NHTSA ID Number: 10203897
Manufacturer Communication Number: WRG-21
TSB/Document Date: 2021-12-03
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.
•
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 Manaual 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: WRG-21R; Revised: 11/10/21
Page 16 of 72
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 4.
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 17 of 72
(STEP 3:)
The PREFERRED method for draining fuel will be to use the special adapter p.n.
42099FL030. CAREFULLY remove the rear seat cushion assembly and fuel pump
access cover. 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.
•
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 male fuel 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: WRG-21R; Revised: 11/10/21
Page 18 of 72
3. While holding the battery sensor firmly with one hand to avoid damage, loosen and disconnect
the ground terminal.
4. If not already done in STEP 3, CAREFULLY remove the rear seat cushion assembly, set it aside
in a clean, safe place and remove the fuel pump access cover. Take care to not damage the foam
seal.
REMINDER: ALWAYS remove the fuel tank filler cap to release any remaining vapor pressure.
5. Fuel Pump Assembly Removal:
•
CAREFULLY using HAND TOOLS ONLY, 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. 96077AJ00A (rare case). NEVER use air or electric
tools when performing this step
•
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, and while covering the pipe
and connector with a clean shop cloth to catch any residual pressurized fuel, slide the
fuel delivery pipe off the fuel pump outlet tube. Insert the plastic temporary plug into the fuel
delivery pipe connector. The one-time use temporary plug is included in the replacement fuel
pump parts kit.
•
CAREFULLY using HAND TOOLS ONLY, remove the nuts securing the fuel pump top
plate to the fuel tank. CAUTION: If the nuts are hard to loosen, use a lubricant on them and
take care not to break the fuel tank studs. NEVER use air or electric tools when performing
this step
•
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.
6. 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
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 19 of 72
shop cloth.
7. 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 (ring
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.
•
Release the retaining claw for the tube at the bottom of the fuel chamber.
•
CAREFULLY release the 3 claws for the pump holder from the fuel chamber then raise the
pump / filter assembly upward.
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 20 of 72
•
CAREFULLY remove the fuel tube assembly from the fuel chamber using a small flat-blade
screwdriver wrapped with protective tape as shown.
•
Using 2 small flat-blade screwdrivers, CAREFULLY release the 2 claws securing the fuel
pump to the regulator.
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 21 of 72
•
Release the 3 remaining claws at the bottom of the fuel pump then CAREFULLY press down
on the top of the pump to push it out the bottom of the fuel filter assembly.
STOP HERE DO NOT remove the pressure regulator or otherwise go any further with disassembly
of the fuel pump assembly.
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.
8. Install the New Fuel Pump Assembly:
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.
Plastic
Non-Marring
Pick Tool
IMPORTANT: Always confirm the original o-ring came out of
the filter assembly during disassembly.
If not, use a rubber-tipped or plastic (non-marring) pick tool to CAREFULLY remove it without
scratching the filter assembly bore.
•
Install the new fuel pump into the fuel filter assembly. Using the image below 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 A starting on pg. 57 for more information and
a video on this CRITICAL step.
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 22 of 72
•
Replace all 3 rubber cushions (feet) on the
bottom of the fuel chamber, replacements are
included in the kit. Failure to replace these
may result in a later noise complaint.
•
CAREFULLY refit the tube assembly back
into the fuel chamber until it clicks into
position.
•
Refit the tube back on to the bottom side of
the fuel chamber.
•
Refit the spring (B) to the rod with the snap ring groove then re-install the pump / filter
assembly into the fuel chamber. IMPORTANT: Confirm tube (A) is routed UNDER the
retaining claw then lock all 3 claws in place.
•
Press the top of the pump assembly downward and install the new c-clip (ring clip) included
in the kit.
•
Re-connect the fuel pump harness. 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.
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 23 of 72
•
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.
9. IMPORTANT: Make sure all the sealing surfaces are free from fuel or foreign matter before
reinstalling the fuel pump assembly.
•
CAREFULLY reinstall the fuel pump assembly into the tank in the proper position /
orientation. ALWAYS use the new gasket included in the kit.
•
IMPORTANT: 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.
•
Using the illustrations below for reference, align the recess of the fuel pump upper plate
cushion to the protrusion (A) of the fuel pump assembly.
•
While keeping cutout (B) of the fuel pump upper plate toward the rear of the vehicle, align
protrusion (C) of the fuel pump upper plate cushion with the cutout.
•
CRITICAL: Lightly hand tighten all nuts in the sequence shown below. Complete tightening
of the 8 retaining nuts to the specified torque: 4.4 Nm, (3.2 ft. lbs. or 38 inch- pounds)
following the sequence shown below. NEVER use air or electric powered tools to tighten
these nuts as the studs may be damaged.
2
FRONT
of
VEHICLE
3
7
5
6
4
8
1
•
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
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 24 of 72
then lock the slider. Tug on the delivery pipe to be sure it is fully locked in place.
END OF for 18-19 LEGACY and OUTBACK 2.5 and 3.6L, WRX, &
FORESTER XT Turbo SERVICE PROCEDURES
IMPORTANT REMINDERS: Discard the plastic 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
10. Reconnect the harness connector to the fuel pump.
11. Reconnect the ground cable to the battery sensor. Torque to 7.5 Nm (5.5 ft. lbs.) while supporting
the sensor with the other hand.
12. 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 top plate
13. Reinstall the inspection cover.
14. 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.
15. Perform Fuel Tank Leak Test: See APPENDIX C on page # 62 for the procedure.
16. Return any removed fuel back to the vehicle.
17. Deodorize the vehicle interior as necessary.
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 25 of 72
Helpful TIPS for 20MY LEGACY/OUTBACK, IMPREZA and ASCENT Models:
The procedure for replacing the fuel pump on Impreza and Ascent is very similar to the Legacy and
Outback. The major differences are described here:
•
Both fuel pump assemblies are retained into the fuel tank by a threaded locking ring (ring nut)
instead of a top plate secured by studs and nuts. There are separate procedures for tightening
these ring nuts. A special tool (42099FL000) is used for both models. A 1/2-inch drive breaker
bar and Torque wrench (for Impreza) are also required. New ring nuts and the required sealing
rings are included in the replacement fuel pump part kits.
•
IMPORTANT: Always press down vertically on the center of the tool with one hand and pull
squarely on the bar or wrench with the other to keep it from slipping off the ring nut.
•
CRITICAL: There are 2 procedures for tightening the ring nuts:
○ The Impreza ring nut is simply tightened to 130 Nm (96 ft. lbs.). followed by a
CRITICAL height measurement check in 3 places to confirm there is no cross-threading.
The black arrow indicates the thread starting point of the ring nut threads.
○ The Ascent, 20MY Legacy, and Outback ring nuts use a starting point identified by
aligning hash marks molded into the top of the fuel tank with another set on the ring nut.
Another set of hash marks molded into the tank and 90 degrees to the right (90 degrees
clockwise from the first set) identify the tightening finish point “Range Marks”. The
Ascent, 20MY Legacy, and Outback procedure also includes a height measurement check
in 3 places to confirm there is no ring nut cross-threading.
ASCENT &
20 Leg/Out
RING
IMPREZA
RING
Ascent Ring Nut Markings:
•
Inspect the new ring nut and identify the set of 3 “teeth” close together as shown above.
NOTE: The center or middle line (GREEN tooth) must be aligned with the triangle ∆ mark
in the middle of the thread starting point hash marks as shown below. Also, there is another ∆
mark on the top of the fuel pump (Indexing Arrow) to be used as a reference for making sure
the pump is properly indexed inside the tank. See Appendix B starting on pg. 60 for more
information and a video on this CRITICAL step.
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 26 of 72
Pump Indexing
Arrow
STARTING POINT
Hash Marks
•
Once the initial alignment is done, start tightening the ring nut with the special tool. As it
tightens, the up and down movement of the fuel pump assembly will be reduced. Once this up
and down movement can no longer be felt (one full turn), it is VERY IMPORTANT to make
sure the indexing arrow of the fuel pump assembly stays aligned with the arrow in the center
of the starting point hash marks. At this point, the ring nut should only need final tightening
to get the middle line into the range of (between) the Finishing Point Range hash marks.
REMINDER: As the final tightening is completed, make sure the indexing arrow is still
aligned with the arrow in the center of the starting point hash marks. If not, loosen the ring nut
reposition the pump properly and re-tighten.
•
TIP: To help stop the pump from turning while tightening the ring nut, make sure the new
gaskets and all the surfaces they contact (top of fuel tank, top and bottom of the fuel pump
flange and both sides of the top seal plate) are thoroughly cleaned of any residual gasoline or
other contamination and completely dry. Areas to focus on are shown in red below.
•
On Impreza, start the ring nut with the indexing arrow
centered between the hash marks. Tighten the ring to
96 ft. lbs. IMPORTANT: As the specified torque
approaches, confirm the indexing arrow on the fuel pump
stays between the hash marks. When successful alignment
and torque are achieved, perform the height adjustment
check procedure below.
Height Adjustment Checks:
Pump Indexing
Arrow
ASCENT
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 27 of 72
•
CRITICAL: These height measurement checks MUST
be made as a final check to confirm the ring nut is not
cross-threaded.
•
Ascent, 20MY Legacy, and Outback:
23.8 +/- 2.5 mm (.937 +/- .098 in.) measured in 3
positions around the ring nut. The best tool for doing this
measurement is a digital caliper as shown below. Measure
from the top edge of the ring nut “teeth” to the top surface
of the tank.
•
Impreza: After the specified torque is reached, measure
the height using a digital caliper as shown below between
the flats adjacent to the ring nut “teeth” to the top surface
of the tank in 3 places. All 3 measurements must be
between 1.5 mm of each other.
NOTE: In cases where the ring nut does not thread properly onto the fuel tank, it will be necessary
to “jump” one thread to avoid cross-threading of the ring nut and tank. To do this, begin threading
the ring nut onto the tank at a minimal angle until slight turning resistance is felt. The ring nut thread
starting points are identified by the triangle arrow ∆ on the Impreza ring and the set of 3 lines close
together on the Ascent ring nut (Green arrows in photo below and highlighted with black marker on
the parts). Once the resistance is felt, apply a quick, downward, non-percussive force to the side of
the ring opposite from where the threads were started. A slight “pop” sound should be heard. Once
the pop has been heard and while keeping downward pressure on the ring nut, continue threading
the ring nut onto the tank until it can no longer be turned by hand. Proceed with the remainder of the
tightening and height adjustment procedures as described above. See Appendix B starting on pg. 60
for more information and a video on this CRITICAL step.
END OF IMPREZA, ASCENT, and 20MY LEAGACY / OUTBACK TIPS
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 28 of 72
20 LEG/OUT &
ASCENT RING
IMPREZA RING
Other differences (between Models) to be aware of:
1. The fuel pump is secured to the filter
assembly with 3 retaining claws instead of 5.
2. Instead of having 2 fuel line connections on
the pump assembly, Impreza, Ascent, 20MY
Legacy & Outback only use 1.
3. Impreza does not utilize a “saddle” type fuel
tank therefore, there is also no jet pump.
4. These models utilize a large o-ring seal between the fuel pump assembly and the tank instead of
a rubber gasket. Ascent, 20MY Legacy & Outback use an additional blue plastic sealing washer
between the lock ring and top of the fuel pump assembly.
5. Ascent, 20MY Legacy & Outback have a jet pump fuel line connection to the fuel chamber inside
the 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.
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TSB/Document ID: WRG-21
Replacement Service Bulletin Number:
MFR Communication Date: 2021-11-10
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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- 【Bidirectional Test Covers 180,00+ vehicles】The CR Pro+ offers extensive actuator coverage, up to 9981 tests for AUDI A4, 4117 tests for Land Rover, 7092 tests for VW 0B-Magotan, 60776 tests for GM Chevrolet, 24611 for Benz S221, 3744 for Porsche, 114 for BMW. Beyond sending commands to basic control-units like headlights, mirrors, A/C clutches, fans, windows, doors and more, CR Pro+ CR Pro+ perform real-time bidirectional control with deeper ECU access, such as complex sensor or electronic responses or inner unit like fuel pump, injector, ignition coil, main relay, transmission coolant valve to catch potential issues. It enables you quickly locate the faults, avoid needless pa r.t swap.
- 【COST-EFFECTIVE 49 RESET SERVICE】iCarsoft Pro+features all Reset/ Adaptation/ Calibration/ Initialization service including ABS Reset/ Oil Reset/ EPB Reset/ ETC Reset/ INJ Reset/ SAS Reset/ BLD Reset/ BMS Reset/ LAP Reset/ SPS Reset/ TPMS Reset/ACS Reset/ AFS Reset/ FPP Reset/ IDL Reset/ BSC Reset/ Door Reset/ Seat Reset/ TCM Reset/ Service Interval Reset/ Brake Reset/ DWR Reset/ ECM Reset etc. IMPORTANT: CR PRO+ has been upgraded to provides numerous car maintenance functions for maintaining car systems/control units outside the systems corresponding to the above functions (in miscellaneous). NOTE:Above services vary by vehicle models, please contact us for the service list for your cars.
- 【OE MULTI-SYSTEMS DIAGNOSTICS】CR Pro+ can diagnose main vehicle systems like Engine, TCM, ABS, Airbag, Brake, BMS, Battery, windows, etc,AND ALSO diagnose vehicle specific systems like Antenna Module / Communication Control Module/ Parking Lock/Voice Control/ AC Reducing Agent Metering System,etc, helping to detect existing faults and potential faults, giving you complete vehicle health analysis. It displays module Info, real-time data graphs, such as transmission temperature, saves freeze frames to pinpoint intermittent faults. Note: Available systems vary by model. Each car model has unique systems. You can contact us for diagnoseable systems of your vehicle.
Last update on 2026-06-12 / Affiliate links / Images from Amazon Product Advertising API
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