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.
FUEL PUMP REPLACEMENT for 2018-20MY IMPREZA 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.
Bulletin Number: WRG-21R; Revised: 11/10/21
Continued...
Page 29 of 72
•
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.
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.
Bulletin Number: WRG-21R; Revised: 11/10/21
Continued...
Page 30 of 72
•
If the fuel gauge shows less than two thirds: go to STEP 4.
(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. 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 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 31 of 72
3. Disconnect the ground terminal from battery and wait 60 seconds before proceeding.
4. If not already done in STEP 3, CAREFULLY remove the rear seat cushion assembly, set it aside
in a clean, safe place. While pushing the corners of the rear seat cushion from above, pull the
knobs of the retaining hooks forward. Lift up on the front of the cushion assembly to disengage
the rear hooks and remove it.
REMINDER: ALWAYS remove the fuel tank filler cap to release any remaining vapor pressure.
CAUTION:
•
The Airbag system satellite safing sensor is located under the front center of the rear seat
cushion. Be careful not to apply any strong impacts to the sensor when working with the rear
seat cushion removed.
5. Fuel Pump Assembly Removal:
Bulletin Number: WRG-21R; Revised: 11/10/21
Continued...
Page 32 of 72
•
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 (VERY RARE case).
•
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.
•
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
securing the fuel pump assembly in the fuel tank.
NOTE: Make sure the removed fuel delivery pipe is ON TOP
of the tool as shown and not pinched under it.
•
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.
•
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.
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 33 of 72
7. 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.
•
Using a flat-blade screwdriver wrapped with protective tape (or equivalent), release the
connector for the fuel tube at the bottom of the fuel chamber. Remove the fuel tube from the
side of the fuel chamber as shown.
•
CAREFULLY disengage three claws of the fuel pump holder from the fuel chamber
assembly. Remove the fuel pump and filter assembly from the chamber.
Fuel Pump Holder
•
CAREFULLY remove the fuel pump holder from the fuel filter assembly.
•
Disengage the 3 claws at the bottom of the fuel pump.
•
Using the flat tip screwdriver or similar tool wrapped with a protective tape, press on the fuel
pump and remove the fuel pump from the fuel filter assembly.
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 34 of 72
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 here 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. Lubricate the new o-ring with gasoline.
•
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. 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
8. 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 A starting on pg. 57 for more information and a video on this CRITICAL step.
•
Refit the fuel pump holder to the fuel filter assembly.
•
Reinstall the fuel filter assembly into the fuel chamber. Make sure the fuel tube and the spring
are properly positioned as shown in the photo and illustration below.
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 35 of 72
•
Confirm the 3 claws securing the fuel filter assembly into the fuel
chamber are fully engaged.
•
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.
•
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. 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.
•
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.
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 36 of 72
(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.
10. CAREFULLY reinstall the fuel pump assembly into the
Pump Indexing
Arrow
tank in the proper position / orientation as shown below.
ALWAYS use the new gasket included in the kit. Position
the indexing arrow ∆ between the molded-in hash marks
(blue arrows) on the fuel tank.
•
•
Install the new ring nut included in the kit. The new ring
nut has a triangle index mark ∆ (shown in black here for
illustration purposes) similar to the fuel pump to indicate
the ring nut thread starting point (if needed).
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 “pop” sound will
occur, the ring nut should now be parallel
to the top of the fuel tank and able to be
tightened by hand. See Appendix B
starting on pg. 60 for more information
and a video on this CRITICAL step.
11. CAUTION: SLOWLY tighten the new ring nut to 130 Nm
(96 ft. lbs.) while paying close attention to make sure the fuel pump
does not rotate along with the ring nut. If the pump were to turn more
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 37 of 72
than 45 degrees, the fuel level sensor will likely be damaged. When
properly tightened, the index mark on the ring nut ∆ should align
with the fuel pump indexing arrow ∆ (Center Line (A).
12. CRITICAL: Using a caliper with depth gauge, measure the
dimension in 3 positions between the top of the ring nut and the top
of fuel tank as shown in the illustration and photo (inset) below. The
difference between the three measurements cannot exceed ±1.5mm
or .060 inch.
CAUTION:
•
If the difference between any of the three measurements exceeds ±1.5mm or .060 inch, loosen
and
re-tighten the ring nut to correct any cross-threading.
•
If the ring nut or fuel pump gasket are deformed, cracked or damaged, they MUST be
replaced.
13. 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 then
lock the slider. Tug on the fuel delivery pipe to be sure it is fully locked in place.
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
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 38 of 72
•
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
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 pg. 62 for the procedure.
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 ASCENT, 20MY LEGACY / OUTBACK 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.
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 39 of 72
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.
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.
(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
Continued...
Bulletin Number: WRG-21R; Revised: 11/10/21
Page 40 of 72
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: WRG-21R; Revised: 11/10/21
Page 41 of 72
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
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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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