailer will be supplied two (2) of each of the following special tools at “no charge”
when they become available.
○ 42099FL030
Fuel Pipe Adapter
○ 42099CA010
Fuel Tank Cap Legacy / Outback
○ 42099FL020
Fuel Tank Cap Ascent/ Impreza
○ SOA635161
•
Hose- Fuel See APPENDIX A starting on pg. 43 for more information.
Each retailer will receive a miscellaneous credit on their parts statement for:
○ Bulk 5/16” Fuel Hose, 10 ft- Quantity of four (4)
○ Brass Hose Adapter- Quantity of four (4)
○ Fuel Hose Clamps- Quantity of eight (8)
Continued...
Bulletin Number: WRD-20R; Revised: 05/07/20
Page 41 of 47
CALIFORNIA “VEHICLE EMISSION RECALL - PROOF OF CORRECTION”
CERTIFICATE
The California Air Resources Board and the Department of Motor Vehicles Registration/Recall
Program requires that all emission related Recall/Campaign or Service Program repairs be completed
before a vehicle registration is renewed. Please provide owners of vehicles registered in the state of
California a completed “Vehicle Emission Recall - Proof of Correction” certificate. Vehicle owners
should be advised to retain this certificate because the California Department of Motor Vehicles may
require they provide proof this service program repair has been completed.
Additional certificates are available through normal parts ordering channels using part number
MSA6P1301. Quantity 1 = 1 booklet of 50 certificates.
SERVICE PROGRAM IDENTIFICATION LABEL:
Type or print the necessary information on a Campaign Identification Label.
The completed label should be attached to the vehicle’s upper radiator support.
Additional labels are available through normal parts ordering channels. The part
number is MSA6P1302, which comes as one sheet of 20 labels.
Part Number
Applicability
Description
Order Quantity
MSA6P1302
All Models
Campaign Completion Labels (contains
one sheet of 20 labels)
1
WRD-20
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.
Continued...
Bulletin Number: WRD-20R; Revised: 05/07/20
Page 42 of 47
APPENDIX A
Alternate Procedure for Draining the Fuel Tank using Hose Adapter SOA635161.
The following information provides photo instruction for using the SOA635161 fuel adapter hose (1
of the 2 supplied) and 42099AE000 fuel line release tool to drain fuel from the tank when necessary.
The adapter connects to the hard metal fuel supply pipe in the engine compartment. In addition, a
readily available barbed hose connection nipple, 5’ length of 5/16” fuel hose, 2 small fuel line hose
clamps and a gasoline safety can are required.
SOA635161 Fuel Hose Adapter (1 of 2 Supplied)
42099AE000 Fuel Line Release Tool
Assemble the drain hose by inserting one end of the barbed nipple into the special tool adapter hose.
Insert the other end of the nipple into one end of the 5’ length of 5/16” fuel hose. IMPORTANT:
For extra safety, hose clamps are recommended on BOTH these connections. Put the other end of the
bulk fuel hose into the gasoline safety can. In-Use photos of the drain hose assembly are supplied
below.
Locate and remove the fuel pump fuse in the under-hood fuse box (M/B). Release the fuel pressure
by starting the engine and allowing it to run until it stalls. NOTE: Even after the engine stalls, there
will still be a small amount of residual pressure left in the fuel system. Crank the engine another 5
seconds with the starter to reduce it.
Use the 42099AE000 release tool as shown here to
remove the fuel supply hose from the hard metal
supply pipe coming from the tank.
IMPORTANT: Place a shop cloth over the
connection point while sliding the hose off the supply
pipe and another in the area underneath the connection
point to catch any remaining fuel in the hose or pipe
when the connection is opened.
42099AE000
Additional important steps for this procedure are supplied after the reference photos below. They
detail the connection points and proper hose routing for each application when draining fuel from
Legacy / Outback, Impreza and Ascent using one of the SOA635161 fuel hose adapter tools.
Continued...
Bulletin Number: WRD-20R; Revised: 05/07/20
Page 43 of 47
LEGACY / OUTBACK (locations are the same for 2.5L and 3.6L models):
Top view, looking down over l/side of engine compartment. Close-up of hose adapter installed
between strut tower and brake fluid reservoir.
Overall top view to better show connection point location.
Hose installation complete and ready for draining.
Continued...
Bulletin Number: WRD-20R; Revised: 05/07/20
Page 44 of 47
IMPREZA:
Top view, looking down over r/front of engine compartment. Close-up of hose adapter installed.
Overall top view to better show connection point location between intake duct and brake piping.
Hose installation complete and ready for draining.
Continued...
Bulletin Number: WRD-20R; Revised: 05/07/20
Page 45 of 47
ASCENT:
Top view, looking down over r/front of engine compartment. Close-up of hose adapter installed.
Overall top view to better show connection point location.
Hose installation complete and ready for draining.
Continued...
Bulletin Number: WRD-20R; Revised: 05/07/20
Page 46 of 47
•
After connecting the drain hose assembly securely, connect the SSM4, turn the ignition ON.
•
From the Active Test item menu, select Fuel Pump Control to operate the fuel pump. Drain
the fuel tank down until the fuel gauge reads at or below 2/3 full.
•
Remove the fuel line adapter using the fuel line release tool from the metal fuel supply pipe
while holding a shop cloth under the connection to catch any residual fuel spillage.
•
Hold the fuel line adapter and hose up together with a shop cloth as you move it away from
the car to prevent any spillage. Allow any residual fuel in the hose to drain into the storage
container.
•
Ensure the metal fuel supply pipe and vehicle fuel line are both clean and dry.
•
Reconnect the engine fuel line connector back onto the metal fuel supply pipe and confirm it
is fully engaged by lightly tugging on it.
•
Proceed with fuel pump replacement as outlined elsewhere in this bulletin by vehicle type.
IMPORTANT: Be sure to check this fuel connection for any leaks once the fuel pump replacement
is complete. There must be NO fuel leaks of any type from this or ANY fuel line connection.
Bulletin Number: WRD-20R; Revised: 05/07/20
Page 47 of 47
- Restores fuel economy
- Stabilizes ethanol
- Maximizes horsepower
- Improves responsiveness
- For use in both gasoline and diesel engines
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TSB/Document ID: WRD-20R
Replacement Service Bulletin Number:
MFR Communication Date: 2020-05-07
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT ADAPTIVE/MOBILITY
MFR Component System:
MFR Component Subsystem:
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