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.
•
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
Continued...
Bulletin Number: WRD-20R Revised Date:08/27/21
Page 29 of 51
14. REMINDER: Discard the removed temporary 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.
15. Reconnect the harness connector to the fuel pump.
16. Reconnect the ground cable to the battery. Torque to 7.5 Nm (5.5 ft. lbs.).
17. 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.
18. Reinstall the inspection cover.
19. Reinstall the seat cushion assembly while making sure the seat belt buckles are properly
positioned. IMPORTANT NOTE: If any of the plastic clips securing the seat cushion to the
body were displaced when removing the seat cushion, they MUST be replaced.
20. Perform Fuel Tank Leak Test: See APPENDIX C on page 49
21. Return any removed fuel back to the vehicle.
22. Deodorize the vehicle interior as necessary.
END OF IMPREZA SERVICE PROCEDURE
FUEL PUMP REPLACEMENT for 2019MY ASCENT Models:
IMPORTANT PRECAUTIONS:
•
Place “NO OPEN FLAMES” signs near the working area.
•
Be careful not to spill any fuel, especially when working inside the vehicle.
•
Catch any leaking fuel from the removed fuel tube(s) using a small drain pan or cloths.
•
If the fuel level in the tank is 2/3 full or more, drain the fuel to below 2/3 full before starting
this procedure to avoid spilling any fuel.
•
To prevent static electricity discharge / spark, always discharge any static electricity before
starting this procedure using an anti-static cord and / or touching a grounded metal part of the
vehicle body (e.g. door striker).
•
Insure there is plenty of ventilation by opening windows of the vehicle and the service area.
•
ALWAYS remove the fuel cap to release any accumulated evaporative / vapor pressure.
As mentioned earlier, select Fuel Filter REMOVAL in the applicable Service Manual to get the
complete, detailed procedure for separating the fuel pump / filter sock from the complete fuel pump
assembly. The following instructions will follow the Service Manual with additional photos to help
clarify the step where applicable.
Continued...
Bulletin Number: WRD-20R Revised Date:08/27/21
Page 30 of 51
1. Park the vehicle where the work will be performed. Release the fuel pressure:
•
Locate and remove the fuel pump fuse in the under-hood fuse box (M/B).
•
Start the engine and allow 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.
2. Enter the driver seat and lower all windows. Using the fuel gauge in the Combination Meter,
check the fuel level.
•
If the fuel gauge shows two thirds (2/3) or more: go to STEP 3
•
If the fuel gauge shows less than two thirds: go to STEP
Continued...
Bulletin Number: WRD-20R Revised Date:08/27/21
Page 31 of 51
(STEP 3:) The PREFERRED method for draining fuel will be to use the special adapter
p.n. 42099FL030. After CAREFULLY removing the retaining bolt trim covers, CAREFULLY
remove the right rear seat assembly following the procedure in the applicable Service Manual
and set it aside in a safe place. REMINDER: Always protect the surrounding trim and painted
surfaces when removing and reinstalling the seat assembly. Using a helper for this step is also
STRONGLY recommended. Remove the section of floor mat covering the fuel pump access
cover. With the access cover removed, apply a length of door edge guard, flexible tubing or
electrical tape around the pump access opening as protection from cuts / abrasions from any
sharp edges. Release the quick disconnect fitting at the fuel pump outlet pipe. While covering
the fuel pipe with a clean shop cloth to catch any residual pressurized fuel, slide the fuel
delivery pipe off the fuel pump outlet. Insert the plastic temporary plug supplied in the kit into
the removed fuel delivery pipe. The one-time use temporary plug is included in the replacement
fuel pump parts kit. This plug is not required if the fuel pump assembly is being replaced due to
the very short disconnection time.
•
Connect a sufficient length of 5/16” rubber fuel hose to the male hose barb portion of the
adapter fitting. Always secure it with a small hose clamp to prevent leakage. Remove the
plastic plug from the adapter and connect the adapter / hose assembly to the discharge tube
of the fuel pump as shown below. Put the other end of the rubber fuel hose securely into
a safety container to collect the drained fuel. Once the drain hose assembly is securely in
place, connect the SSM4, turn the ignition ON and 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
Plug and
Discard
Continued...
Bulletin Number: WRD-20R Revised Date:08/27/21
Page 32 of 51
3. While holding the battery sensor firmly with one hand to avoid damage, loosen and disconnect
the ground terminal and harness connector.
REMINDER: ALWAYS remove the fuel tank filler cap to release any remaining vapor pressure.
4. If not already done in STEP 3, CAREFULLY remove the retaining bolt trim covers and
CAREFULLY remove the right rear second row seat assembly following the procedure in
the applicable Service Manual. ALWAYS disconnect the seat heater connection (if equipped)
before lifting the seat. IMPORTANT NOTE: the side impact sensor is under the carpeting of
the center seating area. Avoid hard impacts to this area during seat removal and installation.
REMINDER: Always protect the surrounding trim and painted surfaces when removing and
reinstalling the seat assembly. Using a helper for this step is also STRONGLY recommended.
Set seat aside in a clean, safe place.
•
Remove the section of floor mat covering the fuel pump access cover. CAREFULLY
remove the fuel pump access cover while paying close attention to avoid damaging the
foam seal between the cover and vehicle body. Replace the seal if damaged with p.n.
96077FL00A (rare case). With the access cover removed, release the quick disconnect fitting
at the fuel pump outlet pipe. While covering the fuel pipe with a clean shop cloth to catch
any residual pressurized fuel, slide the fuel delivery pipe off the fuel pump outlet. Insert
the one-time use plastic temporary plug into the removed fuel delivery pipe. The plug is
included in the replacement fuel pump parts kit.
5. Fuel Pump Assembly Removal:
•
Disconnect the harness connector from the pump.
•
CAREFULLY using HAND TOOLS ONLY and the Ring Nut Wrench tool shown here,
remove the plastic retaining ring nut securing the fuel pump assembly into the fuel tank.
NOTE: Make sure the removed fuel delivery pipe is ON TOP of the tool as shown and not
pinched under it.
Continued...
Bulletin Number: WRD-20R Revised Date:08/27/21
Page 33 of 51
•
CAREFULLY remove the fuel pump assembly from the fuel tank. Use a vacuum tool with
a reservoir, squeeze bottle or an equivalent tool to remove residual fuel from the fuel
chamber of the pump assembly along with a small catch pan to prevent spilling fuel as the
pump assembly is removed. IMPORTANT: Do not let the fuel level sensor arm or float
contact the tank opening during removal.
•
IMPORTANT NOTE: Ascent has a jet pump fuel tube
connection to the fuel chamber inside the fuel tank. When
removing this line, if desired, it can be secured either with
tape or a piece of Mechanic’s wire under the connector
slider to keep it from dropping inside the fuel tank.
•
Once the fuel pump assembly has been removed, install
the applicable plastic plug tool into the fuel tank opening
to prevent contamination from entering the tank and fuel
vapors from accumulating in the vehicle interior. If the
plug is not available, cover the opening with a clean shop
cloth. The plug is not required when replacing the complete fuel pump assembly due to the
very short time the tank will be open for that repair.
6. After disconnecting the pump and sending unit harness connectors from the underside of the top
flange, CAREFULLY remove the fuel sending unit from the pump chamber.
IMPORTANT: If any damage e.g. distorted or melting plastic connectors, overheated wiring or
terminals is identified, the harness MUST be replaced. Release the retaining clip (a plastic trim
tool is being used here) and slide the sending unit upward. NEVER touch the contact surface of
the sending unit and use care to avoid bending or otherwise damaging the float arm and contact
point.
•
CAREFULLY disconnect both the fuel pump and fuel sending unit harness connectors and
remove the wiring from the retaining clips. Note the wire routing prior to disassembly for
reference during reassembly.
•
Compress the spring (fuel filter assembly) and remove / discard the (one-time use) c-clip.
•
IMPORTANT: When releasing the retaining claws as described in the following steps,
move them only as far as needed to disengage them. If any break, the affected component
must be replaced.
Continued...
Bulletin Number: WRD-20R Revised Date:08/27/21
Page 34 of 51
•
Using a screwdriver wrapped with protective tape (or
equivalent), release the retaining claw for the tube at the bottom
of the fuel chamber then disengage the fuel tube from the
outside of the outside of the chamber.
•
CAREFULLY disengage three claws of the fuel pump holder
from the fuel chamber assembly. Remove the fuel pump and
filter assembly from the chamber.
•
Using a screwdriver wrapped with protective tape (or
equivalent), remove the tube assembly from the fuel chamber assembly, and separate the fuel
filter assembly and fuel chamber assembly as shown below.
•
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.
Continued...
Bulletin Number: WRD-20R Revised Date:08/27/21
Page 35 of 51
•
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. It is CRITICAL for the bushing and NEW o-ring to be installed on the
new pump in the proper order. Always lubricate the new o-rings with gasoline.
7. Install the new fuel pump into the fuel filter assembly.
Using the image here as a guide, lay the partially
reassembled pump assembly on the bench horizontally and
insert the new pump into the fuel filter assembly. Using
both hands, CAREFULLY press the new pump and filter
assemblies together until a “click” is heard from ALL of
the new fuel pump’s retaining claws. If the new pump
does not fully seat and lock into position, make sure the
old o-ring (A) is not still in the bore as shown above. See
Appendix B starting on pg. 47 for more information and a
video on this CRITICAL step.
Continued...
Bulletin Number: WRD-20R Revised Date:08/27/21
Page 36 of 51
8. Leak test fuel pump assembly to confirm there is no leaks PRIOR TO installing the assembly into
the fuel tank. Using the Redline Smoke Pro, apply approximately 200Kpa (29 PSI) 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.
9. 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.
Retaining Claw
IMPORTANT: Confirm this fuel
hose runs UNDER the retaining
claw when installing the pump /
filter assembly back into the fuel
chamber as shown here.
Continued...
Bulletin Number: WRD-20R Revised Date:08/27/21
Page 37 of 51
10. 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.
11. CRITICAL: ALL surfaces of the new pump assembly o-ring, top gasket, underside of the ring
nut along with the surfaces described and shown below: fuel tank neck rim (A) pump flange top
and bottom faces (B) and (C) must be thoroughly wiped clean and completely dried BEFORE
re-installation. This will help prevent the pump from turning with the ring nut during final
tightening.
(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.
12. 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 Date:08/27/21
Page 38 of 51
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. See Appendix C starting on pg. 49 for more information and a video
on this CRITICAL step.
•
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). NOTE: (b) MUST be within the End Range hash marks for the ring nut to be fully
tightened.
•
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 Date:08/27/21
Page 39 of 51
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
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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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