WUJ-95R

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:
2015-2016MY Legacy 2.5L
2015-2016MY Outback 2.5L
NUMBER: WUJ-95R
Exhaust Pipe Front (EPF) Bellows Cracking
REVISED: 03/24/20
DATE: 02/11/20
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-95R; Revised: 03/24/20
Page 1 of 12
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-95R; Revised: 03/24/20
Page 2 of 12
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.
See “APPENDIX A” beginning on page 8 for additional Helpful Hints.
NOTE: The new EPF kit 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. The kit includes a complete set of replacement fiberglass insulation pads.
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 six one-time use EPF flange nuts at the cylinder heads. New
nuts are also supplied in the hardware kit.
Continued...
Bulletin Number: WUJ-95R; Revised: 03/24/20
Page 3 of 12
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. CAUTION: The pipe may be hot.
•
Once the EPF has cooled (or if necessary), apply a penetrating oil (e.g. PB Blaster® or
equivalent as directed on the product’s container) to the sensor threads to help with removal.
•
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 insulation pads
4 new clamps for the small heat shields closest to the cylinder head flanges.
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 Pad adhesive p.n. SOA868V9690 must be ordered separately
and is used to secure the new insulation pads 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. USE HAND TOOLS ONLY
when removing them from the EPF to avoid breaking off the retaining studs.
•
ALWAYS wear proper eye protection
•
Use a wire brush to remove any loose rust/scale from the heat shield retaining fasteners.
•
Apply a penetrating lubricant (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 to loosen / remove rusted / siezed heat shield hardware.
•
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,
use a permanent marker to outline the shape and positioning of
each fiberglass insulation pad found on the inside of it whenever
possible. A complete set of new insulation pads is included in the
EPF kit and ALL are to be replaced at reassembly.
Continued...
Bulletin Number: WUJ-95R; Revised: 03/24/20
Page 4 of 12
Use a wire brush to remove any insulation and / or adhesive residue. Proper positioning of the new
insulation pads is key to achieving a rattle-free repair.
TIP: Replacing the insulation pads and swapping
each (pair) of these small shields over to the new
EPF one pipe at a time will help avoid confusion.
•
Before applying any of the new insulation pads, 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 insulation pads.
TIP: Have all the stud 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 insulation pad 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 insulation pad area. Keep in mind, the adhesive is only
used to hold the new insulation pads 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 insulation pad onto it and all the
contours of each shield. Repeat for each remaining shield and insulation pad.
Continued...
Bulletin Number: WUJ-95R; Revised: 03/24/20
Page 5 of 12
IMPORTANT: Keep the adhesive bottle tightly sealed at all times.
•
BEFORE installing the shields onto the new EPF, confirm the new EPF fits into place on the
cylinder head exhaust studs properly without any prying or other manipulation.
•
When all the insulation pads are in place and proper EPF fit is confirmed, proceed with
reassembling the heat shields onto the EPF.
EPF Fastener Torque Specifications:
•
Reassemble the exhaust system and install
using all the new gaskets and hardware
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 EPF reassembly in reverse order of removal.
NOTE: The adhesive used for securing the fiberglass heat insulation pads 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 INCLUDES: TRANSFER OF ALL METAL HEAT SHIELDS.
INCLUDES INSTALLATION OF ALL NEW INSULATION PADS
A122-951
0.7
EPF ASSEMBLY R&R INCLUDES: ALL THE ABOVE COMBINED WITH THE
INSTALLATION OF AT LEAST ONE OR MORE NEW METAL HEAT SHIELDS*
A122-953
Fail
Code
Claim
Type
WUJ-95
RC
0.8
*NOTE: This operation may only be used when replacement of one or more new metal heat shield
(not to be confused with the white insulation pads) is needed to complete the campaign.
REMINDER: All the white fiberglass heat insulation pads included in the EPF kit are required to be
replaced during reassembly of the new EPF.
Continued...
Bulletin Number: WUJ-95R; Revised: 03/24/20
Page 6 of 12
Additional WUJ-95 Claim Submission Information
Description
Part Number
Application
CAL Spec. (PZEV) EPF Kit
SOA635156
CAL Spec. PZEV Vehicles
FED Spec. EPF Kit
SOA635157
FED Spec. Vehicles
Insulation Pad Adhesive
SOA635314
Both FED and CAL Spec. Vehicles**
Replacement Heat Shields and Insulation Pads
Order individually per VIN and EPC
Both FED and CAL Spec. Vehicles**
**NOTE: Replacement Shields, Pads & Adhesive can be claimed with A122-953 ONLY.
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-95R; Revised: 03/24/20
Page 7 of 12
“APPENDIX A”: Additional Helpful Hints
IMPORTANT REMINDERS:
9 ALWAYS wear eye protection!
9 The EPF’s heat shields are stamped sstainless steel and have MANY sharp edges. Always use
CAUTION to avoid nicks, cuts and scrapes.
•
When disassembling the heat shields from the original EPF, pay close attention to the two
shields with retaining studs made onto them instead of nuts / bolt fasteners. TAKE YOUR
TIME with these to avoid having to replace the shield(s) due to a broken stud. Use a
wire brush to clean the stud threads along with a touch of lubricant before reassembly is
recommended.
•
Take a minute to test fit the shields covering the catalytic converter section to the new EPF.
The photo sequence below shows one of the original EPF’s outlet flange studs having clearance
between it and the converter shield mounting bracket. The same stud on the new EPF is shown
pushing against the edge of the bracket. This caused a mis-alignment of the shield mounting
bolt hole and corresponding bracket bolt hole. Some VERY CAREFUL manipulation of the
mounting bracket restored the proper bolt hole alignment.
Clearance
Mis-Alignment
NO Clearance,
Stud is Pushing
on the Bracket
Continued...
Bulletin Number: WUJ-95R; Revised: 03/24/20
Page 8 of 12
•
Some reports have been received regarding the mounting bracket tabs as pictured below.
Occasionally, the fastener holes in the bracket are not fully aligned with the holes in the center
exhaust pipe mounting flange. The pictures show one of the center exhaust pipe mounting
studs displacing the bracket tab. If this happens, it may cause the bolt hole for the converter
shield to become mis-aligned (or, it may have no effect at all). This condition MAY require
some VERY CAREFUL manipulation of the mounting bracket to re-align it with the
converter shield bolt hole.
•
Using a pair of needle nose pliers to squeeze the new clamps
for the small shields at the flanges together will help make
getting the bolts started much easier.
•
When reinstalling the A/F Sensors, NEVER apply anti-sieze
compound on the threads.
•
BEFORE installing the shields onto the new EPF, confirm
the new EPF fits into place on the cylinder head exhaust studs
properly WITHOUT any prying or other manipulation.
Continued...
Bulletin Number: WUJ-95R; Revised: 03/24/20
Page 9 of 12
•
TAKING YOUR TIME when refitting the shields is CRITICAL for a successful repair. As
the original shields are removed, take note (or photos) of how they are stacked together, especially in the middle of the EPF. Numbering the shields with a marker on both sides of a seam
can help too. There will be witness marks left behind on some of them to provide insight to
the order they go together and what should be on top or underneath of what. A routiene will
develop over time as more and more vehicles are repaired. As an example, in the photo below,
there are four thicknesses of heat shield here being held together by these two bolts.
TIPS:
• Using a tapered center punch (or equivalent) as an
alignment tool in the shield bolt holes will make
installing the bolts easier.
•
As the new hardware is installed, leave the nuts
loose until all the shields are in place. This makes
proper shield alignment easier.
•
VERY IMPORTANT: After all the shields
have been reinstalled, torque the nuts to 13 Nm
(9.6 ft. lbs.) EXCEPT for the two on the driver’s side shield shown in the photo below. This
shield covers the bellows section of the EPF and if tightened, the dimension of the bellows may
be changed enough to keep the EPF assembly from fitting back onto the exhaust studs properly.
Bellows
Section
•
Install the EPF assembly and torque the six cylinder head flange nuts to 30 Nm (22.1 ft. lbs.)
THEN tighten the last 2 heat shield bolts shown above to 13 Nm (9.6 ft. lbs.).
•
Re-connect the A/F sensor connectors.
•
Reinstall the center exhaust pipe with the new gaskets supplied in the kit in reverse order of
removal.
Continued...
Bulletin Number: WUJ-95R; Revised: 03/24/20
Page 10 of 12
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-95R; Revised: 03/24/20
Page 11 of 12
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-95R; Revised: 03/24/20
Page 12 of 12