WQR-53R

ATTENTION:
GENERAL MANAGER
PARTS MANAGER
CLAIMS PERSONNEL
SERVICE MANAGER
q
q
q
q
IMPORTANT - All
Service Personnel
Should Read and
Initial in the boxes
provided, right.
PRODUCT CAMPAIGN BULLETIN
APPLICABILITY:	 2003-2004 Baja
2003-2008 Legacy and Outback
2004-2005 Impreza, WRX, STI
SUBJECT:	Takata Front Passenger Air Bag
Inflator Replacement
NUMBER:
DATE:
REVISED:
NHTSA ID:
WQR-53R
June 2, 2015
January 14, 2016
15V-323
UPDATE – January 2016: SUBARU IS EXPANDING THIS RECALL TO INCLUDE
ALL 2005-2008 MODEL YEAR LEGACY AND OUTBACK VEHICLES
The vehicles included in this consolidated national recall include the following:
•
Affected 2004-2005 Impreza, WRX, and STI models from the national expansion of
the WQP-51 recall
•
2003-2004 Legacy, Outback, and Baja vehicles affected by and not yet repaired under
the WQL-48 recall
•
2004 Impreza, WRX, and STI vehicles affected by and not yet repaired under the
WQL-48 recall
•
2005-2008 Legacy and Outback vehicles, including the 2005 models not yet repaired
under the WQP-51 recall
In the event of a crash necessitating deployment of the passenger side frontal air bag, the front
passenger-side air bag inflator in these vehicles could rupture with metal fragments striking
the vehicle occupants potentially resulting in serious injury or death.
Although the percentage of affected vehicles is unknown, this recall will involve replacing the
front passenger air bag inflator on all of the potentially affected vehicles.
AFFECTED VEHICLES
This condition may exist on certain 2003-2004 model year Legacy, Outback, and Baja
vehicles, and certain 2004-2005 model year Impreza, WRX, and STI vehicles and 2005-2008
model year Legacy and Outback models listed below.
MODEL YEAR
2003
2004
2005
2006
2007
2008
MODEL
STARTING
PRODUCTION DATE
ENDING
PRODUCTION DATE
Legacy
01/22/2003
03/17/2003
11/25/2003
11/09/2004
12/08/2005
11/16/2006
05/14/2003
02/10/2004
05/27/2005
07/12/2006
03/12/2007
05/05/2008
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 1
MODEL YEAR
2003
2004
2005
2006
2007
2008
2003
2004
2004
2005
MODEL
STARTING
PRODUCTION DATE
ENDING
PRODUCTION DATE
02/18/2003
02/28/2003
12/01/2003
11/09/2004
12/08/2005
11/16/2006
01/22/2003
03/03/2003
01/08/2003
04/15/2003
02/11/2004
06/02/2005
07/13/2006
03/14/2007
05/05/2008
05/06/2003
07/21/2004
02/13/2004
02/11/2004
05/31/2005
Outback
Baja
Impreza, WRX, STI
Vehicle coverage for this recall must be confirmed by using the Vehicle Coverage Inquiry
function on subarunet.com.
June 2015: All Subaru Impreza, WRX, and STI vehicles affected by the WQP-51 regional
recall that were not yet repaired will be included in the WQR-53 national recall. Any open
WQP-51 coverage has been expired.
September 2015: All vehicles affected by the WQL-48 recall that were not yet repaired
will be transferred into to the WQR-53 national recall. Any open WQL-48 coverage will be
expired once owner notification begins.
January 2016: All 2005 model year Legacy and Outback vehicles affected by the WQP-51
regional recall that were not yet repaired will be included in the WQR-53 national recall. Any
open WQP-51 coverage has been expired.
OWNER NOTIFICATION
Notification letters were previously mailed on June 17, 2015 and July 24, 2015 to owners of
all Subaru Impreza, WRX, and STI vehicles previously affected by the national expansion of
the WQP-51 recall. Copies of those letters are included in this bulletin.
September 2015: Notification letters will be mailed to all owners of vehicles affected by and
not yet repaired under the WQL-48 recall. Copies of these letters are also included in this
bulletin.
January 2016: Notification letters will be mailed to the affected 2005-2008 model year
Legacy and Outback owners with registration history in the high absolute humidity (HAH)
areas, as those vehicles are included in the highest priority group (Priority Group 1) as defined
in the NHTSA (National Highway Traffic Safety Administration) Coordinated Remedy Order.
For more information about this Order, please refer to http://www.safercar.gov/rs/takata/index.
html. A copy of the notification letter is included at the end of this bulletin.
February 2016: Notification letters will be mailed to the remaining affected 2005-2008
model year Legacy and Outback owners. A copy of the owner notification letter is included at
the end of this bulletin.
RETAILER AFFECTED VIN LISTS
Each Subaru retailer will receive an affected VIN list from their Zone Office when owner
notification begins. Vehicles will be assigned to retailers in the affected VIN list as follows:
• Original vehicle owners are assigned to the original selling retailer when their current
address is within a 100 mile radius of that retailer.
• If the original selling retailer is inactive, the VIN has been assigned to the nearest
active retailer.
• For any new owners or when original owners live more than 100 miles from the
original selling retailer, the VIN has been assigned to the nearest active retailer.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 2
Important: Retailer affected VIN lists include owner name and address information for
vehicles affected by this recall. This information will enable retailers to follow-up with
owners of potentially affected vehicles. The lists contain owners’ names and addresses
obtained from State Motor Vehicle Registration Records. The use of such motor vehicle
registration data for any other purpose is unlawful. Accordingly, retailers are required
to limit the use of these lists for the purpose of completion of this safety recall.
SUBARU RETAILER PROGRAM RESPONSIBILITY
Retailers are to promptly perform the applicable service procedures to correct all affected
vehicles in their inventory. Additionally, whenever a vehicle subject to this recall is taken into
inventory or in for service, necessary steps should be taken to ensure the recall correction has
been made before selling or releasing the vehicle.
Any vehicles listed in a recall/campaign that are in the retailer’s stock must be:
•
Immediately identified.
•
Tagged or otherwise marked to prevent their delivery or use prior to inspection and/or
repair.
•
Repaired in accordance with the repair procedures outlined in this Product Campaign
Bulletin.
Please be advised that it is a violation of Federal law for a retailer to deliver a new motor
vehicle covered by a recall under a sale or lease until the defect is remedied. In addition,
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
will be in breach of the Subaru Dealer Agreement.
PARTS INFORMATION
The parts required for this recall are the passenger air bag inflator module kits listed below:
PART NUMBER
APPLICABILITY
DESCRIPTION
ORDER
QUANTITY
98279AE00A
2003-2004 Legacy, 2003-2004
Outback and 2003-2004 Baja
Air Bag Inflator Module Kit
1
98279FE000
2004-2005 Impreza, WRX, and STI
Air Bag Inflator Module Kit
1
98279AG00A
2005-2008 Legacy and Outback
Air Bag Inflator Module Kit
1
In order to maintain an adequate part supply, SOA requests that retailers only order quantities
necessary to satisfy anticipated demand. Orders will be monitored by SOA Parts for
reasonableness based on AOR assigned VIN population.
As a reminder, if a customer requests a loaner car due to the insufficient supply of parts,
retailers should make every effort to comply with this request, and should follow normal
warranty procedures to obtain reimbursement for the loaner car. See Section 8.4.7 of the
Claims Policies and Procedures Manual on subarunet.com for details on rental authorizations.
If you have any questions, please contact the Parts Information Coordinators.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 3
PART RETURN PROCEDURES
Please read the ‘Inflator Returns’ instructions included as ‘Appendix A’ of this bulletin
carefully, as the return procedure has changed.
•
FedEx will no longer handle the return shipments.
•
A company called Stericycle will arrange pick up of the inflators and return them
to Takata.
•
Once a month or upon accumulating 200 kits for return (whichever comes first)
please call Stericycle at 1-877-650-3476 for pick up. Please see step 6 of the return
instructions.
•
Starting in September, 2015 the new inflator return instructions for pick up by
Stericycle will be included with each new air bag inflator kit.
•
If you continue to receive inventory of inflators with the original FedEx
documentation, please follow the instructions in step 4b. of the new ‘Inflator
Returns’ instructions. DO NOT CALL FEDEX.
•
Upon claim approval, Subaru of America, Inc. will generate a Part Return Notice
requesting the old and new inflator serial number information only. DO NOT
WAIT FOR STERICYCLE TO PICK UP THE INFLATOR TO SEND THIS
INFORMATION TO THE PARTS COLLECTION CENTER (PCC).
•
IMPORTANT: Each removed air bag inflator must be returned directly to the
supplier, Takata USA, in the same box in which the new one was received.
The shipping box contains a bar code label, which will be used by Takata USA to document
the replacement of the old inflator with the new inflator. Therefore, it is very important
that the removed inflator be returned in the exact same box that contained the newlyinstalled inflator for that vehicle. If the original box cannot be re-used, please refer to the
shipping instructions under “Requesting a new box/ shipping labels.”
•
IMPORTANT: When affixing the shipping label to the shipping box do not obstruct
the bar code label.
•
A completed SOA Warranty Parts Tag (MSA5W402A) must be attached to the
returned inflator. The tag must contain the following information: claim number,
repair date, full 17-digit VIN, and mileage.
SOA PART RETURN NOTICE
•
Upon claim approval, Subaru of America, Inc. will generate a Part Return Notice
requesting information only.
•
To ensure proper claim credit, the old and new inflator serial numbers must be
recorded on the Part Return Notice and sent to SOA Part Collection Center (PCC) as
instructed on the return notice.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 4
•
•
The completed Part Return Notice should then be sent using the YRC web portal and
utilizing the “Ship Small Parcel” link which will direct the user to the appropriate
UPS web page application to complete the shipment. Please keep the UPS tracking
number for your records.
DO NOT WAIT FOR STERICYCLE TO PICK UP THE PART TO SEND THIS
INFORMATION TO THE PCC.
Under no circumstances should the air bag inflator be sent to Subaru of America, Inc.
SERVICE PROCEDURE
This Campaign involves the replacement of the inflator portion of the passenger-side front
airbag assembly. The subject inflators could have been assembled with improperly manufactured
propellant components which may affect how the assembly inflates in the event of a collision
resulting in an increased risk of injury to vehicle occupants. This procedure will outline removal
of the passenger-side airbag assembly and replacement of the inflator component and related
wiring harness.
VERY IMPORTANT: Failure to follow these service procedures carefully and correctly
may result in an accidental deployment of the inflator and potentially cause serious injury.
Please read through and understand these procedures COMPLETELY before beginning
repairs. In addition, proper operation of the airbag after reassembly may be compromised
if these service procedures are not followed.
Tools Required
DESCRIPTION
Pliers
Wire Cutters
Needle-Nose Pliers
Torque Wrench
Safety Goggles
Flat-Blade Screwdriver
Scissors
Ratchet
8 mm and 10 mm Socket
Airbag Deployment Fixture
BRAND OR TYPE
Inch-Pound
1/4” Drive
J-39401-B
QUANTITY
1
1
1
1
1
1
1
1
1 ea,
1
NOTE: Although the service procedure is similar for Legacy / Outback / Baja and Impreza
models, there are some significant differences. For this reason, procedures for each model
will be outlined.
CAUTION: Before starting this service procedure, perform a visual inspection of both front
airbags looking for any damage or abnormality. Next, turn the ignition switch to the “ON”
position and confirm the airbag warning lamp illuminates then extinguishes normally. If it
does not or if ANY concern is noted with the airbag system, STOP and report these findings
to the customer BEFORE proceeding further. Any concerns identified with the airbag system
(when no airbag deployment has occurred), are not related to this campaign and must be addressed separately. Even if the system has a concern, this may not preclude completion of this
campaign. If you are unsure about proceeding, document and fully diagnose the concern then
contact the SOA Technical Helpline to review your findings. It is in the best interest of the
retailer to fully document any concerns found during this preliminary inspection and review
with the customer BEFORE proceeding with the campaign service procedure.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 5
CAUTION: Before starting this service procedure, perform a visual inspection of both front
airbags looking for any damage or abnormality. Next, turn the ignition switch to the “ON”
position and confirm the airbag warning lamp illuminates then extinguishes normally. If it
does not or if ANY concern is noted with the airbag system, STOP and report these findings
to the customer BEFORE proceeding further. Any concerns identified with the airbag system
(when no airbag deployment has occurred), are not related to this campaign and must be
addressed separately. Even if the system has a concern, this may not preclude completion of
this campaign. If you are unsure about proceeding, document and fully diagnose the concern
then contact the SOA Technical Helpline to review your findings. It is in the best interest
of the retailer to fully document any concerns found during this preliminary inspection and
review with the customer BEFORE proceeding with the campaign service procedure.
•
Vehicles that do not contain Genuine Subaru air bags are not eligible for this
recall repair. For more information on identifying counterfeit air bags and how
to address related customer situations, please refer to STIS for the “Counterfeit
Air Bag Information” Dealer Advisory Bulletin dated October 25, 2012 by going
to Subarunet>Service>STIS>Online Reference - choose Publication Type: ‘Other/
Miscellaneous’ and search keywords: ‘Air Bag’).
•
Do not proceed with this repair if your inspection reveals a non-Genuine Subaru
air bag module has been installed in the vehicle. Follow the instructions described
in the “Counterfeit Air Bag Information” Dealer Advisory Bulletin and contact the SOA
Warranty Helpline to close out the WQL-48 recall coverage on the vehicle.
•
IMPORTANT: Always examine airbag modules closely before and during removal.
Confirm they match the photos of the Genuine Subaru airbag components supplied
throughout this bulletin BEFORE proceeding. The photos below are just 2 examples
of aftermarket or counterfeit airbag components identified by retailers since the release
of this campaign bulletin. These photos are being provided as only 2 examples of what
may be a wide variety of non-OEM components.
•
If an aftermarket or counterfeit passenger airbag or inflator is identified at any point
during the campaign service procedure, STOP IMMEDIATELY. NEVER attempt to
remove or otherwise disable any aftermarket or counterfeit device.
•
Document the presence of the aftermarket or counterfeit device on the repair order and
with photos. Report this information immediately on a Quality Monitoring Report (QMR).
•
Once the QMR has been submitted, contact the Subaru Claims Helpline to discuss the
details. They will advise you on how to proceed with treatment of the open campaign.
No visible stopper plates, a
6-nut configuration and rubber
harness boots are other examples
to indicate this is not a Genuine
Subaru airbag module.
The shape, holes, and
copper-colored stud indicate this
not a Genuine Subaru inflator.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 6
*SERVICE PROCEDURE FOR 2005-2008 MY LEGACY / OUTBACK MODELS*
CAUTION: Refer to the “CAUTION” section in the General Description portion
of Airbag System AB in the Body Section of the Service Manual before handling or
servicing any airbag module!
STEP 1- PREPARATION:
•
•
•
•
•
Turn the ignition “OFF”.
Disconnect the Negative (ground) cable from the battery and wait at least 20 seconds
before proceeding further.
Follow the procedures in the applicable Service Manual for removing the instrument
panel assembly as required to access the passenger side airbag module.
Disconnect the wiring harness and remove the airbag module.
Secure the airbag module to the Airbag Deployment Fixture (part number J-39401-B)
as shown in the photo below.
IMPORTANT: Whenever beginning to remove (or install) the airbag assembly, and
periodically while performing the procedure or after stepping away, remove any possible
static charge from your body by momentarily touching a clean, bare metal ground point
on the vehicle (e.g. the door striker). Remove from your person all electronic devices
including cell phones before proceeding.
IMPORTANT: DO NOT destroy or damage the Kit Box as it MUST be used for the
original inflator’s return shipping.
Open the Kit Box and confirm all the necessary components are included
•
•
•
•
•
•
•
4 Self-Locking nuts
New Inflator (yellow tape applied to one end to identify it as the replacement part)
New Inflator Harness
Electro-Tap (red shorting crimp connector)
New Stopper Plate with D-Shaped hole
Self-Adhesive Foam Protector
Shipping Documentation
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 7
To access the passenger’s airbag module, the complete instrument panel assembly must
be removed. Follow the procedures in the applicable Service Manual for removing the
instrument panel assembly in addition to the necessary related interior trim components.
NOTE: When removing the “A” pillar trim, be VERY CAREFUL not to damage the upper
metal retaining clip. The clip is located just below where the trim panel meets the head liner.
If the metal retaining clip becomes damaged or separated from the trim panel, the trim panel
MUST be replaced as the clip is not available separately. Use a plastic trim tool to push
and release the upper portion of the metal clip from the body. Be careful to not pull the trim
panel open any further than necessary to gain access for releasing the clip. There is a plastic
retaining clip in the lower portion of the trim panel which will release easily once the upper
retaining clip is loose. At reassembly and using a plastic trim tool, make sure the inner lip of
the door weatherstrip overlaps the outer fabric edge of the trim panel to help secure it.
1
Insert Trim Tool
2
Push to
Release
3
4
Lip of Door
Weatherstrip
Overlaps Fabric
Edge of Trim Panel
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 8
Once the instrument panel assembly has been removed from the vehicle, CAREFULLY
separate the airbag module from it.
IMPORTANT: The removed airbag module must be mounted to the Airbag Deployment
Fixture (part number J-39401-B) as shown in the photo below to better secure it during
the inflator and wiring harness component replacement procedures. When mounting the
module to the fixture, pay close attention to the harness routing as shown in the photo below.
Always perform this work in an area away from others to reduce chances of inadvertent
injury should any deployment occur. Take your surroundings into account to avoid possible
hazards should inadvertent deployment occur or sources of static or other electricity that could
potentially induce such a deployment.
STEP 2- Remove both sides of the harness from the retainer bracket holders then secure the
airbag module to the Airbag Deployment Fixture as shown in the photos below.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 9
STEP 3- CAREFULLY cut the yellow harness cover (approximately 1 1/2 inches) enough to
expose the 2 yellow and red wires inside and provide enough room to install the Electro-Tap
(shorting) connector using a scissor or wire cutter (no knives or razors).
TAKE YOUR TIME AND BE CAREFUL TO NOT CUT THE 2 WIRES!
STEP 4- Short the yellow and red wires together by installing the Electro-Tap connector. The
connector creates a short circuit which acts as a safeguard to prevent against static discharge
that may deploy the removed inflator. The tab portion of the Electro-Tap connector MUST be
cut off prior to use to insure a good short-circuit is made as shown in the illustration below.
Follow the sequence below for installing the Electro-Tap connector. Use pliers to squeeze
closed the two sections of the connector together, one section at a time.
This tab MUST
be cut off
Insert 1 wire in
the Electro-Tap
Fold
1
2
3
Place the other
wire in the
Electro-Tap,
fold then crimp
closed with pliers
Crimp closed
with pliers
4
5
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 10
STEP 5- Once the Electro-Tap connector is fully crimped in place, cut the yellow and red
wires on the body harness connector side of the Electro-Tap connector as shown below.
STEP 6- Loosen but do not remove the two 10mm self-locking nuts securing the stopper
plate securing the end of the inflator with the blue and white wires as leaving them in place
will help keep the airbag assembly together. Remove the two nuts and the stopper plate on the
on the opposite end of the inflator mounting bracket and discard them. NEVER ATTEMPT
TO REMOVE THE HARNESS CONNECTORS FROM THE INFLATOR! With the
stopper plate removed and the other 2 self-locking nuts loosened, slide the original inflator
out of the mounting bracket while feeding the cut off portion of the wiring harness under the
remaining stopper plate. Place the removed original air bag inflator in the “cradle” of the Kit
Box insert.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 11
STEP 7 - VERY IMPORTANT: Record the 11-digit alpha-numeric serial number
for both the new and the removed inflators on the hard copy of the Repair Order. This
information will be required for completion of the Part Return Notice which will be forwarded
by the retailer to the PCC.
STEP 8- Install the new inflator into the mounting bracket so the yellow taped end aligns with
the stopper plate still installed on the mounting bracket. Make sure the “D-shaped” portion of
the inflator harness connector boss aligns with the “D-shaped” portion of the hole in the new
replacement stopper plate as shown below. Do not peel the white harness connection dust
cover at this time. Use 2 NEW self-locking nuts to secure the new stopper plate but do not
fully tighten them. Remove the other 2 nuts securing the other stopper plate on the mounting
bracket and replace them with 2 NEW self-locking nuts. When properly installed, both ends
of the inflator will be seated tight against both stopper plates with no gaps.
Properly Aligned
3
2
No Gap
1
4
No Gap
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 12
STEP 9- Once all 4 NEW nuts are in place, torque to 31 - 38 inch pounds in the sequence
shown above. Use a marker to mark the nuts after torquing to indicate they have been fully
tightened.
STEP 10- Install the black foam self-adhesive protector onto the D-Shaped stopper and
mounting bracket positioned as shown in the photo sequence below. Once adhered in place on
the new stopper plate, fold over the excess as shown. Always make sure the placement area for
the protector is free of any grease or dirt before application.
1
2
3
4
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 13
STEP 11- The new inflator wiring harness has 2 “sides” with round 2-pin connectors on
both ends. The side with the yellow corrugated tube and red / yellow wires will connect to
the end of the inflator with the D-Shaped wiring harness connector boss, new stopper plate
and foam protector as shown below. Peel off the white dust cover from the D-Shaped end of
the inflator ONLY. IMPORTANT: NEVER PEEL BOTH THE WHITE DUST COVERS
OFF AT THE SAME TIME! CAREFULLY align the pins with the female terminals of the
harness connector (red / yellow wires) as shown in the photos below. Once pin alignment is
confirmed, push down firmly to engage the connector’s 3 locking tangs into the locking
groove inside the connector boss. Confirm the connector is locked by prying up LIGHTLY
with a small flat-blade screwdriver. Repeat the procedure on the opposite end with the blue /
white wires.
VERY IMPORTANT: When connecting the new harness to the inflator, both sides of
the harness MUST be routed toward the module’s mounting brackets as shown in the
photos below.
Locking Groove
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 14
STEP 12- Refit the ends of the harness corrugated tubes to the retaining grooves of the
mounting bracket as shown to complete the airbag module reassembly.
STEP 13- CAREFULLY reinstall the airbag module assembly into the instrument panel as
shown below.
STEP 14- To eliminate a possible source of a rattling sound from the dash, wrap the 2 hooks
and locator pin with non-woven material, p.n. SOA963W110 (or an equivalent self-adhesive
foam) as shown below.
Hook
Locator Pin
Hook
REMINDER: 1 sheet of the SOA963W110 non-woven material is enough for approximately
8 vehicles.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 15
STEP 15- Reinstall the instrument panel assembly into the vehicle in reverse order of
disassembly. Once the negative battery cable has been reconnected, turn the ignition key
“ON” and confirm the AIRBAG warning light comes on then cycles off properly. Once
proper warning light operation is confirmed, reinstall the remaining components to complete
the procedure.
STEP 16- Place the removed original air bag inflator in the “cradle” of the Kit Box insert,
with a completed SOA warranty parts tag (MSA5W402A) attached to it. The tag must contain
the following information: Claim Number, Repair Date, 17-digit VIN, and vehicle mileage.
Refer to the “PART RETURN PROCEDURES” section of this bulletin (page 4) for further
return shipping instructions and information. Ensure both the removed and installed
inflator serial numbers have been recorded correctly as previously instructed on the
repair order hard copy before returning the removed part to your Parts Department.
IMPORTANT: UNDER NO CIRCUMSTANCES SHOULD ANY AIR BAG
INFLATORS BE RETURNED TO SUBARU OF AMERICA, INC.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 16
*SERVICE PROCEDURE FOR 2003-2004 LEGACY / OUTBACK AND BAJA MODELS*
CAUTION: Refer to the “CAUTION” section in the General Description portion
of Airbag System AB in the Body Section of the Service Manual before handling or
servicing any airbag module!
STEP 1- PREPARATION:
•
Turn the ignition “OFF”.
•
Disconnect the Negative (ground) cable from the battery and wait at least 20 seconds
before proceeding further.
•
Remove the glove box assembly following the procedure in the applicable Service
Manual and using the tips below.
The glove box is held in place by 8 screws.
оо The 2 upper left and right hand corner screws have a distinctive gold finish and
10mm hex head. It is helpful to leave these 2 screws until last when removing and
install first during replacement to support the weight of the assembly.
оо It is necessary to remove the knockout plugs (stopper in the Service Manual) to
gain access to all the mounting screws.
оо It is possible to leave the stoppers in place during servicing by carefully bending
in the sides of the glove box until the stoppers are cleared.
•
To prevent damage, do not bend them in any further than necessary.
•
IMPORTANT: Whenever beginning to remove (or install) the airbag assembly,
and periodically while performing the procedure or after stepping away, remove
any possible static charge from your body by momentarily touching a clean, bare
metal ground point on the vehicle (e.g. the door striker). Remove from your
person all electronic devices including cell phones before proceeding.
•
Disconnect the airbag module harness connector (A) and release it from the support
beam bracket.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 17
•
Remove the 3 retaining bolts and CAREFULLY remove the airbag module from
the vehicle and place it on a clean cloth to protect the dash trim outer surface portion
from damage.
IMPORTANT: DO NOT destroy or damage the Kit Box as it MUST be used for the
original inflator’s return shipping.
•
Open the Kit Box and confirm all the necessary components are included:
4 Self-Locking nuts
New Inflator (yellow tape applied to one end to identify it as the replacement part)
New Inflator Harness
Electro-Tap (red shorting crimp connector)
Shipping Documentation and Instructions
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 18
•
IMPORTANT: The removed airbag module must be mounted to the Airbag
Deployment Fixture (part number J-39401-B) as shown in the photo below to
better secure it during the inflator and wiring harness component replacement
procedures. When mounting the module to the fixture, pay close attention to the
harness routing as shown in the photo below. Always perform this work in an area
away from others to reduce chances of inadvertent injury should any deployment
occur. Take your surroundings into account to avoid possible hazards should
inadvertent deployment occur or sources of static or other electricity that could
potentially induce such a deployment.
STEP 2- Remove the harness clip from the retainer bracket by rotating the harness / clip 90
degrees then releasing it from the bracket with needle-nose pliers.
STEP 3- CAREFULLY cut the yellow harness cover (approximately 1 1/2 inches) enough
to expose the 2 yellow wires inside and provide enough room to install the Electro-Tap
(shorting) connector using a scissor or wire cutter (no knives or razors). TAKE YOUR
TIME AND BE CAREFUL TO NOT CUT THE 2 YELLOW WIRES!
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 19
STEP 4- Short the 2 yellow wires together by installing the Electro-Tap connector. The
connector creates a short circuit which acts as a safeguard to prevent against static discharge
that may deploy the removed inflator. The tab portion of the Electro-Tap connector MUST
be cut off prior to use to insure a good short-circuit is made as shown in the illustration below.
Follow the sequence below for installing the Electro-Tap connector. Use pliers to squeeze
closed the two sections of the connector together, one section at a time.
This tab MUST
be cut off
Insert 1 wire in
the Electro-Tap
Fold
1
2
3
Place the other
wire in the
Electro-Tap,
fold then crimp
closed with pliers
Crimp closed
with pliers
4
5
STEP 5- Once the Electro-Tap connector is fully crimped in place, cut the 2 yellow wires on
the body harness connector side of the Electro-Tap connector.
CUT
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 20
STEP 6- Remove the two 8mm self-locking nuts securing the stopper plate. Loosen but do
not remove the other two nuts on the mounting bracket as leaving them in place will help
keep the airbag assembly together.
NEVER ATTEMPT TO REMOVE THE HARNESS CONNECTORS FROM THE
INFLATOR!
Stopper Plate
STEP 7- With the stopper plate removed and the other 2 self-locking nuts loosened, unseat
the inflator off the mounting bracket end plate then rotate it slightly CLOCKWISE to make it
easier to remove as shown below. Slide the original inflator out of the mounting bracket while
feeding the cut off portion of the wiring harness through the “D-Shaped” hole in the end plate.
NEVER ATTEMPT TO REMOVE THE HARNESS CONNECTORS FROM THE
INFLATOR! Place the removed original air bag inflator in the “cradle” of the Kit Box insert.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 21
STEP 8- VERY IMPORTANT: Record the 11-digit alpha-numeric serial number
for both the new and the removed inflators on the hard copy of the Repair Order. This
information will be required for completion of the Part Return Notice which will be forwarded
by the retailer to the PCC.
STEP 9- Install the new inflator into the mounting bracket so the yellow taped end aligns with
the removed stopper plate. Make sure the “D-shaped” portion of the inflator harness connector
boss aligns with the “D-shaped” portion of the hole in the end of the mounting bracket as
shown below. When properly installed, the end of the inflator will be seated tight against the
mounting bracket. Do not peel the white harness connection dust cover at this time.
Inflator properly
seated against
mounting bracket
(NO GAP)
STEP 10- As shown below, install but do not fully tighten 2 of the NEW self-locking nuts
while holding the stopper plate tight against the inflator. Remove the nuts still installed on
the mounting bracket and replace them with 2 NEW self-locking nuts. Once all 4 NEW nuts
are in place, torque to 31 - 38 inch pounds in the sequence shown below. Use a marker to
mark the nuts after torquing to indicate they have been fully tightened.
3
1
2
4
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 22
STEP 11- The new inflator wiring harness has a “long side” and a “short side” with round 2-pin
connectors on both ends. The short side with red wires will connect to the end of the inflator
with the round wiring harness connector boss, yellow tape and removable stopper plate. VERY
IMPORTANT: When connecting the new harness to the inflator, both sides of the harness
MUST be routed toward the module’s mounting brackets as shown in the photos below.
Peel off the white dust cover from the round connector boss end of the inflator ONLY.
CAREFULLY align the pins with the female terminals of the harness connector (2 red
wires) as shown in the sequence below. IMPORTANT: NEVER PEEL BOTH THE
WHITE DUST COVERS OFF AT THE SAME TIME! Once pin alignment is confirmed,
push down firmly to engage the connector’s 3 locking tangs into the locking groove inside
the connector boss. Confirm the connector is locked by prying up LIGHTLY with a small
flat-blade screwdriver. Repeat the procedure on the D-shaped connector boss end (2 yellow
wires). Reinstall the black wiring harness retaining clip into the mounting bracket to
complete the airbag reassembly.
Locking Groove
STEP 12- Reinstall the airbag assembly into the vehicle in reverse order of disassembly.
Before installing the glove box assembly, reconnect the negative battery cable. Turn the
ignition key “ON” and confirm the AIRBAG warning light comes on then cycles off properly.
Once proper warning light operation is confirmed, reinstall the glove box assembly to
complete the procedure.
STEP 13- Place the removed original air bag inflator in the “cradle” of the Kit Box insert,
with a completed SOA warranty parts tag (MSA5W402A) attached to it. The tag must
contain the following information: Claim Number, Repair Date, 17-digit VIN, and vehicle
mileage. Refer to the “PARTS RETURN PROCEDURES” section of this bulletin (page
3) for further return shipping instructions and information. Ensure both the removed and
installed inflator serial numbers have been recorded correctly as previously instructed
on the repair order hard copy before returning the removed part to your Parts
Department.
IMPORTANT: UNDER NO CIRCUMSTANCES SHOULD ANY AIR BAG
INFLATORS BE RETURNED TO SUBARU OF AMERICA, INC.
• Refer to Page 20 for instructions on completing and installing the Recall
Identification Label.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 23
*SERVICE PROCEDURE FOR IMPREZA, WRX and STI MODELS*
CAUTION: Refer to the “CAUTION” section in the General Description portion
of Airbag System AB in the Body Section of the Service Manual before handling or
servicing the airbag module!
STEP 1- PREPARATION:
•
•
•
Turn the ignition “OFF”.
Disconnect the Negative (ground) cable from the battery and wait at least 20 seconds
before proceeding further.
Remove the glove box assembly following the procedure in the applicable Service
Manual.
IMPORTANT: Whenever beginning to remove (or install) the airbag assembly, and
periodically while performing the procedure or after stepping away, remove any possible
static charge from your body by momentarily touching a clean, bare metal ground point
on the vehicle (e.g. the door striker). Remove from your person all electronic devices
including cellphones before proceeding.
•
Disconnect the airbag module harness connector
from the support beam bracket.
•
Remove the 3 retaining bolts and CAREFULLY
remove the airbag module from the vehicle and
place it on a clean cloth to protect the dash trim
surface portion from damage.
NOTE: There may be a Security Module secured
with the lower airbag module mounting bolt on some
models.
IMPORTANT: DO NOT destroy or damage the kit box as it MUST be used for the
original inflator’s return shipping.
•
Open the Kit Box and confirm all the necessary components are included:
4 Self-Locking nuts
New Inflator (yellow tape applied to one end to identify it as the replacement part)
New Inflator Harness
Electro-Tap (red shorting crimp connector)
1 ½” X 2 ¼” piece of self-adhesive Sponge Tape
Shipping Documentation and Instructions
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 24
•
IMPORTANT: The removed airbag module must be mounted to the Airbag
Deployment Fixture (part number J-39401-B) as shown in the photo below to
better secure it during the inflator and wiring harness component replacement
procedures. Always perform this work in an area away from others to reduce chances
of inadvertent injury should any deployment occur. Take your surroundings into
account to avoid possible hazards should inadvertent deployment occur or sources of
static or other electricity that could potentially induce such a deployment.
STEP 2- Peel the Sponge Tape and remove the harness clip from the retainer bracket by
pushing the tangs inward with a flat-blade screwdriver as shown below. Always remove any
Sponge Tape adhesive residue from the airbag mounting bracket using mild solvent on a clean
shop cloth. CAUTION: Never use any silicone-based products for this purpose.
STEP 3- CAREFULLY cut the yellow harness cover enough (approximately 2 inches) to
expose the 2 red or yellow wires inside and provide enough room to install the Electro-Tap
(shorting) connector using a wire cutter or scissor (no knives or razors). TAKE YOUR
TIME AND BE CAREFUL TO NOT CUT THE 2 WIRES!
Red Wires
Yellow Wires
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 25
STEP 4- Short the 2 wires together by installing the Electro-Tap connector. The connector
creates a short circuit which acts as a safeguard to prevent against static discharge that may
deploy the removed inflator. The tab portion of the Electro-Tap connector MUST be cut off
prior to use to insure a good short-circuit is made as shown in the illustration below. Follow
the sequence below for installing the Electro-Tap connector. Use pliers to squeeze closed the
two sections of the connector together, one section at a time.
This tab MUST
be cut off
Insert 1 wire in
the Electro-Tap
Fold
1
2
3
Place the other
wire in the
Electro-Tap,
fold then crimp
closed with pliers
Crimp closed
with pliers
4
5
STEP 5- Once the Electro-Tap connector is fully crimped in place, cut the 2 wires on the
body harness connector side of the Electro-Tap connector.
CUT
STEP 6- Remove the two 8mm self-locking nuts securing the stopper plate. Loosen but do
not remove the other two nuts on the mounting bracket as leaving them in place will help
keep the airbag assembly together.
Remove
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 26
STEP 7- With the stopper plate removed and
the other 2 self-locking nuts loosened, unseat
the inflator off the mounting bracket end
plate then rotate it slightly CLOCKWISE
to make it easier to remove as shown in the
photo to the right. Slide the inflator out of its
mounting while feeding the cut off portion of
the wiring harness through the “D-Shaped”
hole in the end of the mounting bracket.
NEVER ATTEMPT TO REMOVE THE
HARNESS FROM THE INFLATOR!
Place the removed original air bag inflator in
the “cradle” of the Kit Box insert.
STEP 8- VERY IMPORTANT: Record the 11-digit alpha-numeric serial number
for both the new and the removed inflators on the hard copy of the Repair Order. This
information will be required for completion of the Part Return Notice which will be forwarded
by the retailer to the PCC. The new serial number is also a requirement for claim entry.
STEP 9- Install the new inflator into the mounting bracket with the harness connector end going
in first toward the mounting bracket. Make sure the “D-shaped” portion of the inflator harness
connector boss aligns with the “D-shaped” portion of the hole in the end of the mounting
bracket as shown below. When properly installed, the end of the inflator will be seated tight
against the mounting bracket. Do not peel the white harness connection dust cover at this time.
Inflator properly
seated against
mounting bracket
(NO GAP)
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 27
STEP 10- As shown below, install but do not fully tighten 2 of the NEW self-locking nuts
while holding the stopper plate tight against the inflator. Remove the nuts still installed on the
mounting bracket and replace them with 2 NEW self-locking nuts. Once all 4 NEW nuts are
in place, torque to 31 - 38 inch pounds in the sequence shown below. Use a marker to mark
the nuts after torquing indicating they have been fully tightened.
3
2
1
4
STEP 11- VERY IMPORTANT: When connecting the new harness to the inflator,
the harness MUST be routed toward the module’s mounting brackets as shown in the
photo below. Peel off the white dust cover and CAREFULLY align the 2 inflator pins with
the female terminals of the harness connector as shown in the sequence below. Once pin
alignment is confirmed, push down firmly to engage the connector’s 2 locking tangs into the
locking groove of the connector boss. Confirm the connector is fully locked by prying up
LIGHTLY with a small flat-blade screwdriver.
Locking Groove
STEP 12- Reinstall the wiring harness retaining clip into its position on the mounting bracket.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 28
STEP 13- Peel the adhesive backing and install the new Sponge Tape onto the yellow harness
tube first then adhere it to the airbag mounting bracket as shown in the illustrations below.
Placement of Sponge Tape
IMPORTANT: The
Sponge tape must be
installed more than
half-way around the
yellow harness tube.
Harness
Sponge Tape
STEP 14- Reinstall the airbag assembly into the vehicle in reverse order of disassembly.
NOTE: If the accessory security module is installed to one of the airbag module mounting
bolts, torque that specific bolt to 7.5 +/-1ft. lb. rather than the normal 5.4 ft. lb. specified in
the Service Manual. Before installing the glove box assembly, reconnect the negative battery
cable. Turn the ignition key “ON” and confirm the AIRBAG warning light comes on then
cycles off properly. Once proper warning light operation is confirmed, reinstall the glove
box assembly while making sure the cord loop for the opening dampener (if equipped) stays
connected to complete the procedure.
STEP 15- Place the removed air bag inflator in the “cradle” of the Kit Box insert, with a
completed SOA warranty parts tag (MSA5W402A) attached to it. The tag must contain the
following information: Claim Number, Repair Date, 17-digit VIN, and vehicle mileage.
Refer to the “PARTS RETURN PROCEDURES” section of this bulletin (page 3) for further
return shipping instructions and information.
IMPORTANT: UNDER NO CIRCUMSTANCES SHOULD ANY AIR BAG
INFLATORS BE RETURNED TO SUBARU OF AMERICA, INC.
Bulletin Number: WQR-53R; Revised: January 14, 2016
Continued...
Page 29
RECALL IDENTIFICATION LABEL
Type or print the necessary information on a Service Program identification label. The
completed label should be attached to the vehicle’s upper radiator support.
Additional labels are available through normal parts ordering channels. The part number is
MSA6P1302. Ordering qty 1 = 1 sheet of 20 labels.
PART NUMBER
APPLICABILITY
DESCRIPTION
ORDER QUANTITY
MSA6P1302
All models
Campaign Completion Labels
(contains one sheet of 20 labels)
1
WQR-53
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES
Credit to perform this recall will be based on the submission of properly completed repair order
information. Retailers may submit claims through ‘Vehicle Claim Entry’ on Subarunet.com.
Listed below is claim entry information:
CLAIM
TYPE
RC
CAMPAIGN
CODE
DESCRIPTION
LABOR
TIME
2003-2004 Legacy, Outback, Baja
2004-2005 Impreza, WRX, STI
Front Passenger Air Bag Inflator Replacement
0.8
2005-2008 Legacy, Outback
Front Passenger Air Bag Inflator Replacement
1.8
LABOR
A182-031
WQR-53
PART NUMBER
APPLICABILITY
DESCRIPTION
QUANTITY
98279AE00A
2003-2004 Legacy,
Outback, and Baja
Air Bag Inflator Module Kit
1
98279FE000
2004-2005
Impreza, WRX,
and STI
Air Bag Inflator Module Kit
1
98279AG00A
2005-2008 Legacy
and Outback
Air Bag Inflator Module Kit
1
Miscellaneous Detail
Enter the serial number of the NEW air bag inflator installed in the
“Misc. Details” field.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 30
OWNER NOTIFICATION LETTER
IMPORTANT SAFETY RECALL
This notice applies to the VIN identified
in the address section printed below.
Subaru Recall Campaign WQR-53
NHTSA Recall No. 15V-323
June 2015
Dear Subaru Owner:
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
SUBARU OF AMERICA, INC. has decided that a defect, which relates to motor vehicle safety, exists in certain
2004 and 2005 model year Impreza, WRX, and STI vehicles.
You received this notice because our records indicate that you currently own one of these vehicles.
DESCRIPTION OF THE SAFETY DEFECT AND SAFETY HAZARD
The affected vehicles are equipped with a passenger side frontal air bag that may be susceptible to moisture intrusion
which, over time, could cause the inflator to rupture upon its deployment.
In the event of a crash necessitating deployment of the passenger’s frontal air bag, the inflator could rupture with
metal fragments striking the vehicle occupants potentially resulting in serious injury or death.
REMEDY
WHAT YOU SHOULD DO
You should immediately contact your Subaru retailer (dealer) for an appointment to have the front passenger air
bag inflator replaced with a new one.
Until this repair is performed, do not allow passengers to ride in the front passenger seat.
Subaru will replace the inflator for your front passenger air bag at no cost to you.
HOW LONG WILL THE REPAIR TAKE?
The time to replace the front passenger air bag inflator is approximately 40 minutes. However, it may be necessary
to leave your vehicle for a longer period of time on the day of your scheduled appointment to allow your Subaru
retailer flexibility in scheduling. Please present this letter to your Subaru retailer at the time this repair procedure is
performed.
CHANGED YOUR ADDRESS OR SOLD YOUR SUBARU?
If you have moved or sold your vehicle, please complete the enclosed prepaid postcard and mail it to us. Or if
you prefer to update this information online, please go to www.subaru.com, select ‘Customer Support,’ then select
‘Address Update’ or ‘Ownership Update’ from the drop down menu.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 31
IF YOU NEED FURTHER ASSISTANCE:
To locate the nearest Subaru retailer you can access our website at www.subaru.com and select ‘Find a Retailer.’
For additional information and the most Frequently Asked Questions, please go to:
• http://www.wqr53.service-campaign.com
If you need additional assistance, please contact us directly:
•
By e-mail: Go to www.subaru.com and select “Contact Us”
•
 y telephone: 1-800-SUBARU3 (1-800-782-2783)
B
Monday through Thursday between 7:30 a.m. and 8:00 p.m. ET
Friday between 10:30 a.m. and 5:00 p.m. ET
Saturday between 9:00 a.m. and 3:30 p.m. ET
•
 y U.S. Postal mail: Write us at Subaru of America, Inc., Attn: Customer-Retailer Services Department,
B
P.O. Box 6000, Cherry Hill, NJ 08034-6000
Please contact us immediately if the Subaru retailer fails or is unable to make the necessary repairs free of charge.
You may also contact the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave. SE,
West Building, Washington, DC 20590 or call the toll free Auto Safety Hotline at 1-888-327-4236 (TTY: 1-800424-9153) or go to http://www.safercar.gov if you believe the Subaru retailer has failed or is unable to remedy your
vehicle without charge within a reasonable amount of time.
Your continued satisfaction with your Subaru is important to us. Please understand that we have taken this action in
the interest of your safety and your vehicle’s proper operation. We sincerely apologize for any inconvenience this
matter may cause and urge you to schedule an appointment as soon as possible to have this repair performed.
Sincerely,
Subaru of America, Inc.
Notice to Lessors: Under Federal law the lessor of a vehicle who receives this letter must provide a copy of it to the vehicle lessee(s)
within 10 business days from receipt. The lessor must also keep a record of the lessee(s) to whom this letter is sent, the date sent, and the
applicable vehicle identification number (VIN). (For the purposes of this section, a lessor means a person or entity that in the last twelve
months prior to the date of this notification has been the owner, as referenced on the vehicle’s title, of any five or more leased vehicles. A
leased vehicle is a vehicle leased to another person for a term of at least four months.)
A subsidiary of Fuji Heavy Industries Ltd.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 32
OWNER NOTIFICATION LETTER
IMPORTANT SAFETY RECALL
This notice applies to the VIN identified
in the address section printed below.
Subaru Recall Campaign WQR-53
NHTSA Recall No. 15V-323
July 2015
Dear Subaru Owner:
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
SUBARU OF AMERICA, INC. has decided that a defect, which relates to motor vehicle safety, exists in certain
2004 and 2005 model year Impreza, WRX, and STI vehicles.
You received this notice because our records indicate that you currently own one of these vehicles.
DESCRIPTION OF THE SAFETY DEFECT AND SAFETY HAZARD
The affected vehicles are equipped with a passenger side frontal air bag that may be susceptible to moisture intrusion
which, over time, could cause the inflator to rupture upon its deployment.
In the event of a crash necessitating deployment of the passenger’s frontal air bag, the inflator could rupture with
metal fragments striking the vehicle occupants potentially resulting in serious injury or death.
REPAIR
Subaru will replace the inflator for your front passenger air bag at no cost to you.
WHAT YOU SHOULD DO
We are currently experiencing a parts shortage for affected Impreza, WRX, and STI vehicles. As the
parts supply improves, you will be notified with another letter advising you to schedule an appointment
with your Subaru retailer (dealer) to have the front passenger airbag inflator replaced with a new one if
you have not already had the repair performed.
Until this repair is performed, do not allow passengers to ride in the front passenger seat.
HOW LONG WILL THE REPAIR TAKE?
The time to replace the front passenger air bag inflator is approximately 40 minutes. However, it may be necessary
to leave your vehicle for a longer period of time on the day of your scheduled appointment to allow your Subaru
retailer flexibility in scheduling. Please present this letter to your Subaru retailer at the time this repair procedure is
performed.
CHANGED YOUR ADDRESS OR SOLD YOUR SUBARU?
If you have moved or sold your vehicle, please complete the enclosed prepaid postcard and mail it to us. Or if
you prefer to update this information online, please go to www.subaru.com, select ‘Customer Support,’ then select
‘Address Update’ or ‘Ownership Update’ from the drop down menu.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 33
IF YOU NEED FURTHER ASSISTANCE:
To locate the nearest Subaru retailer you can access our website at www.subaru.com and select ‘Find a Retailer.’
For additional information and the most Frequently Asked Questions, please go to:
• http://www.wqr53.service-campaign.com
If you need additional assistance, please contact us directly:
•
By e-mail: Go to www.subaru.com and select “Contact Us”
•
 y telephone: 1-800-SUBARU3 (1-800-782-2783)
B
Monday through Thursday between 7:30 a.m. and 8:00 p.m. ET
Friday between 10:30 a.m. and 5:00 p.m. ET
Saturday between 9:00 a.m. and 3:30 p.m. ET
•
 y U.S. Postal mail: Write us at Subaru of America, Inc., Attn: Customer-Retailer Services Department,
B
P.O. Box 6000, Cherry Hill, NJ 08034-6000
Please contact us immediately if the Subaru retailer fails or is unable to make the necessary repairs free of charge.
You may also contact the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave. SE,
West Building, Washington, DC 20590 or call the toll free Auto Safety Hotline at 1-888-327-4236 (TTY: 1-800424-9153) or go to http://www.safercar.gov if you believe the Subaru retailer has failed or is unable to remedy your
vehicle without charge within a reasonable amount of time.
Your continued satisfaction with your Subaru is important to us. Please understand that we have taken this action in
the interest of your safety and your vehicle’s proper operation. We sincerely apologize for any inconvenience this
matter may cause and urge you to schedule an appointment as soon as possible to have this repair performed.
Sincerely,
Subaru of America, Inc.
Notice to Lessors: Under Federal law the lessor of a vehicle who receives this letter must provide a copy of it to the vehicle lessee(s)
within 10 business days from receipt. The lessor must also keep a record of the lessee(s) to whom this letter is sent, the date sent, and the
applicable vehicle identification number (VIN). (For the purposes of this section, a lessor means a person or entity that in the last twelve
months prior to the date of this notification has been the owner, as referenced on the vehicle’s title, of any five or more leased vehicles. A
leased vehicle is a vehicle leased to another person for a term of at least four months.)
A subsidiary of Fuji Heavy Industries Ltd.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 34
OWNER NOTIFICATION LETTER
IMPORTANT SAFETY RECALL
This notice applies to the VIN identified
in the address section printed below.
Subaru Recall Campaign WQR-53
Legacy, Outback, and Baja
NHTSA Recall No. 15V-323
September 2015
Dear Subaru Owner:
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
SUBARU OF AMERICA, INC. has decided that a defect, which relates to motor vehicle safety, exists in
certain 2003-2004 model year Legacy, Outback, and Baja vehicles.
DESCRIPTION OF THE SAFETY DEFECT AND SAFETY HAZARD
Subaru is consolidating two previous national recalls into one. The vehicles included in this consolidated
national recall may contain a front passenger-side air bag inflator which could rupture with metal
fragments striking the vehicle occupants potentially resulting in serious injury or death.
You received this notice because our records indicate that you currently own one of these vehicles and the
recall has not yet been completed. If you have already had this repair performed, please disregard this
notice.
REPAIR
Subaru will replace the inflator for your front passenger air bag at no cost to you.
WHAT YOU SHOULD DO
You should immediately contact your Subaru retailer (dealer) for an appointment to have the front passenger air bag
inflator replaced with a new one.
You should immediately contact your Subaru retailer (dealer) for an appointment to have the
front passenger air bag inflator replaced with a new one.
HOW LONG WILL THE REPAIR TAKE?
The time to replace the front passenger air bag inflator is approximately 40 minutes. However, it may be
necessary to leave your vehicle for a longer period of time on the day of your scheduled appointment to
allow your Subaru retailer flexibility in scheduling. Please present this letter to your Subaru retailer at the
time this repair procedure is performed.
CHANGED YOUR ADDRESS OR SOLD YOUR SUBARU?
If you have moved or sold your vehicle, please complete the enclosed prepaid postcard and mail it to us.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 35
IF YOU NEED FURTHER ASSISTANCE:
To locate the nearest Subaru retailer you can access our website at www.subaru.com and select “Find a Retailer”.
For additional information and the most Frequently Asked Questions, please go to:
• http://www.wqr53.service-campaign.com
If you need additional assistance, please contact us directly:
•
By e-mail: Go to www.subaru.com and select “Contact Us”
•
 y telephone: 1-800-SUBARU3 (1-800-782-2783)
B
Monday through Thursday between 7:30 a.m. and 8:00 p.m. ET
Friday between 10:30 a.m. and 5:00 p.m. ET
Saturday between 9:00 a.m. and 3:30 p.m. ET
•
 y U.S. Postal mail: Write us at Subaru of America, Inc., Attn: Customer-Retailer Services Department,
B
P.O. Box 6000, Cherry Hill, NJ 08034-6000
Please contact us immediately if the Subaru retailer fails or is unable to make the necessary repairs free of charge.
You may also contact the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave. SE,
West Building, Washington, DC 20590 or call the toll free Auto Safety Hotline at 1-888-327-4236 (TTY: 1-800424-9153) or go to http://www.safercar.gov if you believe the Subaru retailer has failed or is unable to remedy your
vehicle without charge within a reasonable amount of time.
Your continued satisfaction with your Subaru is important to us. Please understand that we have taken this action in
the interest of your safety and your vehicle’s proper operation. We sincerely apologize for any inconvenience this
matter may cause and urge you to schedule an appointment as soon as possible to have this repair performed.
Sincerely,
Subaru of America, Inc.
Notice to Lessors: Under Federal law the lessor of a vehicle who receives this letter must provide a copy of it to the vehicle lessee(s)
within 10 business days from receipt. The lessor must also keep a record of the lessee(s) to whom this letter is sent, the date sent, and the
applicable vehicle identification number (VIN). (For the purposes of this section, a lessor means a person or entity that in the last twelve
months prior to the date of this notification has been the owner, as referenced on the vehicle’s title, of any five or more leased vehicles. A
leased vehicle is a vehicle leased to another person for a term of at least four months.)
A subsidiary of Fuji Heavy Industries Ltd.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 36
OWNER NOTIFICATION LETTER
IMPORTANT SAFETY RECALL
This notice applies to the VIN identified
in the address section printed below.
Subaru Recall Campaign WQR-53
Impreza, WRX, and STI
NHTSA Recall No. 15V-323
September 2015
Dear Subaru Owner:
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
SUBARU OF AMERICA, INC. has decided that a defect, which relates to motor vehicle safety, exists in
certain 2004 model year Impreza, WRX, and STI vehicles.
DESCRIPTION OF THE SAFETY DEFECT AND SAFETY HAZARD
Subaru is consolidating two previous national recalls into one. The vehicles included in this consolidated
national recall may contain a front passenger-side air bag inflator which could rupture with metal
fragments striking the vehicle occupants potentially resulting in serious injury or death.
You received this notice because our records indicate that you currently own one of these vehicles and the
recall has not yet been completed. If you have already had this repair performed, please disregard this
notice.
REPAIR
Subaru will replace the inflator for your front passenger air bag at no cost to you.
WHAT YOU SHOULD DO
We are currently experiencing a parts shortage for affected Impreza, WRX, and STI vehicles. As the parts
supply improves, you will be notified with another letter advising you to schedule an appointment with
your Subaru retailer (dealer) to have the front passenger airbag inflator replaced with a new one if you
have not already had the repair performed.
Until this repair is performed, do not allow passengers to ride in the front passenger seat.
HOW LONG WILL THE REPAIR TAKE?
The time to replace the front passenger air bag inflator is approximately 40 minutes. However, it may be
necessary to leave your vehicle for a longer period of time on the day of your scheduled appointment to
allow your Subaru retailer flexibility in scheduling.
CHANGED YOUR ADDRESS OR SOLD YOUR SUBARU?
If you have moved or sold your vehicle, please complete the enclosed prepaid postcard and mail it to us.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 37
IF YOU NEED FURTHER ASSISTANCE:
To locate the nearest Subaru retailer you can access our website at www.subaru.com and select ‘Find a
Retailer.’
For additional information and the most Frequently Asked Questions, please go to:
• http://www.wqr53.service-campaign.com
If you need additional assistance, please contact us directly:
• By e-mail: Go to www.subaru.com and select “Contact Us”
• B
 y telephone: 1-800-SUBARU3 (1-800-782-2783)
Monday through Thursday between 7:30 a.m. and 8:00 p.m. ET
Friday between 10:30 a.m. and 5:00 p.m. ET
Saturday between 9:00 a.m. and 3:30 p.m. ET
• B
 y U.S. Postal mail: Write us at Subaru of America, Inc., Attn: Customer-Retailer Services
Department,
P.O. Box 6000, Cherry Hill, NJ 08034-6000
Please contact us immediately if the Subaru retailer fails or is unable to make the necessary repairs free of
charge.
You may also contact the Administrator, National Highway Traffic Safety Administration, 1200 New
Jersey Ave. SE, West Building, Washington, DC 20590 or call the toll free Auto Safety Hotline at 1-888327-4236 (TTY: 1-800-424-9153) or go to http://www.safercar.gov if you believe the Subaru retailer has
failed or is unable to remedy your vehicle without charge within a reasonable amount of time.
Your continued satisfaction with your Subaru is important to us. Please understand that we have taken
this action in the interest of your safety and your vehicle’s proper operation. We sincerely apologize for
any inconvenience this matter may cause.
Sincerely,
Subaru of America, Inc.
Notice to Lessors: Under Federal law the lessor of a vehicle who receives this letter must provide a copy of it to the vehicle lessee(s)
within 10 business days from receipt. The lessor must also keep a record of the lessee(s) to whom this letter is sent, the date sent, and the
applicable vehicle identification number (VIN). (For the purposes of this section, a lessor means a person or entity that in the last twelve
months prior to the date of this notification has been the owner, as referenced on the vehicle’s title, of any five or more leased vehicles. A
leased vehicle is a vehicle leased to another person for a term of at least four months.)
A subsidiary of Fuji Heavy Industries Ltd.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 38
OWNER NOTIFICATION LETTER
IMPORTANT SAFETY RECALL
This notice applies to the VIN identified
in the address section printed below.
Subaru Recall Campaign WQR53
NHTSA Recall No. 15V-323
2005-2008 Legacy and Outback
January 2016
Dear Subaru Owner:
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
Subaru of America, Inc. has decided that a defect which relates to motor vehicle safety exists in certain 2005-2008
model year Subaru Legacy and Outback vehicles.
You received this notice because our records indicate that you currently own one of these vehicles.
REASON FOR THIS NOTICE
Subaru is expanding a previously issued recall to include additional vehicles. Your vehicle is among those added.
SAFETY HAZARD
In the event of a crash necessitating deployment of the front passenger air bag, the inflator could rupture
with metal fragments striking vehicle occupants and potentially causing serious injury or death.
The registration history of your vehicle indicates that your vehicle has been registered in an area of high
absolute humidity. Therefore, your vehicle is included in the highest priority group (Priority Group 1) as
defined in the NHTSA (National Highway Traffic Safety Administration) Coordinated Remedy Order.
For more information about this Order, please refer to http://www.safercar.gov/rs/takata/index.html.
REMEDY
Subaru will replace the inflator for your front passenger air bag at no cost to you.
WHAT YOU SHOULD DO
You should immediately contact your Subaru retailer (dealer) for an appointment to have the front
passenger air bag inflator replaced with a new one.
It is important that you are aware that your vehicle is affected by this safety recall and that you should take the
following precaution:
Until this repair is performed, do not allow passengers to ride in the front passenger seat.
HOW LONG WILL THE REPAIR TAKE?
The time to replace the front passenger air bag inflator is approximately one hour and 45 minutes. It may be
necessary to leave your vehicle for a longer period of time on the day of your scheduled appointment to allow your
Subaru retailer flexibility in scheduling. Please present this letter to your Subaru retailer at the time this repair
procedure is performed.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 39
CHANGED YOUR ADDRESS OR SOLD YOUR SUBARU?
If you have moved or sold your vehicle, please complete the enclosed prepaid postcard and mail it to us. Or if
you prefer to update this information online, please go to www.subaru.com, select ‘Customer Support,’ then select
‘Address Update’ or ‘Ownership Update’ from the drop down menu.
IF YOU NEED FURTHER ASSISTANCE:
To locate the nearest Subaru retailer you can access our website at www.subaru.com and select ‘Find a Retailer.’
For additional information and the most Frequently Asked Questions, please go to:
• http://www.wqr53.service-campaign.com
If you need additional assistance, please contact us directly:
•
By e-mail: Go to www.subaru.com and select “Contact Us”
•
 y telephone: 1-800-SUBARU3 (1-800-782-2783)
B
Monday through Thursday between 7:30 a.m. and 8:00 p.m. ET
Friday between 10:30 a.m. and 5:00 p.m. ET
Saturday between 9:00 a.m. and 3:30 p.m. ET
•
 y U.S. Postal mail: Write us at Subaru of America, Inc., Attn: Customer-Retailer Services Department,
B
P.O. Box 6000, Cherry Hill, NJ 08034-6000
Please contact us immediately if the Subaru retailer fails or is unable to make the necessary repairs free of charge.
You may also contact the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave. SE,
West Building, Washington, DC 20590 or call the toll free Auto Safety Hotline at 1-888-327-4236 (TTY: 1-800424-9153) or go to http://www.safercar.gov if you believe the Subaru retailer has failed or is unable to remedy your
vehicle without charge within a reasonable amount of time.
Your continued satisfaction with your Subaru is important to us. Please understand that we have taken this action in
the interest of your safety and your vehicle’s proper operation. We sincerely apologize for any inconvenience this
matter may cause and urge you to schedule an appointment as soon as possible to have this repair performed.
Sincerely,
Subaru of America, Inc.
Notice to Lessors: Under Federal law the lessor of a vehicle who receives this letter must provide a copy of it to the vehicle lessee(s)
within 10 business days from receipt. The lessor must also keep a record of the lessee(s) to whom this letter is sent, the date sent, and the
applicable vehicle identification number (VIN). (For the purposes of this section, a lessor means a person or entity that in the last twelve
months prior to the date of this notification has been the owner, as referenced on the vehicle’s title, of any five or more leased vehicles. A
leased vehicle is a vehicle leased to another person for a term of at least four months.)
A subsidiary of Fuji Heavy Industries Ltd.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 40
OWNER NOTIFICATION LETTER
IMPORTANT SAFETY RECALL
This notice applies to the VIN identified
in the address section printed below.
Subaru Recall Campaign WQR53
NHTSA Recall No. 15V-323
2005-2008 Legacy and Outback
February 2016
Dear Subaru Owner:
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
Subaru of America, Inc. has decided that a defect which relates to motor vehicle safety exists in certain
2005-2008 model year Subaru Legacy and Outback vehicles.
You received this notice because our records indicate that you currently own one of these vehicles.
REASON FOR THIS NOTICE
Subaru is expanding a previously issued recall to include additional vehicles. Your vehicle is among those
added.
SAFETY HAZARD
In the event of a crash necessitating deployment of the front passenger air bag, the inflator could rupture
with metal fragments striking vehicle occupants and potentially causing serious injury or death.
REMEDY
Subaru will replace the inflator for your front passenger air bag at no cost to you.
WHAT YOU SHOULD DO
We are currently experiencing a parts shortage. However it is important that you are aware that your vehicle is
affected by this safety recall and that you should take the following precaution:
Until this repair is performed, do not allow passengers to ride in the front passenger seat.
As the parts supply improves, you will be notified with another letter advising you to schedule an appointment with
your Subaru retailer (dealer) to have the front passenger airbag inflator replaced with a new one if you have not
already had the repair performed.
HOW LONG WILL THE REPAIR TAKE?
The time to replace the front passenger air bag inflator is approximately one hour and 45 minutes. It may
be necessary to leave your vehicle for a longer period of time on the day of your scheduled appointment to
allow your Subaru retailer flexibility in scheduling. Please present this letter to your Subaru retailer at the
time this repair procedure is performed.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 41
CHANGED YOUR ADDRESS OR SOLD YOUR SUBARU?
If you have moved or sold your vehicle, please complete the enclosed prepaid postcard and mail it to us.
IF YOU NEED FURTHER ASSISTANCE:
To locate the nearest Subaru retailer you can access our website at www.subaru.com and select “Find a Retailer”.
For additional information and the most Frequently Asked Questions, please go to:
• http://www.wqr53.service-campaign.com
If you need additional assistance, please contact us directly:
•
By e-mail: Go to www.subaru.com and select “Contact Us”
•
 y telephone: 1-800-SUBARU3 (1-800-782-2783)
B
Monday through Thursday between 7:30 a.m. and 8:00 p.m. ET
Friday between 10:30 a.m. and 5:00 p.m. ET
Saturday between 9:00 a.m. and 3:30 p.m. ET
•
 y U.S. Postal mail: Write us at Subaru of America, Inc., Attn: Customer-Retailer Services Department,
B
P.O. Box 6000, Cherry Hill, NJ 08034-6000
Please contact us immediately if the Subaru retailer fails or is unable to make the necessary repairs free of charge.
You may also contact the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave. SE,
West Building, Washington, DC 20590 or call the toll free Auto Safety Hotline at 1-888-327-4236 (TTY: 1-800424-9153) or go to http://www.safercar.gov if you believe the Subaru retailer has failed or is unable to remedy your
vehicle without charge within a reasonable amount of time.
Your continued satisfaction with your Subaru is important to us. Please understand that we have taken this action in
the interest of your safety and your vehicle’s proper operation. We sincerely apologize for any inconvenience this
matter may cause and urge you to schedule an appointment as soon as possible to have this repair performed.
Sincerely,
Subaru of America, Inc.
Notice to Lessors: Under Federal law the lessor of a vehicle who receives this letter must provide a copy of it to the vehicle lessee(s)
within 10 business days from receipt. The lessor must also keep a record of the lessee(s) to whom this letter is sent, the date sent, and the
applicable vehicle identification number (VIN). (For the purposes of this section, a lessor means a person or entity that in the last twelve
months prior to the date of this notification has been the owner, as referenced on the vehicle’s title, of any five or more leased vehicles. A
leased vehicle is a vehicle leased to another person for a term of at least four months.)
A subsidiary of Fuji Heavy Industries Ltd.
Continued...
Bulletin Number: WQR-53R; Revised: January 14, 2016
Page 42
SHIPPING DOCUMENTATION AND INSTRUCTIONS (Appendix A)
INFLATOR RETURNS
These Return Instructions are for the Continental US dealerships (48 States).
NOTE: Locations outside of the Continental United States (Hawaii, Alaska, Puerto Rico, Virgin Islands INCLUDING Mexico and Canada
CANNOT follow below shipping instructions. Instead, dealerships in these locations MUST contact the following Takata/Menlo USA
representative directly for shipping instructions: Miguel Prigadaa – Tel #: 210-250-5078 or Email:
[email protected]
4b. Shipping Instructions – Label each Box
1. Shipping Documents
a) If you continue receiving Inflator Kits with the original Fedex Documentation:
a) Box Label
• Supplied with each Kit
• To be affixed to each box
b) Over-pack Label
1.
c) Bill of Lading
2.
3.
• To be supplied by
Stericycle.
• To be affixed to the
outside of each pallet
• To be supplied by
Stericycle.
• Print 2 copies: 1 for
Dealer Records, 1 for
LTL Driver
Peel off the backing of the Fedex Ground PRP Shipping label and
affix to top of box to left of the Class 9 label.
•
Use the scribe line on the box as a guide
•
The FedEx Ground PRP Shipping label must not touch any
portion of the printing to the right of the scribe line.
Discard the remaining Documentation
Do Not contact FedEx
d) ERG Document
• To be supplied by
Stericycle.
• To be provide by the
Dealer to the LTL
Driver for each
shipment
5. Shipping Instructions – Prepare the Pallet
2. Packing Instructions
a) Accumulate and palletize Kits
b) Arrange Kits on Pallet as pictured here
•
20 boxes per row/layer (5x4)
•
10 rows/layers per pallet (200 boxes)
c) Shrink-wrap Kits to Pallet
d) Affix Over-pack Label on (1) side of Pallet (Not on Top)
a) Confirm box is in acceptable condition. If a new box
is needed, follow the New Box instructions located
In Box 8 of this page.
b) Place the un-deployed airbag inflator in
the “cradle” of the box insert.
6. Shipping Instructions – Schedule LTL Pickup
3. Closure Instructions
a) Close and tape the top box flap, per box closure instructions located on front
panel of box.
a) Upon Accumulating 200 kits (1 Over-pack/Pallet) Minimum
•
Call Stericycle at 1-877-650-3476
•
If 200 Kits have not been accumulated in 30 days, please call Stericycle for
direction
•
Upon claim approval, Subaru of America, Inc. will generate a Part Return
Notice requesting information only. DO NOT WAIT FOR STERICYCLE TO
PICK UP THE PART TO RETURN THIS INFORMATION TO SOA.
c) Have the following Information Available
•
Dealer #
•
Quantity of Over-packs/Pallets
•
Quantity of Passenger Inflator Kits on each Pallet
•
Email Address where shipping Documentation can be received
7. Shipping Instructions – Ship
a) Give 1 Copy of BOL and 1 Copy of ERG to Driver
b) Retain 1 Copy of BOL for Dealership records and archive for 2 Years
8. Requesting a New Box / Shipping Labels
4a. Shipping Instructions - Label each Box
a) New Labels will begin shipping in each kit starting mid August, 2015
Subaru Inflator Kit will
contain this two-part
label:
Peel off ‘Ship To’
Label.
Affix Label to Box.
Do not cover up Class 9 Marking.
After affixing Address
Label to the box, the
other part of the label
may be discarded.
Bulletin Number: WQR-53R; Revised: January 14, 2016
If a new box or replacement shipping labels are needed, please contact the
representative listed below by phone or email to request replacement
materials.
Primary Contact: Armando Gonzalez - Tel #: 210-250-5079
E-Mail: [email protected]
To help expedite your request, please be prepared to provide the following
information:
a) Serial number on the original box
b) What Type of shipping material needed
•
Replacement Box
•
Two Part Return Label
•
Bill of Lading
•
ERG Form
c) Dealer Shipping Information
•
Contact name
•
Dealer Address
•
Phone Number
Page 43