NHTSA ID Number: 10201799
Manufacturer Communication Number: WRG-21R
TSB/Document Date: 2021-10-04
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.
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TSB/Document ID: WRG-21R
Replacement Service Bulletin Number:
MFR Communication Date: 2021-09-23
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
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
© 2021 Subaru of America, Inc. All rights reserved.
PRODUCT CAMPAIGN BULLETIN
APPLICABILITY:
2018-2019MY Legacy and Outback 2.5L and 3.6L NUMBER: WRG-21R
2020MY Legacy and Outback 2.5L and 2.4L (Turbo)
DATE: 08/24/21
2018-2020MY Impreza
REVISED: 09/23/21
2019-2020MY Ascent
NHTSA ID : 21V587
2018MY Forester (Turbo)
2018-2019MY WRX
2018-2019MY BRZ
SUBJECT:
Fuel Pump Impeller Failure
INTRODUCTION:
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.
AFFECTED VEHICLES:
A total of 172,308 U.S. vehicles will be affected by this recall, as listed below:
Model Year
Carline
Production Date Range
Affected vehicle count
2019-2020
Ascent
January 14, 2019 – May 20, 2019
22,831
2018-2019
BRZ
April 6, 2018 – November 6, 2018
2,409
2018
Forester (turbo)
April 20, 2018 – August 7, 2018
2,010
2018-2020
Impreza
May 3, 2018 – May 31, 2019
28,105
2018-2020
Legacy
June 25, 2018 – October 18, 2019
17,487
2018-2020
Outback
June 25, 2018 – October 18, 2019
88,860
2018-2019
WRX
April 20, 2018 – November 1, 2018
10,606
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. In
addition to the Vehicle Coverage Inquiry lookup function by VIN, retailers may view and download
their affected VIN list from subarunet.com/Recalls & Campaigns/Recall Affected VIN List.
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: WRG-21R; Revised: 09/23/21
Page 1 of 69
DESCRIPTION OF THE DEFECT AND SAFETY RISK:
The affected vehicles may be equipped with a low pressure fuel pump produced during a specific
timeframe that may include an impeller which has been manufactured with a lower density. Under
certain conditions, the lower density fuel pump impeller may deform and 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.
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 follow the applicable service procedures, to correct all affected vehicles in
their inventory (used, demo & SSLP). Additionally, 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:
Owner Notification
Subaru will notify affected vehicle owners by first class mail on or before September 27, 2021.
Retailers will be advised when the notification is scheduled.
Interim Notification – 2020 MY turbo Legacy and Outback vehicles
9/23/2021: Subaru is in the process of acquiring parts for the affected 2020 model year turbo Legacy
and Outback vehicles, and expects sufficient inventory to be available at all RDCs within the next few
weeks. Therefore, an interim notification letter will be mailed to the affected 2020 MY turbo Legacy
and Outback owners. The total number of customers that will receive this interim notification is
2,798. Once sufficient parts inventory is available for this application, the affected owners will be
notified again by first class mail to schedule an appointment to have this recall repair completed.
Continued...
Bulletin Number: WRG-21R; Revised: 09/23/21
Page 2 of 69
PARTS INFORMATION:
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 / WRG-21
Fuel Pump Kit
Kit Part Number
Model Year
Model Application
X4202AL000
18-19
Legacy / Outback 2.5L
X4202AL010
18-19
Legacy / Outback 3.6L
X4202XC220
20
Legacy / Outback 2.4L
X4202AN110
20
Legacy / Outback 2.5L
X4202FL000
18-20
Impreza
X4202XC000
19-20
Ascent
X4202CA330
18-19
BRZ
18
Forester (Turbo)
18-19
WRX
X4202SG660
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.
NOTE: Previously Kit Number X4202XC220 required a release from the Parts PIC team. This Kit
Number can be ordered through PRIME as of September 16th, 2021.
Continued...
Bulletin Number: WRG-21R; Revised: 09/23/21
Page 3 of 69
The information below provides component part content breakdown of the fuel pump kits:
Continued...
Bulletin Number: WRG-21R; Revised: 09/23/21
Page 4 of 69
Continued...
Bulletin Number: WRG-21R; Revised: 09/23/21
Page 5 of 69
Continued...
Bulletin Number: WRG-21R; Revised: 09/23/21
Page 6 of 69
NOTE: Previously Kit Number X4202XC220 required a release from the Parts PIC team. This Kit
Number can be ordered through PRIME as of September 16th, 2021.
Continued...
Bulletin Number: WRG-21R; Revised: 09/23/21
Page 7 of 69
Continued...
Bulletin Number: WRG-21R; Revised: 09/23/21
Page 8 of 69
Continued...
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Page 9 of 69
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Continued...
Bulletin Number: WRG-21R; Revised: 09/23/21
Page 11 of 69
ADDITIONAL REQUIRED MATERIALS / SPECIAL TOOLS:
•
42099FL030 Fuel Pipe Adapter: Connects directly to the
fuel pump outlet pipe at the fuel tank. Remove & discard the
temporary plug before use. NOTE: Retailers were automatically
shipped 2 of these adapters at no charge for use with the original
WRD-20R campaign.
•
42099CA010 (for Forester, WRX, BRZ, and 18-19
Legacy / Outback) and 42099FL020 (for Ascent,
Impreza, and 20 Legacy / Outback) 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.
•
42099FL000 Ring Nut Wrench: Used to remove and install
the fuel pump assembly locking rings on Ascent, Impreza, and 20MY
Legacy/Outback. This is already a required essential Subaru Special
Service Tool.
•
42099CA000 BRZ Ring Nut Wrench: Used to remove and install the
fuel pump assembly locking rings on BRZ models. 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. This is
already a required essential Subaru Special Service Tool.
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.
Continued...
Bulletin Number: WRG-21R; Revised: 09/23/21
Page 12 of 69
SERVICE PROCEDURES / TABLE OF CONTENTS:
Carline
Begins on Page
Legacy / Outback 2.5L & 3.6L
16
Legacy / Outback 2.4L & 2.5L
38
Impreza, Ascent, Legacy /
Outback 2.4L & 2.5L TIPS
25
BRZ TIPS
50
Forester XT Turbo
16
WRX
16
Impreza
29
Ascent
38
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 A on pg.
57 and APPENDIX B on pg. 60 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.
Continued...
Bulletin Number: WRG-21R; Revised: 09/23/21
Page 13 of 69
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 & BRZ), if the plastic
retaining clips (a) (p.n. 64396KA010 for
18-19 Legacy / Outback and 64333FJ000
for Impreza, WRX, Forester, and 20 Legacy /
Outback) 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 (except BRZ). 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.
Continued...
Bulletin Number: WRG-21R; Revised: 09/23/21
Page 14 of 69
On WRX, Forester, and 18-19 Legacy / Outback models, use a small container or magnetic dish to
keep all the retaining ring nuts together while the pump assembly is removed.
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.
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.
Continued...
Bulletin Number: WRG-21R; Revised: 09/23/21
Page 15 of 69
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 18-19 LEGACY and OUTBACK 2.5 and 3.6L, WRX, &
FORESTER XT Turbo 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.
•
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