NHTSA ID Number: 10240103
Manufacturer Communication Number: 09-103-23
TSB/Document Date: 2023-08-02
Summary
This bulletin the announces diagnostic procedures and availability of new Engine Control Module (ECM) reprogramming files to address DTC P2404 (Evap System Leak Detection Pump Sensor Circuit Range/Performance) detection.
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TSB/Document ID: 09-103-23
Replacement Service Bulletin Number:
MFR Communication Date: 2023-07-10
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
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
© 2023 Subaru
of America, Inc. All rights reserved.
SERVICE BULLETIN
APPLICABILITY:
2015MY Legacy & Outback
SUBJECT:
NUMBER: 09-103-23
DATE: 07/10/23
DTC P2404 / Reprogramming Files
INTRODUCTION:
This bulletin the announces diagnostic procedures and availability of new Engine Control Module
(ECM) reprogramming files to address DTC P2404 (Evap System Leak Detection Pump Sensor
Circuit Range/Performance) detection. In rare cases, the internal pump for the Evaporative Leak
Check Module (ELCM) system can seize temporarily. The new files contain enhanced logic to
prevent the ELCM pump from seizing temporarily. If P2404 is found stored in the fault memory,
follow the procedures outlined below.
PAK FILE APPLICABILITY:
Model
Spec.
2.5L NA,
MT
2.5L NA,
CVT
15 Legacy
& Outback
2.5L NA,
CVT
File Name
Old Part Number
Decryption
Keyword
New CID #
22765AF34J.pak
22765AF34A
22765AF34B
22765AF34C
22765AF34D
22765AF34E
22765AF34F
22765AF34G
22765AF34H
56A0A88D
EB4GI00A
22765AV37A.pak
22765AF35A
22765AF35B
22765AF35C
22765AF35D
22765AF35E
22765AF35F
22765AF35G
22765AF35H
22765AF35J
E9CD44A0
EB4GI00B
22765AV38A.pak
22765AF36A
22765AF36B
22765AF36C
22765AF36D
22765AF36E
22765AF36F
22765AF36G
22765AF36H
22765AF36J
C1312261
EB4GI00C
22765AK16H.pak
22765AK16A
22765AK16B
22765AK16C
22765AK16D
22765AK16E
22765AK16F
22765AK16G
ED337380
EB4GI00c
22765AF45H.pak
22765AF45A
22765AF45B
22765AF45C
22765AF45D
22765AF45E
22765AF45F
22765AF45G
6FE961CB
DB4GI00D
These reprogramming files have been included in the January 2023 SSM software update.
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: 09-103-23; Date: 07/10/23
Page 1 of 9
SERVICE PROCEDURE FLOWCHART:
Perform reprogramming outlined
in STEP 11.
Perform diagnosis following the
applicable Service Manual. Once
repaired, Perform the reprograming
procedure outlined in STEP 11.
6.
Continued...
Bulletin Number: 09-103-23; Date: 07/10/23
Page 2 of 9
8.
6.
Continued...
Bulletin Number: 09-103-23; Date: 07/10/23
Page 3 of 9
6.
11.
Contact Subaru Techline with ability to
provide SSM data and the testing results
attained using this bulletin.
SERVICE PROCEDURE / INFORMATION:
STEP 1: Using Subaru Select Monitor (SSM), check for diagnostic trouble codes P2404. Confirm
P2404 is stored and proceed to the next step. Always save SSM data and record the results of the
following tests.
STEP 2: Are any of the diagnostic trouble codes listed below also stored withing the ECM?
•
P2419 - Evap System Switching Valve Control Circuit Low
•
P2420 - Evap System Switching Valve Control Circuit High
•
P2401 - Evap System Leak Detection Pump Control Circuit Low
•
P2402 - Evap System Leak Detection Pump Control Circuit High
•
P24BA - Evap System Leak Detection Pump Pressure Sensor Circuit Low
•
P24BB - Evap System Leak Detection Pump Pressure Sensor Circuit High
•
P24B9 - Evap System Leak Detection Pump Pressure Sensor Circuit Range/Performance
NO – Proceed to STEP 3.
YES – Perform diagnosis following the applicable Service Manual. Once repaired,
perform the reprogramming procedure outlined in STEP 11.
Continued...
Bulletin Number: 09-103-23; Date: 07/10/23
Page 4 of 9
STEP 3: Refer to the applicable Service Manual and review: General Description > Repair Contents
> Action required before & after Battery Disconnect. Additionally, record any stored seat position(s)
before proceeding. Relearn any seat position memory after work is complete. If the power rear gate
(PRG) height has been customized, that position must also be noted and relearned. CAREFULLY
disconnect the ground terminal from the battery sensor.
STEP 4: Remove the left rear wheel and mud guard. Refer to STIS: Body & Electrical/WIRING
SYSTEM > EXTERIOR/INTERIOR TRIM > Mud Guard
STEP 5: CAREFULLY disconnect the ELCM drain tube. Inspect for signs of water or oil.
Have signs of water or oil been detected withing the ELCM drain tube?
YES – Clean and dry the drain tube using a non-alcohol base cleaner. Proceed to STEP 6.
NO – Proceed to STEP 6.
STEP 6: Connect the vehicle to a recommended power supply. See APPENDIX A for addition
information regarding power supply. Using SSM, perform the Evaporative System Leak Test. Collect
and save all data.
Continued...
Bulletin Number: 09-103-23; Date: 07/10/23
Page 5 of 9
Once the evaporative system leak test is complete, check the DTCs and examine the vacuum value
results. Record the value shown in the row labeled MID: $3C, TID: $C4, and Scaling ID: $FE. This
value should be lower than -0.26 PSI.
Is DTC P2404 stored within the ECM?
NO – Proceed to STEP 7.
YES – Proceed to STEP 8.
STEP 7: Was the vacuum value result observed in STEP 6 found to be lower than -0.26 PSI?
YES – Proceed to STEP 11.
NO – Proceed to STEP 8.
STEP 8: Using SSM, perform the ELCM Pump Active Test for a period of 35 minutes or more. See
APPENDIX A for addition information regarding power supply.
Continued...
Bulletin Number: 09-103-23; Date: 07/10/23
Page 6 of 9
Once the ELCM Pump Active Test has been performed for a period of 35 minutes or more, repeat the
Evaporative System Leak Test outlined in STEP 6. Check the DTCs and the vacuum value results.
Is DTC P2404 stored within the ECM?
NO – Proceed to STEP 9.
YES – Proceed to STEP 10.
STEP 9: Was the vacuum value result observed during the second Evaporative System Leak Test
found to be lower than -0.26 PSI?
YES – Proceed to STEP 11.
NO – Proceed to STEP 10.
STEP 10: Replace the Evaporate Leak Check Module and repeat the Evaporative System Leak Test
outlined in STEP 6. Check the DTCs and the vacuum value results.
Is DTC P2404 stored within the ECM?
NO – Proceed to STEP 11.
YES – Contact Subaru Techline with ability to provide SSM data and the testing results
attained using this bulletin.
STEP 11: Reprogram the ECM following the normal FlashWrite procedure. See APPENDIX A for
addition information regarding power supply.
WARRANTY / CLAIM INFORMATION:
For vehicles within the Basic New Car Limited, an applicable Emission Warranty period or covered
by an active Subaru Added Security Classic or Gold plan, this repair may be submitted using the
following claim information:
Labor Description
Labor Operation #
Labor Time
ECM REPROGRAMMING & DRAIN TUBE CLEAN / EVAP TESTING
A455-223
1.0H
LEAK CHECK MODULE R&R AND ECM REPROGRAMMING
A455-244
1.9H
Fail Code
UPG-48
IMPORTANT: Always note the original Calibration Identification number (CID) the vehicle came in
with on the repair order before reprogramming and, make sure to list the NEW CID for any newlyinstalled programming (as confirmed from the actual control module AFTER installation). The NEW
CID MUST also be noted on the repair order as this information is required for entry in the claim
specific data field during claim submission.
NOTE: The PAK file listings provided in this bulletin are the latest available at the time of
publishing. Updates are often released thereafter without revision to the original bulletin. For this
reason, it is critical to always have the latest version of Select Monitor software installed on your
system. You can confirm if a later version is available by entering the CID listed in this bulletin into
FlashWrite. If a newer CID is shown as available in FlashWrite, reprogram using that file.
Continued...
Bulletin Number: 09-103-23; Date: 07/10/23
Page 7 of 9
IMPORTANT REMINDERS:
•
SOA strongly discourages the printing and/or local storage of service information as previously
released information and electronic publications may be updated at any time.
•
Always check for any open recalls or campaigns anytime a vehicle is in for servicing.
•
Always refer to STIS for the latest service information before performing any repairs.
Continued...
Bulletin Number: 09-103-23; Date: 07/10/23
Page 8 of 9
APPENDIX A
Subaru of America, Inc. (SOA) highly recommends utilizing either the Subaru Midtronics DCA8000
Dynamic Diagnostic Charging System or the Subaru Midtronics GR8-1100 Diagnostic Battery
Charger to the vehicle in the Power Supply Mode feature anytime a vehicle control module is
being reprogrammed. Once the Midtronics charger is connected to the vehicle, if the battery is fully
charged, it will take less than three (3) minutes to boot-up the charger, select the Power Supply Mode,
and have the battery voltage stabilized and ready for reprogramming.
NOTES:
•
For instructions on using the Power Supply Mode, reference the applicable User Manual for
the Midtronics DCA-8000 Dynamic Diagnostic Charging System and the Midtronics GR81100 Diagnostic Battery Charger on STIS.
•
Confirm all electrical loads such as lights, audio, HVAC, seat heaters, and rear defroster are all
switched OFF before setting up the charger for Power Supply Mode.
•
Select the correct battery type (Enhanced Flooded, Flooded, Gel, AGM or AGM Spiral).
•
Input the CCA which matches the vehicle’s battery. NOTE: OE and replacement batteries have
different CCA ratings. Always confirm the battery’s CCA rating before proceeding.
•
If using a DCA-8000 Dynamic Diagnostic Charging System, set the power supply voltage to
13.5 Volts.
•
DO NOT connect the DST-i or DST-010 until the Power Supply mode function has completed
its battery test mode and the Charging Voltage has dropped to and shows a steady 13.5 Volts on
the display.
•
Once Power Supply Mode reaches a steady 13.5 Volts, connect the DST-i or DST-010 to the
OBD connector and proceed with initiating the normal FlashWrite reprogramming process.
•
Amperage will fluctuate based upon the vehicle’s demand for power. NOTE: If the voltage
rises beyond 14 Volts while programming is in process, the procedure will abort. This can
indicate a need to test or charge the vehicle battery before any further attempt at programming
is made.
•
ALWAYS set the power supply voltage to 13.5 Volts when using Power Supply Mode. NEVER
turn the ignition switch on when charging at voltages 15 Volts or higher.
REMINDER: If the DCA-8000 or GR8-1100 indicates the vehicle’s battery must be charged, charge
the battery fully before proceeding to reprogram the vehicle while using the Power Supply Mode.
NOTE: Control module failures resulting from battery discharge during reprogramming are not a
matter for warranty. Should any DTCs reset after the reprogramming update is performed, diagnose
per the procedure outlined in the applicable Service Manual.
VERY IMPORTANT:
This information is applicable to the Subaru Midtronics DCA-8000 Dynamic Diagnostic Charging
System and the Subaru Midtronics GR8-1100 Diagnostic Battery Charger ONLY. It does not apply to
any other brand / type of “generic” battery charger whatsoever. ONLY the DCA-8000 and the GR81100 and their Power Supply Mode feature have been tested and approved by SOA.
Bulletin Number: 09-103-23; Date: 07/10/23
Page 9 of 9
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