NHTSA ID Number: 10201058
Manufacturer Communication Number: WRD-20R
TSB/Document Date: 2021-09-04
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.
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: 08/27/21
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 has been updated to “Open”.
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 Date:08/27/21
Page 1 of 51
SERVICE, PARTS, AND CLAIM INSTRUCTIONS:
Sufficient remedy parts supply is now 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
Retailers are to promptly perform the applicable service procedures to correct all affected vehicles in
their inventory (new, used, demo & SSLP).
In addition, 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 on June 4, 2020. A copy of the owner
letter is shown at the end of this bulletin.
PARTS INFORMATION:
Now that sufficient quantities of the Fuel Pump Kits are available, repairs using complete Fuel Pump
Assemblies must be discontinued.
Retailers with ongoing repairs using complete Fuel Pump Assemblies may complete them and submit
for payment using the claim reimbursement information located on pg. 41 of this bulletin.
For the remaining vehicles included in this campaign, the parts required to perform these repairs have
been assembled into Fuel Pump Kits, numbered for each model 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
Continued...
Bulletin Number: WRD-20R Revised Date:08/27/21
Page 2 of 51
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 Date:08/27/21
Page 3 of 51
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. Remove & discard the temporary plug before
use.
•
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. 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.
•
Redline Detection Smoke Pro (RDL-95-0051).
Used for leak testing the fuel tank chamber and
fuel pump assembly.
Continued...
Bulletin Number: WRD-20R Revised Date:08/27/21
Page 4 of 51
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:
Carline
Begins on Page
Legacy / Outback
8
Impreza & Ascent TIPS
17
Impreza
20
Ascent
30
Service Procedure Information for ALL MODELS:
NOTES:
•
The following information is intended to SUPPLEMENT the
following and Service Manual procedures.
•
Two new videos have been linked below to provide additional
information regarding:
1) Installation of the new fuel pump component into the filter housing
2) Hints for getting the new retaining Ring Nut threads properly engaged
onto the fuel tank threads.
•
These video links are included in APPENDIX B on pg. 48 and
APPENDIX C on pg. 51 along with additional information.
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.
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.
Continued...
Bulletin Number: WRD-20R Revised Date:08/27/21
Page 5 of 51
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
nuts together while the pump assembly is removed.
Continued...
Bulletin Number: WRD-20R Revised Date:08/27/21
Page 6 of 51
Have a small fuel-safe drain pan in place to catch any spilled fuel as the pump assembly is
CAREFULLY lifted out of the fuel tank. If available, use a vacuum bleeder with a collection
reservoir and hose to draw some of the stored fuel out of the fuel chamber surrounding the pump and
filter to help avoid spillage. NOTE: On Ascent, there is a jet pump fuel tube attached to the lower
portion of the fuel pump assembly as shown below, right which must also be removed before the
pump assembly can be completely removed from the vehicle. Release the retaining clip with a small
flat-blade screwdriver and remove the line but, secure the line with electrical tape or Mechanic’s wire
to keep it from falling into the tank once it is removed. If not secured, it will fall into the tank and
have to be “fished” out prior to reinstalling the pump assembly.
IMPORTANT: After the pump assembly is removed, ALWAYS install the applicable fuel tank
cap (plug) as shown below or, cover the fuel tank opening with shop cloths or a fender cover (or
an equivalent) to keep fuel odors from accumulating inside the cabin. These tools are not required
when replacing the complete fuel pump assembly due to the very short time the tank will be open to
complete the repair.
LEGACY / OUTBACK 2.5 & 3.6L PUMP
NOTE: When searching STIS for the applicable
Service Manual procedures for reference, select Fuel
Filter REMOVAL to get the detailed procedure for
separating the pump / filter sock assembly from the
complete fuel pump assembly. Fuel Filter removal
is NOT required to complete this procedure. The
replacement pumps come with a new filter sock
already in place as shown here.
IMPREZA / ASCENT PUMP
Continued...
Bulletin Number: WRD-20R Revised Date:08/27/21
Page 7 of 51
For this recall, the 2-wire (Blue / Black) fuel pump wiring harness
indicated as 1-time use in the Service Manual is reused but, should be
inspected for damage or any evidence of overheating (discoloration
of connectors, etc.). IMPORTANT: If any damage e.g. distorted
or melting plastic connectors, overheated wiring or terminals is
identified, the harness MUST be replaced. It easily unplugs from the
fuel pump.
When reinstalling the thinner (Black / Red) fuel sender wires into the
2 retaining clips, they go into the clips first and are held in place by the
thicker fuel pump harness wires.
FUEL PUMP REPLACEMENT for 2019MY LEGACY and OUTBACK 2.5 and 3.6L Models:
If the PDF is very large, it may not load in the preview below.
Some older TSBs had multiple PDFs — visit the NHTSA Website to view all PDFs.
If the TSB PDF does not show, download or view it on the NHTSA Website.
Click on the (+) Plus Sign
Then Click on Associated Document(s)
Search NHTSA Database for Recalls
Search NHTSA Database for Vehicle Investigations
View Latest Vehicle Investigations
Search NHTSA Database for Vehicle Complaints
View Latest Vehicle Complaints
TSB/Document ID: WRD-20R
Replacement Service Bulletin Number:
MFR Communication Date: 2021-08-27
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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