ATTENTION:
GENERAL MANAGER

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PARTS MANAGER

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CLAIMS PERSONNEL

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IMPORTANT - All
Service Personnel
Should Read and
Initial in the boxes
provided, right.

SERVICE MANAGER

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© 2024 Subaru of America, Inc. All rights reserved.

SERVICE BULLETIN
APPLICABILITY:

2019-24MY Forester

SUBJECT:

Knocking Type Sound from
Engine Compartment

NUMBER: 12-255-24R
DATE:

09/19/24

REVISED:

09/30/24

INTRODUCTION:
This bulletin announces the repair procedure developed to address cases of a knocking type sound
emitting from the engine compartment. The front bulkhead panel dowel on the driver side can rub
against the toe board causing a knocking sound when driving over small bumps. If this knocking
sound from the engine compartment is duplicated, follow the service procedures outlined in this
bulletin.
A sample of the sound can be heard in the video provided in the link below.
Sample Link Video

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: 12-255-24R; Revised: 09/30/24

Page 1 of 9

REQUIRED TOOLS & MATERIALS:
Tool Description

Image

Details

3M 401 Masking Tape (or
equivalent)

To function as a drill guide and
holding the bottle cap to the body
of the vehicle.

Bottle Cap

For catching grinding material.

90° Angle Mini Air Die
Grinder

For expanding dowel hole.

1/4” Shank 1” Flute Radius
End Carbide Burr

For expanding dowel hole.

Metric Ruler

For Confirming dowel hole size.

Touch-up Paint (Does not
have to be exact match)

For sealing the expanded area.

PART INFORMATION:
Part Description

Part Number

CAP-COWL PANEL, UPPER

91486KJ010

Quantity

As Needed
CAP-COWL PANEL, LOWER

91486FL020

Continued...
Bulletin Number: 12-255-24R; Revised: 09/30/24

Page 2 of 9

SERVICE PROCEDURE / INFORMATION:
STEP 1: Remove the front cowl assembly as per the applicable Service Manual. Refer to STIS:
EXTERIOR/INTERIOR TRIM > Cowl Panel

STEP 2: Remove the two nuts and four bolts mounting the front bulkhead panel to the toe board. The
front bulkhead panel can then be removed from the vehicle.

Continued...
Bulletin Number: 12-255-24R; Revised: 09/30/24

Page 3 of 9

STEP 3: Locate the elongated dowel hole on the passenger side. This is the receiving hole for the
passenger side dowel pin.

STEP 4: Apply masking tape to be used a guidelines. Set the tape distance to 8mm.

IMPORTANT: ONLY the passenger side toe board dowel hole requires expansion. Though the
knocking type sound can be heard from the driver side dowel, expanding the passenger side dowel
hole will allow sufficient centering of the bulkhead panel. This will eliminate any unwanted tension
on the driver side bulkhead dowl.

Continued...
Bulletin Number: 12-255-24R; Revised: 09/30/24

Page 4 of 9

STEP 5: To avoid the spread of grinding material. Place the bottle cap under the dowel hole. Secure
the bottle cap with masking tape. A magnet can also be used to catch fallen grinding material.

STEP 6: Using the die grinder and carbide burr, expand the dowel hole to the edges of the measured
tape (8mm). Capture and dispose of all grinding material. The hole will be a circle shaped when
complete.

STEP 7: Apply touch-up paint to the expanded area. This will help prevent any rust formation.
Remove the masking tape. Allow at least 15 minutes to dry before proceeding to the next step. The
paint does not have to be an exact match. If paint has been rubbed off the the driver side dowl hole,
touch-up paint can be applied to prevent rust.

Continued...
Bulletin Number: 12-255-24R; Revised: 09/30/24

Page 5 of 9

STEP 8: Apply dark touch-up paint to any dowel surfaces that has had any paint rub off due to dowl/
hole contact. Allow 15 minutes to for the touch-up paint to dry before installation.
NOTE: Bright green colored paint is shown below for instructional purposes

.
STEP 9: Prepare two pieced of paper cut 30mm X 20mm. These will be used to protect the newly
painted dowels.

STEP 10: Round the paper and secure with tape as shown below. The curled pieces must be 30mm in
length.

Continued...
Bulletin Number: 12-255-24R; Revised: 09/30/24

Page 6 of 9

STEP 11: Install the pieces of paper onto the bulkhead panel dowels. If needed, additional tape can
be use for added security.
NOTE: These paper pieces are only installed temporarily.

STEP 12: With the aid of a partner, install the bulkhead panel onto the vehicle. Confirm the panel is
centered.

Continued...
Bulletin Number: 12-255-24R; Revised: 09/30/24

Page 7 of 9

STEP 13: Remove both pieces of protective paper and tape.

STEP 14: Install the bulkhead panel mounting bolts and nuts. Torque to 7.5Nm (0.76kgfm,
5.5ft-lbs).

STEP 15: Install the front cowl assembly as per the applicable Service Manual. Refer to STIS:
EXTERIOR/INTERIOR TRIM > Cowl Panel

Continued...
Bulletin Number: 12-255-24R; Revised: 09/30/24

Page 8 of 9

WARRANTY / CLAIM INFORMATION:
For vehicles within the Basic New Car Limited Warranty period, this repair may be submitted using
the following claim information:
Labor Description:

Labor Operation #

Labor Time:

Fail Code

Bulkhead Panel Noise repair

B900486

0.8

OBL-25

NOTE: Up to $5.00 can be claimed in sublet for touch-up paint used during this service procedure.

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: 12-255-24R; Revised: 09/30/24

Page 9 of 9