NHTSA ID Number: 10201055
Manufacturer Communication Number: WRG-21
TSB/Document Date: 2021-09-04
Summary
Subaru of America, Inc. (Subaru) is initiating a new safety recall for certain 2019-2020 MY Ascent, 2018-2019 MY BRZ, 2018 MY Forester (Turbo), 2018-2020 MY Impreza, 2018-2020 MY Legacy, 2018-2020 MY Outback, and 2018-2019 MY WRX vehicles in which the fuel pump may become inoperative.
FUEL PUMP ASSEMBLY COMPONENT BREAKDOWN
BRZ REAR SEAT MOUNTING POINTS
RING NUT WRENCH
42099CA000
•
NOTE: The fuel access cover on the BRZ is sealed differently than other models. The
BRZ uses butyl tape instead of a foam gasket. This will require the use of a protective sheet
supplied in the fuel pump kit for BRZ.
Continued...
Bulletin Number: WRG-21; Date: 08/24/21
Page 50 of 66
Removal of the Fuel Pump
•
Using a plastic trim tool CAREFULLY, remove the cover without bending or damaging the
sealing surfaces. Separate the harness from the cover and store the cover outside the vehicle.
This will help prevent the spread of butyl tape within the interior. When reinstalling the cover
and additional butyl tape is required, 3M TM Windo-Weld TM Ribbon Sealer #08610 can be
used.
Butyl Tape
42099CA02
•
Installation of the protective door edge guard around the service hole along with the supplied
protective sheet (42099CA020) is required to prevent the spread of butyl
tape.
•
Remove the ring nut with hand tools along with special
tool # 42099CA000.
Replacement of the Fuel Pump
•
Special attention is required regarding the jet pump o-ring. The o-ring is a one-time use part
and is supplied within the BRZ parts kit. Remove the o-ring from the fuel chamber using
a rubber-tipped or plastic (non-marring) pick tool to CAREFULLY remove it without
scratching the bore. A small amount of engine oil can be use when installing the new o-ring
onto the jet pump. Always confirm the o-ring is correctly seated.
Continued...
Bulletin Number: WRG-21; Date: 08/24/21
Page 51 of 66
•
Confirm the fuel pump harness is routed correctly. Install the thinner fuel lever sensor wires
into the two retaining clips before installing the larger pump wiring.
•
Leak test the fuel pump assembly to confirm there are no leaks PRIOR TO reinstalling the
assembly into the fuel tank. Using the Redline Smoke Pro, apply approximately 0.47PSI
(3.2Kpa) to the pump assembly as shown. Confirm the applied pressure can be held for 10
seconds. If the pressure can be held, continue with installation. If pressure cannot be held,
check the jet pump seating and o-ring condition. If the pump does not pass the leak test and
disassembly is required, it is IMPORTANT to never reuse the one-time use o-ring.
Continued...
Bulletin Number: WRG-21; Date: 08/24/21
Page 52 of 66
Installing the Fuel Pump Assembly
•
A different type gasket is used for BRZ.
•
Clean the gasket contact surfaces. Then install the gasket and fuel pump assembly as shown
below.
Ring Nut Marking:
•
Match the center index marking of the fuel tank with the fuel pump assembly as shown below.
Continued...
Bulletin Number: WRG-21; Date: 08/24/21
Page 53 of 66
•
Install the new plate (sealing) ring on top of the pump assembly followed by the ring nut.
•
Align the markings as shown (in yellow) below to ensure the proper thread starting point for
the ring nut. Turn the ring nut approximately one full rotation by hand. Take special care to
not allow the pump assembly to turn while tightening the ring nut.
•
Using special tool #42099CA000, torque the ring nut to 85Nm (62.7 ft-lbs.).
Continued...
Bulletin Number: WRG-21; Date: 08/24/21
Page 54 of 66
Height Adjustment Checks:
•
CRITICAL: The height measurement check MUST be performed as a final check to confirm
the ring nut is not cross-threaded. The height measurement is similar to other models except,
the BRZ requires the ring nut wrench to be installed while performing the measurement.
60mm should be measured in 3 positions around the ring wrench as shown below. Measure
from the top of the ring wrench to the top surface of the fuel tank.
Continue to: Fuel Tank Leak Test (APPENDIX C)
END OF TIPS FOR 2018-19MY BRZ MODELS
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES:
Credit to perform this recall will be based on properly completed repair order information.
Retailersmay submit claims through Subarunet.com.
Labor Description
WRG-21 Fuel Pump Kit
Replacement
Model
Labor Operation #
Labor Time
BRZ
B186-903
1.0
IMPREZA
B186-903
1.0
ASCENT
B186-903
1.2
LEGACY & OUTBACK
B186-903
FORESTER
B186-903
1.0
WRX
B186-903
1.0
ALL
C186-908
0.2
Up to 1/3 Tank Fuel Drained
1.0
Fail Code
Claim
Code
WRG-21
RC
Continued...
Bulletin Number: WRG-21; Date: 08/24/21
Page 55 of 66
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
IMPORTANT REMINDERS:
a. 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.
b. Always check for any open recalls or campaigns anytime a vehicle is in for servicing.
c. Always refer to STIS for the latest service information before performing any repairs.
Continued...
Bulletin Number: WRG-21; Date: 08/24/21
Page 56 of 66
APPENDIX A
Replacement Fuel Pump Component Installation Tips
These tips have been assembled to help Technicians successfully complete these repairs quickly
and accurately by identifying and clarifying specific repair areas which could lead to concerns after
reassembly. These conditions may include fuel supply concerns resulting from o-rings that are:
•
Damaged or torn
•
Out of position, pinched or stretched
•
Improperly installed in relation to the bushing (o-ring and bushing positions reversed).
CRITICAL STEP: After removing the
original fuel pump component from the
filter housing, ALWAYS confirm the
original o-ring either came out with the
pump or, it is removed from its bore
BEFORE atempting to install the new
fuel pump as shown here.
Both the illustration and picture below show the proper configuration of the fuel pump, bushing and
o-ring prior to reassembly. The new o-ring is positioned for proper sealing on top of the bushing.
A - NEW O-Ring Supplied in the Parts Kit
B - Bushing (Reused from Original Pump)
The images below are snapshots from a video which shows how the o-ring can become compromised
when repeated attempts are made to press / force the new fuel pump back into the filter housing. A
small “window” was cut into the filter housing used here to visually demonstrate how when repeated
attempts are made to get the new pump to engage the retaining claws of the original filter housing, the
o-ring can become dislodged from the fuel pump outlet tube and damaged. The new o-ring shown
below has been colored YELLOW to make it easier to see.
Continued...
Bulletin Number: WRG-21; Date: 08/24/21
Page 57 of 66
Three prime reasons for Technicians to have difficulties with getting the new pump to fully seat /
latch back into the filter housing properly are:
•
The original fuel pump o-ring is still in place in the filter housing bore
•
The new o-ring was not properly lubricated with gasoline prior to attempting the reassembly
•
Repeated attempts to get the pump fully seated have caused the o-ring to come of f the outlet
tube of the fuel pump as shown below.
CRITICAL TIP: Align and press the new fuel pump FIRMLY, SQUARELY and STRAIGHT
intothe filter housing in ONE smooth, continuous motion.
VERY IMPORTANT: When pressing the fuel pump into the filter housing, if it does not seat
properly with all the retaining clips “clicking” into position MUST be removed from the filter
housing, the bushing and o-ring “reset” and the o-ring re-lubricated before trying again. Do this with
each attempt to assemble until successful. If the o-ring becomes pinched, stretched or otherwise
damaged, it MUST be replaced.
VERY IMPORTANT REMINDER: When installing the new fuel pump into the filter hopusing,
it is CRITICAL to press the new fuel pump FIRMLY SQUARELY and STRAIGHT into the filter
housing in ONE smooth, continuous motion. Misalignment will prevent the o-ring from seating
squarely in the bore and when the hand pressure is released to try again, the o-ring can easily become
dislodged from the fuel pump outlet tube resulting in the mis-alignment shown above and in the
illustrations below.
Continued...
Bulletin Number: WRG-21; Date: 08/24/21
Page 58 of 66
The RED circles represent a cross-section of the o-ring.
The new fuel pump is being pressed firmly and squarely into the filter housing bore and successfully
“clicks” into place.
Here, the new fuel pump is being pressed into the filter housing bore at an angle which will likely
result in the outlet tube butting against the shoulder of the bore the o-ring seals against followed by
repeat attempts which often end up with the o-ring becoming dislodged.
Installation video of the new fuel pump component into the filter housing
Continued...
Bulletin Number: WRG-21; Date: 08/24/21
Page 59 of 66
APPENDIX B
Ascent and Impreza Fuel Pump Assembly Ring Nut Installation Tip
Fig. 1 shows the Ring Nut installed
on the tank threads but crossthreaded / mis-aligned. Attempting
to tighten the Ring Nut with the tool
when mis-aligned like this will likely
damage the threads on both parts.
Fig. 2 shows the Special Tool
installed onto the Ring Nut making
the mis-alignment easier to identify
before attempting to tighten it.
Figs. 3 & 4 show the Special Tool
is installed onto the Ring Nut then,
a firm, sharp, straight downward
force being applied to the tool
to “jump” the threads resulting in
proper alignment and start to a
normal, successful tightening
procedure.
Continued...
Bulletin Number: WRG-21; Date: 08/24/21
Page 60 of 66
Hints for getting the new retaining Ring Nut threads video properly engaged onto the fuel tank threads.
Continued...
Bulletin Number: WRG-21; Date: 08/24/21
Page 61 of 66
APPENDIX C
Fuel Tank Leak Test
•
The Fuel Tank Leak Test MUST be performed on ALL models after fuel pump replacement
has been performed. This will confirm proper sealing of the fuel tank chamber.
(STEP :1) Using the Redline Detection Smoke Pro (RDL-95-0051), apply 10kpa (1.45 PSI) at
the vent tube. NOTE: These pressures for this test are higher than those specified when confirming
proper sealing of the fuel pump. Check to ensure the pressure is retained for 10 seconds. Is the
pressure retained?
YES – The inspection is complete. Reassemble the removed parts in the reverse order.
NO – The pressure is not retained. Possible improper installation of the gasket, ring nut or fuel pump
upper plate is suspected. Check the installation condition and replace any damaged part(s) with new.
Re-install correctly and perform this inspection again.
Bulletin Number: WRG-21; Date: 08/24/21
Page 62 of 66
URGENT
IMPORTANT SAFETY RECALL
This notice applies to the VIN below
Subaru of America, Inc
PO Box 9103
Camden, NJ 08101-9877
844-373-6614
www.subaru.com
Subaru Safety Recall WRG-21
NHTSA Recall ID 21V-587
September 2021
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 certain 2019-2020 model year Ascent, 2018-2019 model year BRZ, 2018
model year turbo Forester, 2018-2020 model year Impreza, 2018-2020 model year Legacy,
2018-2020 model year Outback, and 2018-2019 model year WRX vehicles.
You received this notice because our records indicate that you currently own one of these
vehicles.
REASON FOR THIS SAFETY RECALL
Your vehicle may be equipped with a low-pressure fuel pump assembled with an impeller
that may become deformed. 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.
SAFETY RISK
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. An inoperative
fuel pump may result in the engine stalling without the ability to restart the vehicle,
increasing the risk of a crash.
WHAT SUBARU WILL DO
Subaru
will replace the fuel pump at no cost to you.
What You Should Do
You should contact any authorized Subaru retailer (dealer) for an appointment to have this
safety recall repair performed, at no cost to you.
HOW LONG WILL THE REPAIR TAKE?
The time required to replace the fuel pump for Ascent vehicles is approximately 1 hour
and 45 minutes. The time required to replace the fuel pump for BRZ, Forester, Impreza,
Legacy, Outback, and WRX vehicles is approximately 1 hour and 15 minutes. Your retailer
can provide you with a better estimate of the overall time for this service visit, as it may
be necessary to make your vehicle available for a longer period of time for scheduling
purposes.
For your convenience, your retailer may provide you with a loaner or rental vehicle, at no
cost to you, until the repair is complete.
CALIFORNIA REGISTERED OWNERS
The California Air Resources Board requires that emission related campaigns be completed
prior to California’s vehicle registration renewal process; without this repair, you will not
be able to register your vehicle during your next annual registration. Upon completion of
this campaign, your California dealer will complete and provide you a “Proof of Correction
Certificate.” If required, present the certificate to the California Department of Motor
Vehicles (the “DMV”) when renewing your California registration as proof of campaign
completion. If the DMV does not request the certificate, we recommend that you keep it for
your records.
In addition, the State of California requires that every vehicle must pass an emission test
(SMOG Check) every two years and before it is sold. Without the repair we are providing at
no charge, your vehicle may not pass this test.
OWNER INFORMATION
Government regulations require that recall notifications be sent to the last known owner of
record. That information is based primarily on state registration and title data. If you are a
lessor of this vehicle, federal regulations require you to forward this notice to your lessee
within ten days.
If you have moved or sold your vehicle, please update this information online at www.
subaru.com, select ‘Customer Support,’ then select ‘Address Update’ or ‘Ownership
Update’ from the “Quick Links” menu.
IF YOU HAVE PREVIOUSLY PAID FOR A REPAIR
If you have already paid for repairs associated with this condition, you may be eligible for
reimbursement. Reimbursement consideration will be based on the amount an authorized
Subaru retailer in your area would charge for the same repair.
Please send the original service repair order, which has the name of the repair facility, date
of repair, mileage at the time of repair, complete 17-digit vehicle identification number (VIN),
and your name, with correct mailing address and telephone number to the address listed
below:
Subaru of America, Inc.
Customer Advocacy Department, Attention: WRG-21 Recall
P.O. Box 9103, Camden, NJ 08101-9877
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 it may take up to 60 days for this process to be completed.
IF YOU NEED FURTHER ASSISTANCE:
To locate the nearest Subaru retailer, you can access our website at www.subaru.com and
select ‘Find a Retailer.’
For additional information, please go to: http://www.wrg21.service-campaign.com.
If you need additional assistance, please contact us directly:
•
By e-mail: Go to www.subaru.com and select “Customer Support”
•
By telephone: 1-844-373-6614
Monday through Friday between 8:00 a.m. and 7:00 p.m. ET
•
By U.S. Postal mail: Write us at Subaru of America, Inc.
Attn: Customer Advocacy Department
P.O. Box 9103, Camden, NJ 08101-9877
To subscribe to the NHTSA Recall Notification email System, please go to: https://wwwodi.nhtsa.dot.gov/nhtsa/subscriptions.
Please contact us immediately if the Subaru retailer fails or is unable to make the necessary
repairs free of charge.
You may also contact the Administrator, National Highway Traffic Safety Administration
(NHTSA), 1200 New Jersey Ave., SE, Washington, DC 20590 or call the toll-free Vehicle
Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153) or go to http://www.safercar.
gov if you believe the Subaru retailer 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.
Sincerely,
Subaru of America, Inc.
A subsidiary of SUBARU CORPORATION
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TSB/Document ID: WRG-21
Replacement Service Bulletin Number:
MFR Communication Date: 2021-08-24
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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