WUJ-95

ATTENTION:
CLAIMS PERSONNEL q
IMPORTANT - All
Service Personnel
Should Read and
Initial in the boxes
provided, right.
SERVICE MANAGER
© 2020 Subaru of America, Inc. All rights reserved.
GENERAL MANAGER q
PARTS MANAGER
q
q
SERVICE PROGRAM BULLETIN
APPLICABILITY:
		
SUBJECT:
NUMBER: WUJ-95
2015-2016MY Legacy 2.5L
2015-2016MY Outback 2.5L
DATE: 02/11/20
Exhaust Pipe Front (EPF) Bellows Cracking
INTRODUCTION:
Subaru of America, Inc. (Subaru) is initiating a service campaign for certain 2015-2016MY Legacy
and Outback 2.5L models which may experience an exhaust noise and/or odor coming from cracks at
the bellows section of the front exhaust pipe which includes the catalytic converter. A leak occurring
at the front exhaust pipe may result in deterioration of emission performance. As a result, the vehicle
may fail to meet emission levels certified by the EPA and/or California ARB.
AFFECTED VEHICLES:
Vehicles included in this service campaign are 2015-2016 Legacy and Outback 2.5L. This recall will
affect approximately 243,750 vehicles. Coverage for all affected vehicles must be confirmed by using
the Vehicle Coverage Inquiry function on subarunet.com. The affected VINs will be made available
in phases, as the owner notification letters are scheduled for release. Please refer to the ‘Owner
Notification’ section of this bulletin for more information.
Model Year
Carline
Affected Production Dates
2015-2016
Legacy
12/16/2013 - 9/30/2015
2015-2016
Outback
12/09/2013 – 9/30/2015
DESCRIPTION OF THE REPAIR:
Subaru retailers will replace the front exhaust pipe.
RETAILER RESPONSIBILITY:
Retailers are to promptly perform this repair on all affected vehicles in their inventory. Additionally,
whenever a vehicle subject to this service program is taken into inventory or in for service, necessary
steps should be taken to ensure the repairs have been made before selling or releasing the vehicle.
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: WUJ-95; Date: 02/11/20
Page 1 of 9
OWNER NOTIFICATION:
Affected vehicle owners will be notified in phases based on their physical location, the emissions
specification of their vehicle (Cal-spec or Fed-spec), and parts production schedules. Listed in the
table below is the current phased mailing plan:
Date
Emissions
specification (spec)
Mailing
Phase
Assigned Retailers’
Facing RDC(s)
Applicable WUJ-95
Kit Part Number
Approximate
Quantity
February 2020
California-spec (PZEV)
PZEV 1
Coppell RDC
Ontario RDC
Portland Lombard RDC
SOA635156
50,000
February 2020
Federal-spec
FED 1
Aurora RDC
SOA635157
16,000
SOA635157
18,000
March 2020
Federal-spec
FED 2
SNE, SDC
Coppell RDC
Ontario RDC
Portland Lombard RDC
April 2020
California-spec (PZEV)
PZEV 2
SNE
SOA635156
27,000
May 2020
California-spec (PZEV)
PZEV 3
SDC
SOA635156
19,000
June 2020
California-spec (PZEV)
PZEV 4
Florence RDC
SOA635156
30,000
July 2020
California-spec (PZEV)
PZEV 5
Aurora RDC
Douglasville RDC
Lebanon RDC
SOA635156
19,000
August 2020
Federal-spec
FED 3
Douglasville RDC
Florence RDC
SOA635157
25,000
September 2020
Federal-spec
FED 4
Lebanon RDC
SOA635157
40,000
This schedule is subject to change based on parts availability.
RETAILER AFFECTED VIN LISTS:
Each Subaru retailer will receive an affected VIN list for each phased mailing from their Zone office
as the owner notification letters are released. Vehicles will be assigned to retailers in the affected VIN
list as follows. Please note that this logic has recently changed:
1. If there is a preferred retailer on file, the VIN will be assigned to the preferred retailer.
2. If there is no preferred retailer on file:
a. Original vehicle owners are assigned to the original selling retailer if their current DMV
registration address is within a 50-mile radius of that retailer.
b. If the original selling retailer is inactive, the VIN is assigned to the nearest active retailer.
c. If the owner is not the original owner, the VIN is assigned to the nearest active retailer.
PART INFORMATION:
During transportation from the supplier, the spacing between the exhaust flanges may change due
to vibration. Although the amount of this change is small, it is enough to require more force than
normal to install the EPF onto the engine during vehicle assembly. The amount of force may have
caused cracking to develop in the bellows section of the EPF resulting in exhaust leakage. Since the
area of the leak is upstream of the catalyst, emission system performance may be compromised. In
some cases, customers may notice an unusual noise and / or exhaust odor.
Continued...
Bulletin Number: WUJ-95; Date: 02/11/20
Page 2 of 9
Description
Part Number
Application
Cal Spec. (PZEV) Kit
SOA635156
PZEV (Cal Spec) Vehicles
Fed Spec. Kit
SOA635157
Fed. Spec. Vehicles
Insulation Pad Adhesive SOA868V9690
Both Fed and PZEV Vehicles
SERVICE PROCEDURE / INFORMATION:
REMINDER: Customer satisfaction and retention starts with performing quality repairs.
The service procedures for removal and reinstallation of the EPF assembly remain unchanged.
NOTE: The new EPF is supplied without heat shields. The heat shields used on the original EPF
will need to be CAREFULLY removed along with their fiberglass insulators and transferred to the
new part.
EPF heat shield -related repair guidelines are provided below. Always refer to the applicable
Service Manual and review the full requirements of the repair being performed. The Service Manual
procedures contain information critical to performing an effective repair the first time and every
time. This includes but is not limited to: important SAFETY precautions, proper inspection criteria,
necessary special tools, required processes and related one-time-use parts needed for a complete and
lasting repair.
(3) PREPARATION:
•
•
•
•
•
•
Record the customer’s radio station presets (and Navigation favorites where applicable) then
disconnect the ground cable from the battery sensor.
Remove the engine under cover.
CAREFULLY disconnect the Air Fuel Ratio and Oxygen Sensor harness connectors.
Disconnect the center exhaust pipe at the spring bolt connection. New nuts and spring bolts are
supplied in the hardware kit but, the springs are to be reused.
Remove the center bolt from the hanger bracket but do not unhook the exhaust pipe from it yet.
Loosen / remove and discard the one-time use EPF flange nuts at the cylinder heads. New nuts
are also supplied in the hardware kit.
Continued...
Bulletin Number: WUJ-95; Date: 02/11/20
Page 3 of 9
IMPORTANT REMINDER / CAUTION: The EPF assembly is heavy. Use a helper if necessary
to avoid dropping it during removal.
•
Remove the center exhaust pipe from the EPF.
•
CAREFULLY remove the Air Fuel Ratio and Oxygen Sensors from the EPF assembly.
NOTES:
• Both EPF kits (SOA635156 for CAL-spec and SOA635157 for FED-spec. vehicles) include:
○○
○○
○○
○○
○○
A new EPF WITHOUT heat shields
All new fiberglass heat insulators (use as needed to replace missing / eroded parts)
4 new heat shield clamps
A replacement hardware kit for the heat shields and spring nuts / bolts
A replacement exhaust gasket kit (cylinder head flange (2), front pipe
(1) and center “donut” (1) gaskets).
Insulation adhesive p.n. SOA868V9690 must be ordered separately
and is used to secure the new insulators to the inside of the heat shields
prior to reassembly. The part number to use for Warranty claim entry
is SOA635314 (qty. 1). Each quart-sized (32 oz.) container has a brush
applicator cap. IMPORTANT: Always keep the cap tightly sealed between
uses for longest life. Replace the adhesive if it becomes dried out or
cannot be applied properly using the brush.
•
(4) HEAT SHIELD TRANSFER:
IMPORTANT NOTE: All heat shields are intended to be reused in most cases. USE HAND
TOOLS ONLY when removing them from the EPF to avoid breaking off the retaining studs.
•
Use a wire brush to remove any loose rust/scale from the heat shield retaining fasteners.
•
Apply a penetrating oil (e.g. PB Blaster® or equivalent) as directed on the product’s
container to the heat shield fasteners to help loosen and remove them without breakage.
•
In some cases, VERY CAREFUL use of a torch or an induction heating tool may be
necessary.
•
When the fasteners initially begin to loosen, work them back and forth while applying
additional penetrant to help lubricate the threads. TAKING YOUR TIME during this
step will help prevent breaking off fasteners and avoid heat shield replacements. Repeat as
necessary until all the heat shields have been removed from the EPF.
IMPORTANT: As each heat shield is CAREFULLY removed, note the shape and positioning of
each fiberglass insulator found on the inside of it whenever possible.
TIP: Use a marker to outline the position for the replacement insulator at reassembly then properly
discard any remaining insulation material as they all will be replaced.
Use a wire brush to remove any insulation and / or adhesive residue. Replacement of damaged, loose
or eroded insulators will prevent post-repair rattles. Proper positioning of the insulators is key to
achieving a rattle-free repair.
Continued...
Bulletin Number: WUJ-95; Date: 02/11/20
Page 4 of 9
•
Before applying any of the new insulators, wipe the inside and outside of the shields clean of
any residual oil / penetrant used with a mild solvent on a clean shop cloth. Use caution to not
remove the position markings for the replacement insulators.
TIP: Have all the stud/bolt threads and shields going back onto the new EPF cleaned and their
respective heat insulation pads ready to apply. Doing it this way avoids having to open and close the
adhesive container repeatedly.
•
Remove the brush cap from the adhesive container and apply a small amount of the material
to each shield toward the center of where the new insulator will be positioned. Marking an
outline for where the adhesive should be applied can also be used as shown below.
•
For reference, a “dab” or two of adhesive about the size of a silver dollar is plenty. There is
no need to cover the entire insulator area. Keep in mind, the adhesive is only used to hold the
new insulators in place during EPF reassembly as they will be held (“clamped”) in position
once all the retaining hardware is tightened.
•
Apply the adhesive to the shield then press the new insulator onto it and all the contours of
each shield. Repeat for each remaining shield and insulator.
Continued...
Bulletin Number: WUJ-95; Date: 02/11/20
Page 5 of 9
IMPORTANT: Keep the insulation adhesive bottle tightly sealed at all times.
•
When all the insulators are in place, proceed with reassembling the heat shields onto the EPF.
•
Each kit includes 4 new heat shield clamps to be used when installing the heat shields closest
to the cylinder head flanges.
EPF Fastener Torque Specifications:
•
Reassemble the exhaust system
and install using new gaskets and
hardware as supplied in the kit.
Fastener
Nm
Ft. Lbs.
Cylinder Head Flange Nuts
30
22.1
EPF to Center Pipe
42.5
31.3
Heat Shield Nuts / Bolts / Clamps
13
9.6
Center Pipe Spring Bolt Nuts
18
13.3
Center Pipe Hanger Bolt
35
25.8
Air-Fuel Ratio and O2 Sensor
21
15.5
REMINDER: The exhaust gaskets along with new manifold nuts and exhaust pipe nuts and bolts
are all one-time use and MUST always be replaced.
•
Finish the reassembly in reverse order of removal.
NOTE: The adhesive used for securing the fiberglass heat insulators is water-based and odorless.
Any residual moisture will be eliminated the first time the new EPF comes up to temperature. For
this reason, a slight amount of residual vapor may be noticed on the vehicle’s initial re-start.
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES:
Credit to perform this recall will be based on properly completed repair order information. Retailers
may submit claims through Subarunet.com.
Labor Description
Labor
Operation #
Labor
Time
EPF ASSEMBLY R&R, TRANSFER HEAT SHIELDS, NO
REPLACEMENTS OR REPAIRS TO INSULATORS NEEDED
A122-951
0.7
EPF ASSEMBLY R&R, ONE OR MORE HEAT SHIELD
REPLACEMENT NEEDED, REPLACE INSULATORS AS NEEDED
A122-953
0.8
Fail
Code
Claim
Type
WUJ-95
RC
NOTE: Use p.n. SOA635314 (qty. 1) when claiming for the catalytic converter insulation pad
adhesive.
Continued...
Bulletin Number: WUJ-95; Date: 02/11/20
Page 6 of 9
CALIFORNIA “VEHICLE EMISSION RECALL - PROOF OF CORRECTION”
CERTIFICATE
The California Air Resources Board and the Department of Motor Vehicles Registration/Recall
Program requires that all emission related Recall/Campaign or Service Program repairs be completed
before a vehicle registration is renewed. Please provide owners of vehicles registered in the state of
California a completed “Vehicle Emission Recall - Proof of Correction” certificate. Vehicle owners
should be advised to retain this certificate because the California Department of Motor Vehicles may
require they provide proof this service program repair has been completed.
Additional certificates are available through normal parts ordering channels using part number
MSA6P1301. Quantity 1 = 1 booklet of 50 certificates.
SERVICE PROGRAM IDENTIFICATION LABEL:
Type or print the necessary information on a Campaign 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, which comes as one sheet of 20 labels.
Part Number
Applicability
Description
Order Quantity
MSA6P1302
All Models
Campaign Completion Labels
(contains one sheet of 20 labels)
1
WUJ-95
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: WUJ-95; Date: 02/11/20
Page 7 of 9
Subaru of America, Inc
PO Box 9103
Camden, NJ 08101-9877
844-373-6614
www.subaru.com
Subaru Service Program WUJ-95
Voluntary Emissions Recall
February 2020
Dear Subaru Owner:
We would like to thank you for your selection of a Subaru vehicle. We take pride in our products and are committed
to your continued satisfaction.
Subaru has become aware that certain 2015-2016 2.5L Legacy and Outback models may experience an exhaust
noise and/or smell coming from cracks at the bellows of the front exhaust pipe which includes the catalytic converter. A leak occurring at the front exhaust pipe may result in deterioration of emission performance. As a result,
your vehicle may fail to meet emission levels certified by the EPA and/or California ARB.
			
REASON FOR THIS VOLUNTARY EMISSIONS RECALL:
The front exhaust pipe assembly may have been installed under a stressful condition. As a result, the front exhaust
pipe bellows may experience cracking during use possibly leading to exhaust gas leakage. Under this condition, a
leak occurring at the front exhaust pipe may result in deterioration of emission performance.
You have received this notice because our records indicate that you currently own one of these vehicles.
REPAIR:
Your Subaru retailer (dealer) will replace the front exhaust pipe at no cost to you.
WHAT YOU SHOULD DO:
You should immediately contact your Subaru retailer (dealer) for an appointment to have this inspection and any
necessary repair performed.
HOW LONG WILL THE REPAIR TAKE?
The time to perform the replacement is approximately 1 hour. However, your retailer can provide you with a better
estimate of the overall time for this service visit, as it may be necessary to make your vehicle available for a longer
period of time.
CALIFORNIA REGISTERED OWNERS:
The California Air Resources Board requires that emission-related campaigns be completed prior to California’s
vehicle registration renewal process; without this repair, you will not be able to register your vehicle during your
next annual registration. Upon completion of this campaign, your California dealer will complete and provide you a
“Proof of Correction Certificate.” If required, present the certificate to the California Department of Motor Vehicles
(the “DMV”) when renewing your California registration as proof of campaign completion. If the DMV does not
request the certificate, we recommend that you keep it for your records.
In addition, the State of California requires that every vehicle must pass an emission test (SMOG Check) every
two years and before it is sold. Without the service we are providing at no charge, your vehicle may not pass this
test.
Continued...
Bulletin Number: WUJ-95; Date: 02/11/20
Page 8 of 9
CHANGED YOUR ADDRESS OR SOLD YOUR SUBARU?
If you have moved or sold your vehicle, please update this information online at 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.’
If you need additional assistance, please contact us directly:
•
By e-mail: Go to www.subaru.com, Customer Support and select “Contact Us”
•
By telephone: 1-844-373-6614
Monday through Friday between 8:00 a.m. and 7:00 p.m. ET
•
By U.S. Postal mail: Write us at: Subaru of America, Inc.
Attn: Customer-Retailer Services Department
P.O. Box 9103, Camden, NJ 08101-9877
Please contact us immediately if the Subaru retailer fails or is unable to make the necessary repairs free of charge.
Your continued satisfaction with your Subaru is important to us. Please understand that we have taken this action
in the interest of 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 SUBARU CORPORATION
Bulletin Number: WUJ-95; Date: 02/11/20
Page 9 of 9