WRD-20R

ATTENTION:
GENERAL MANAGER
q
PARTS MANAGER
q
CLAIMS PERSONNEL
q
IMPORTANT - All
Service Personnel
Should Read and
Initial in the boxes
provided, right.
SERVICE MANAGER
q
© 2020 Subaru of America, Inc. All rights reserved.
PRODUCT CAMPAIGN BULLETIN
APPLICABILITY:
		
		
SUBJECT:
2019MY Legacy and Outback 2.5 and 3.6L
2019MY Impreza
2019MY Ascent
Fuel Pump Impeller Failure
NUMBER: WRD-20R
DATE: 04/23/20
NHTSA: 20V-218
REVISED: 07/16/20
INTRODUCTION:
Subaru of America, Inc. (Subaru) is initiating a new safety recall for certain 2019 model year Ascent,
Impreza, Legacy, and Outback vehicles in which the fuel pump may become inoperative.
DESCRIPTION OF THE DEFECT AND SAFETY RISK:
The affected vehicles may be equipped with a low pressure fuel pump which includes an impeller
that was manufactured with a lower density. If the surface of the lower density impeller is exposed
to solvent drying for longer periods of time, it may develop fine cracks. Those cracks may lead to
excessive fuel absorption, resulting in impeller deformation. Over time, the impeller may become
deformed enough to interfere with the body of the fuel pump, potentially causing the low pressure
fuel pump to become inoperative.
If the low pressure fuel pump becomes inoperative, the check engine warning light or malfunction
indicator light may illuminate, and/or the engine may run rough. In the worst case, an inoperative
fuel pump may result in the engine stalling without the ability to restart the vehicle, increasing the
risk of a crash.
AFFECTED VEHICLES:
A total of 188,207 U.S. vehicles will be affected by this recall, as listed below:
Model Year
Carline
Production Date Range
Affected Vehicle Count
2019
Ascent
June 26, 2018 - January 18,2019
40,950
2019
Impreza
June 18, 2018 – February 25, 2019
40,797
2019
Legacy
June 29, 2018 – February 19, 2019
20,182
2019
Outback
June 29, 2018 – February 19, 2019
86,278
Not all vehicles in the production ranges listed above are affected by this recall. Coverage must be
confirmed by using the Vehicle Coverage Inquiry function on Subarunet.com prior to repair. The
status of this recall has been updated to “Open”.
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: WRD-20R; Revised: 07/16/20
Page 1 of 49
SERVICE, PARTS, AND CLAIM INSTRUCTIONS:
Sufficient remedy parts supply is now available. The remedy parts must be ordered through PRIME.
Please refer to ‘Recalls & Campaigns/PRIME Max Quantities’ on Subarunet for the orderable
quantities.
RETAILER RESPONSIBILITY:
Please be advised that it is a violation of Federal law for a dealer to deliver a new motor
vehicle covered by a recall under a sale or lease until the defect is remedied. Therefore, 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 may be subject
to civil penalties of up to $21,000 per violation (i.e., for each vehicle), as provided in 49 CFR
§578.6 and will also be in breach of the Subaru Dealer Agreement.
Any vehicles listed in any recall/campaign that are in retailer stock must be:
•
Immediately identified
•
Tagged or otherwise marked to prevent their delivery or use prior to repair
•
Repaired in accordance with the repair procedures outlined in the Product Campaign Bulletin
Retailers are to promptly perform the applicable service procedures to correct all affected vehicles in
their inventory (new, used, demo & SSLP).
In addition, whenever a vehicle subject to this recall is taken into retailer inventory necessary steps
should be taken to ensure the recall correction has been made before selling or releasing the vehicle.
OWNER NOTIFICATION:
Subaru will notify affected vehicle owners by first class mail on June 4, 2020. A copy of the owner
letter is shown at the end of this bulletin.
Now that sufficient quantities of the Fuel Pump Kits are available, repairs using complete Fuel Pump
Assemblies must be discontinued.
Retailers with ongoing repairs using complete Fuel Pump Assemblies may complete them and submit
for payment using the claim reimbursement information located on pg. 41 of this bulletin.
For the remaining vehicles included in this campaign, the parts required to perform these repairs have
been assembled into Fuel Pump Kits, numbered for each model and labeled accordingly as shown
below to help insure installation of the proper kit into the applicable model.
Description
WRD-20 Fuel
Pump Kit
Kit Part Number
Model Application
X4202AL000
Legacy / Outback 2.5L
X4202AL010
Legacy / Outback 3.6L
X4202FL000
Impreza
X4202XC000
Ascent
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 2 of 49
The illustrations below list the component part content breakdowns for each of the four kits:
X4202FLOOO/PUMP IMPREZA
Part Number
42029FL020**
42025FL01A
42032FL01A
42056FL000
Part Name
KIT FUEL PUMP: Contains fuel pump, filter sock, fuel
pump o-rings, and c-clip.
GASKET FUEL PUMP
RING NUT
PLUG TEMPORARY
Qty
Part Number
1
42029XC000**
1
1
1
42025FL000
42032FL000
42057FL000
42056FL000
X4202ALOOO/PUMP LEGACY/OBK 2.5L
Part Number
42029AL000**
42025AL040
42056FL000
Part Name
KIT FUEL PUMP: Contains fuel pump, filter sock, fuel
pump o-rings, c-clip, and fuel pump cushions (3).
GASKET FUEL PUMP
PLUG TEMPORARY
X4202XCOOO/PUMP ASCENT
Part Name
KIT FUEL PUMP: Contains fuel pump, filter
sock, fuel pump o-rings, and c-clip.
GASKET FUEL PUMP
RING NUT
PLATE RING NUT
PLUG TEMPORARY
Qty
1
1
1
1
1
X4202ALO1O/PUMP LEGACY/OBK 3.6L
Qty
Part Number
1
42029AL010**
1
2
42025AL030
42056FL000
Part Name
KIT FUEL PUMP: Contains fuel pump, filter sock, fuel pump
o-rings, c-clip, and fuel pump cushions (3).
GASKET FUEL PUMP
PLUG TEMPORARY
Qty
1
1
2
** NOTE: The “KIT FUEL PUMP” part numbers supplied are for reference only and cannot be
ordered separately.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 3 of 49
ADDITIONAL REQUIRED MATERIALS / SPECIAL TOOLS:
•
42099FL030 Fuel Pipe Adapter: Connects directly to the
fuel pump outlet pipe at the fuel tank. Each retailer will be
receiving two (2) of these automatically when they become
available. Remove & discard the temporary plug before
use.
•
SOA635161 Hose Fuel: This is a commonly
available service part which can be used on all
affected vehicles. This adapts the incoming fuel
supply pipe and a section of bulk rubber fuel
line. Each retailer will be receiving two (2) of
these automatically when they become available. An additional fuel draining procedure will
be added to this bulletin once these parts are available at retailers. See APPENDIX A on
starting pg. 43 for more information.
•
42099CA010 (for Legacy and Outback) and
42099FL020 (for Ascent and Impreza) Fuel
Tank Caps: To be put back into the fuel
pump opening in the fuel tank after pump
removal. These caps will help contain fuel
odors and prevent contamination from
entering the tank while the pump assembly
is removed. Each retailer will be receiving
two (2) of each part number automatically
when they become available.
•
42099FL000 Ring Nut Wrench: Used to remove and install
the fuel pump assembly locking rings on Ascent
and Impreza. This is already a required essential Subaru
Special Service Tool.
•
18471AA000 Fuel Pipe Adapter: Used to drain fuel by
connecting one end to the supply pipe connector at the fuel
rail in the engine compartment and a length of bulk fuel hose
going to a safety gasoline container on the other. This tool is
already a required essential Subaru Special Service Tool and
will be only be needed when performing repairs if fuel
draining is required.
•
42099AE000 Release Tool: Used to disengage the fuel
pipe connector in the engine bay. This is already a required
essential Subaru Special Service Tool.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 4 of 49
NOTE: These adapters are only necessary when there is a need to lower the fuel level in the fuel
tank:
• To drain fuel directly from the fuel pump outlet, use adapter 42099FL030.
•
To drain fuel from the fuel pipe hard line in the engine compartment, use adapter
SOA635161. See APPENDIX A starting on pg. 43 for more information.
•
To drain fuel from the fuel rail connection in the engine compartment, use adapter
18471AA000.
In addition, some or all of the following 3) three items are needed to
facilitate draining the fuel tank when required.:
• A readily available 5/16” barbed hose connecting nipple
•
A 5-foot section of bulk 5/16” rubber fuel hose
•
Two (2) small fuel line hose clamps.
IMPORTANT: A length of door edge guard, flexible tubing or heavy duty electrical tape to apply
around the fuel pump access opening to avoid cuts / abrasions from sharp edges is required for all
fuel pump replacement repairs.
SERVICE PROCEDURES / TABLE OF CONTENTS:
Carline
Begins on Page
Legacy / Outback
8
Impreza & Ascent TIPS
17
Impreza
20
Ascent
29
Service Procedure Information for ALL MODELS:
NOTE: The following information is intended to SUPPLEMENT the following and Service Manual
procedures.
VERY IMPORTANT: To avoid gasoline spillage, THIS PROCEDURE MUST BE
PERFORMED WHEN THE FUEL LEVEL IN THE TANK IS AT OR BELOW 2/3 FULL. If
over 2/3 full, the tank will need to be drained to 2/3 or less before attempting to remove the complete
fuel pump assembly.
ALWAYS follow ALL the CAUTIONS and procedures for safely releasing fuel pressure and
draining fuel from the fuel tank as supplied in the applicable Service Manual.
ALWAYS remove the fuel filler cap to release any accumulated vapor pressure as a first step.
If draining fuel from the fuel tank is necessary, follow the applicable procedure this bulletin along
with “USING THE SELECT MONITOR” procedure in the applicable Service Manual.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
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When removing the rear seat cushion (all models
except Ascent), if the plastic retaining clips (a) (p.n.
64396KA010 for Legacy / Outback and 64333FJ000
for Impreza) in the floor come out, they become
one-time use items and MUST be replaced during
reassembly. When installing the seat cushion, always
confirm the seat belt buckles are returned to the proper
positions.
When removing the fuel pump access cover, there is a foam seal between the cover and the vehicle
body. Use CAUTION when removing the cover to not damage the foam seal. If found to be or if it
becomes damaged, the replacement seal part numbers are: 96077AJ00A for Legacy / Outback and
96077FL00A for Impreza and Ascent.
It cannot be stressed enough to have plenty of clean shop cloths and / or
absorbent pads available to use when removing the fuel line(s) from the fuel
pump. A small drip tray or pan is also recommended to use for catching any
dripping fuel when removing the fuel pump assembly from the tank.
IMPORTANT: When performing these procedures, shop cloths contaminated
with gasoline will be created. It is CRITICAL they be handled safely and
following proper disposal guidelines. Always store contaminated shop cloths in
an approved safety can as shown here.
After removing the rear seat cushion assembly and
the (main) fuel pump access cover, use a length
of small hose (sliced lengthwise), vinyl door edge
guard as shown here or electrical tape to cover the
edge of the access opening in the floor panel. This
will protect any removed fuel line(s) and Technician
hands from cuts or abrasions resulting from sharp
edges. The photo here shows the power harness
unplugged and shop cloths in place to absorb
residual fuel that may remain in the lines after
removal from the pump assembly. CAREFULLY
release the retaining clip(s) with a small flat-blade screwdriver, put a cloth over the connection and
remove the line(s). Immediately install the plug(s) provided in the replacement fuel pump kits into
the removed line(s) to avoid any spillage. This will help reduce the chances of post-repair customer
concerns of fuel odor inside the cabin.
On Legacy and Outback models, use a small container or magnetic dish to keep all the retaining ring
nuts together while the pump assembly is removed.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 6 of 49
Have a small fuel-safe drain pan in place to catch any spilled fuel as the pump assembly is
CAREFULLY lifted out of the fuel tank. If available, use a vacuum bleeder with a collection
reservoir and hose to draw some of the stored fuel out of the fuel chamber surrounding the pump and
filter to help avoid spillage. NOTE: On Ascent, there is a jet pump fuel tube attached to the lower
portion of the fuel pump assembly as shown below, right which must also be removed before the
pump assembly can be completely removed from the vehicle. Release the retaining clip with a small
flat-blade screwdriver and remove the line but, secure the line with electrical tape or Mechanic’s wire
to keep it from falling into the tank once it is removed. If not secured, it will fall into the tank and
have to be “fished” out prior to reinstalling the pump assembly.
IMPORTANT: After the pump assembly is removed, ALWAYS install the applicable fuel tank
cap (plug) as shown below or, cover the fuel tank opening with shop cloths or a fender cover (or
an equivalent) to keep fuel odors from accumulating inside the cabin. These tools are not required
when replacing the complete fuel pump assembly due to the very short time the tank will be open to
complete the repair.
IMPREZA / ASCENT
LEGACY / OUTBACK
LEGACY / OUTBACK 2.5 & 3.6L PUMP
NOTE: When searching STIS for the applicable
Service Manual procedures for reference, select Fuel
Filter REMOVAL to get the detailed procedure for
separating the pump / filter sock assembly from the
complete fuel pump assembly. Fuel Filter removal
is NOT required to complete this procedure. The
replacement pumps come with a new filter sock
already in place as shown here.
IMPREZA / ASCENT PUMP
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 7 of 49
For this recall, the 2-wire (Blue / Black) fuel pump wiring harness
indicated as 1-time use in the Service Manual is reused but,
should be inspected for damage or any evidence of overheating
(discoloration of connectors, etc.). IMPORTANT: If any damage
e.g. distorted or melting plastic connectors, overheated wiring or
terminals is identified, the harness MUST be replaced. It easily
unplugs from the fuel pump.
When reinstalling the thinner (Black / Red) fuel sender wires into the
2 retaining clips, they go into the clips first and are held in place by the
thicker fuel pump harness wires.
FUEL PUMP REPLACEMENT for 2019MY LEGACY and OUTBACK 2.5 and 3.6L Models:
IMPORTANT PRECAUTIONS:
•
Place “NO OPEN FLAMES” signs near the working area.
•
Be careful not to spill any fuel, especially when working inside the vehicle.
•
Catch any leaking fuel from the removed fuel tube(s) using a small drain pan or cloths.
•
If the fuel level in the tank is 2/3 full or more, drain the fuel to below 2/3 full before starting
this procedure to avoid spilling any fuel.
•
To prevent static electricity discharge / spark, always discharge any static electricity before
starting this procedure using an anti-static cord and / or touching a grounded metal part of the
vehicle body (e.g. door striker).
•
Insure there is plenty of ventilation by opening windows of the vehicle and the service area.
•
ALWAYS remove the fuel cap to release any accumulated evaporative / vapor pressure.
As mentioned earlier, select Fuel Filter REMOVAL in the applicable Service Manaual to get the
complete, detailed procedure for separating the fuel pump / filter sock from the complete fuel pump
assembly. The following instructions will follow the Service Manual with additional photos to help
clarify the step where applicable.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 8 of 49
1. Park the vehicle where the work will be performed. Release the fuel pressure:
•
Locate and remove the fuel pump fuse in the under-hood fuse box (M/B).
•
Start the engine and allow it to run until it stalls. NOTE: Even after the engine stalls, there
will still be a small amount of residual pressure left in the fuel system. Crank the engine
another 5 seconds with the starter.
2. Enter the driver seat and lower all windows. Using the fuel gauge in the Combination Meter,
check the fuel level.
•
If the fuel gauge shows two thirds (2/3) or more: go to STEP 3
•
If the fuel gauge shows less than two thirds: go to STEP 4.
3. (STEP 3A:) If the fuel level is above 2/3, use the following procedure
and fuel pipe adapter 18471AA000 (required tool) for connecting to
the female fuel supply connection at the fuel rail. Connect the adapter
and clamp a length of fuel hose to the other end. Empty the hose into a
safety container as shown in the photo sequence below.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 9 of 49
Once the drain hose assembly is securely in place, connect the SSM4, turn the ignition ON and
from the Active test item menu, select Fuel Pump Control to operate the fuel pump. Drain the
fuel tank down until the fuel gauge reads at or below 2/3 full.
(STEP 3B:) Once available, the PREFERRED method for draining fuel will be to use the
special adapter p.n. 42099FL030. CAREFULLY remove the rear seat cushion assembly
and fuel pump access cover. Apply a length of door edge guard, flexible tubing or electrical
tape around the pump access opening as protection from cuts / abrasions from any sharp edges.
Release the quick disconnect fitting at the fuel pump outlet pipe. While covering the fuel pipe
with a clean shop cloth to catch any residual pressurized fuel, slide the fuel delivery pipe off
the fuel pump outlet. Insert the plastic temporary plug supplied in the kit into the removed fuel
delivery pipe. The one-time use temporary plug is included in the replacement fuel pump parts
kit.
•
Connect a sufficient length of 5/16” rubber fuel hose to the male hose barb portion of the
adapter fitting. Always secure it with a small hose clamp to prevent leakage. Remove the
plastic plug from the adapter and connect the adapter / hose assembly to the male fuel
discharge tube of the fuel pump as shown below. Put the other end of the rubber fuel hose
securely into a safety container to collect the drained fuel. Once the drain hose assembly
is securely in place, connect the SSM4, turn the ignition ON and from the Active test item
menu, select Fuel Pump Control to operate the fuel pump. Drain the fuel tank down until the
fuel gauge reads at or below 2/3 full.
Remove
Plug and
Discard
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 10 of 49
4. While holding the battery sensor firmly with one hand to avoid damage, loosen and disconnect
the ground terminal.
5. If not already done in STEP 3, CAREFULLY remove the rear seat cushion assembly, set it aside
in a clean, safe place and remove the fuel pump access cover. Take care to not damage the foam
seal.
REMINDER: ALWAYS remove the fuel tank filler cap to release any remaining vapor pressure.
6. Fuel Pump Assembly Removal:
•
CAREFULLY using HAND TOOLS ONLY, remove the fuel pump access cover while
paying close attention to avoid damaging the foam seal between the cover and vehicle body.
Replace the seal if damaged with p.n. 96077AJ00A (rare case). NEVER use air or electric
tools when performing this step
•
Apply a length of door edge guard, flexible tubing or electrical tape around the pump access
opening as protection from cuts / abrasions from any sharp edges.
•
Release the quick disconnect fitting at the fuel pump outlet pipe, and while covering the
pipe and connector with a clean shop cloth to catch any residual pressurized fuel,
slide the fuel delivery pipe off the fuel pump outlet tube. Insert the plastic temporary plug
into the fuel delivery pipe connector. The one-time use temporary plug is included in the
replacement fuel pump parts kit.
•
CAREFULLY using HAND TOOLS ONLY, remove the nuts securing the fuel pump top
plate to the fuel tank. CAUTION: If the nuts are hard to loosen, use a lubricant on them and
take care not to break the fuel tank studs. NEVER use air or electric tools when performing
this step
•
CAREFULLY remove the fuel pump assembly from the fuel tank. Use a vacuum tool
with a reservoir, squeeze bottle or an equivalent tool to remove residual fuel from the fuel
chamber of the pump assembly along with a small catch pan to prevent spilling fuel as the
pump assembly is removed. IMPORTANT: Do not let the fuel level sensor arm or float
contact the tank opening during removal.
7. Once the fuel pump assembly has been removed, install the applicable plastic plug tool into
the fuel tank opening to prevent contamination from entering the tank and fuel vapors from
accumulating in the vehicle interior. If the plug is not available, cover the opening with a clean
shop cloth.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 11 of 49
8. After disconnecting the pump and sending unit harness connectors from the underside of the top
flange, CAREFULLY remove the fuel sending unit from the pump chamber.
IMPORTANT: If any damage e.g. distorted or melting plastic connectors, overheated wiring or
terminals is identified, the harness MUST be replaced. Release the retaining clip (a plastic trim
tool is being used here) and slide the sending unit upward. NEVER touch the contact surface of
the sending unit and use care to avoid bending or otherwise damaging the float arm and contact
point.
•
CAREFULLY disconnect both the fuel pump and fuel sending unit harness connectors and
remove the wiring from the retaining clips. Note the wire routing prior to disassembly for
reference during reassembly.
•
Compress the spring (fuel filter assembly) and remove / discard the (one-time use) c-clip
(ring clip).
•
IMPORTANT: When releasing the retaining claws as described in the following steps,
move them only as far as needed to disengage them. If any break, the affected component
must be replaced.
•
Release the retaining claw for the tube at the bottom of the fuel chamber.
•
CAREFULLY release the 3 claws for the pump holder from the fuel chamber then raise the
pump / filter assembly upward.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 12 of 49
•
CAREFULLY remove the fuel tube assembly from the fuel chamber using a small flat-blade
screwdriver wrapped with protective tape as shown.
•
Using 2 small flat-blade screwdrivers, CAREFULLY release the 2 claws securing the fuel
pump to the regulator.
•
Release the 3 remaining claws at the bottom of the fuel pump then CAREFULLY press
down on the top of the pump to push it out the bottom of the fuel filter assembly.
STOP HERE DO NOT remove the pressure regulator or otherwise go any further with disassembly
of the fuel pump assembly.
IMPORTANT: Remove the o-ring and spacer from the original fuel pump. The spacer is reused. Put
the removed pump in a vise and crush it as shown above to eliminate any chance of it being reused.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 13 of 49
9. Install the New Fuel Pump Assembly:
•
Transfer the white plastic spacer (B) to the new pump and install
Plastic
the new o-ring (A) from the kit to hold the spacer in place. It is
Non-Marring
Pick Tool
CRITICAL for the bushing and NEW o-ring to be installed
on the new pump in the proper order. Always lubricate the
new o-rings with gasoline. IMPORTANT: Always confirm the
original o-ring came out of the filter assembly during disassembly.
If not, use a rubber-tipped or plastic (non-marring) pick tool to
CAREFULLY remove it without scratching the filter assembly bore.
(C)
(A)
(B)
•
Install the new fuel pump into the fuel filter assembly. Using the image below as a guide, lay
the partially reassembled pump assembly on the bench horizontally and insert the new pump
into the fuel filter assembly. Using both hands, CAREFULLY press the new pump and filter
assemblies together until a “click” is heard from ALL of the new fuel pump’s retaining claws.
If the new pump does not fully seat and lock into position, make sure the old o-ring (A) is not
still in the bore as shown above.
•
Replace all 3 rubber cushions (feet) on the
bottom of the fuel chamber, replacements are
included in the kit. Failure to replace these
may result in a later noise complaint.
•
CAREFULLY refit the tube assembly back
into the fuel chamber until it clicks into
position.
•
Refit the tube back on to the bottom side of
the fuel chamber.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 14 of 49
•
Refit the spring (B) to the rod with the snap ring groove then re-install the pump / filter
assembly into the fuel chamber. IMPORTANT: Confirm tube (A) is routed UNDER the
retaining claw then lock all 3 claws in place.
(B)
(A)
•
Press the top of the pump assembly downward and install the new c-clip (ring clip) included
in the kit.
•
Re-connect the fuel pump harness. CAREFULLY refit the fuel level sensor assembly to the
fuel chamber. Put the (thinner) fuel lever sensor wires into the 2 retaining clips first followed
by the fuel pump wires IN THAT ORDER.
10. IMPORTANT: Make sure all the sealing surfaces are free from fuel or foreign matter before
reinstalling the fuel pump assembly.
•
CAREFULLY reinstall the fuel pump assembly into the tank in the proper position /
orientation. ALWAYS use the new gasket included in the kit.
•
IMPORTANT: Use CAUTION to keep the fuel level sensor arm from contacting the fuel
tank opening. If the arm were to become bent, the fuel gauge may not read properly.
•
Using the illustrations below for reference, align the recess of the fuel pump upper plate
cushion to the protrusion (A) of the fuel pump assembly.
•
While keeping cutout (B) of the fuel pump upper plate toward the rear of the vehicle, align
protrusion (C) of the fuel pump upper plate cushion with the cutout.
•
CRITICAL: Lightly hand tighten all nuts in the sequence shown below. Complete
tightening of the 8 retaining nuts to the specified torque: 4.4 Nm, (3.2 ft. lbs. or 38 inchpounds) following the sequence shown below. NEVER use air or electric powered tools to
tighten these nuts as the studs may be damaged.
(B)
FRONT
of
VEHICLE
2
3
(C)
7
(A)
5
6
4
8
1
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 15 of 49
•
Remove and discard the plastic temporary plug from the fuel delivery pipe and re-connect the
pipe to the fuel pump outlet tube. Make sure the connector is all the way onto the outlet tube
then lock the slider. Tug on the delivery pipe to be sure it is fully locked in place.
IMPORTANT REMINDERS: Discard the plastic fuel line plug as it is a one-time use item.
Reusing the plug may damage the connector’s internal o-ring and cause a fuel leak.
•
Ensure both the pipe and tube are clean and dry
•
If the slider does not move easily, confirm the pipe is engaged on the tube
•
ALWAYS confirm the pipe is fully engaged after connecting and check for any leaks
11. Reconnect the harness connector to the fuel pump.
12. Reconnect the ground cable to the battery sensor. Torque to 7.5 Nm (5.5 ft. lbs.) while supporting
the sensor with the other hand.
13. Turn on the ignition switch to run the fuel pump. The engine does not need to be started. Check
closely for any leaks around ALL fuel delivery tube connections removed as part of this repair
(including those under the hood if fuel was drained) and around the top plate
14. Reinstall the inspection cover.
15. Reinstall the seat cushion assembly while making sure the seat belt buckles are properly
positioned. IMPORTANT NOTE: If any of the plastic clips securing the seat cushion to the
body were displaced when removing the seat cushion, they MUST be replaced.
16. Return any removed fuel back to the vehicle.
17. Deodorize the vehicle interior as necessary.
END OF LEGACY / OUTBACK SERVICE PROCEDURES
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 16 of 49
Helpful TIPS for 2019MY IMPREZA and ASCENT Models:
The procedure for replacing the fuel pump on Impreza and Ascent is very similar to the Legacy and
Outback. The major differences are described here:
•
Both fuel pump assemblies are retained into the fuel tank by a threaded locking ring (ring
nut) instead of a top plate secured by studs and nuts. There are separate procedures for
tightening these ring nuts. A special tool (42099FL000) is used for both models. A 1/2-inch
drive breaker bar and Torque wrench (for Impreza) are also required. New ring nuts and the
required sealing rings are included in the replacement fuel pump part kits.
•
IMPORTANT: Always press down vertically on the center of the tool with one hand and
pull squarely on the bar or wrench with the other to keep it from slipping off the ring nut.
•
CRITICAL: There are 2 procedures for tightening the ring nuts:
○ The Impreza ring nut is simply tightened to 130 Nm (96 ft. lbs.). followed by a
CRITICAL height measurement check in 3 places to confirm there is no cross-threading.
The black arrow indicates the thread starting point of the ring nut threads..
○ The Ascent ring nut uses a starting point identified by aligning hash marks molded into
the top of the fuel tank with another set on the ring nut. Another set of hash marks
molded into the tank and 90 degrees to the right (90 degrees clockwise from the first set)
identify the tightening finish point “Range Marks”. The Ascent procedure also includes a
height measurement check in 3 places to confirm there is no ring nut cross-threading.
ASCENT RING
IMPREZA RING
Ascent Ring Nut Markings:
•
Inspect the new ring nut and identify the set of 3 “teeth” close together as shown above.
NOTE: The center or middle line (GREEN tooth) must be aligned with the triangle ∆ mark
in the middle of the thread starting point hash marks as shown below. Also, there is another
∆ mark on the top of the fuel pump (Indexing Arrow) to be used as a reference for making
sure the pump is properly indexed inside the tank.
Pump Indexing
Arrow
STARTING POINT
Hash Marks
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 17 of 49
•
Once the initial alignment is done, start tightening the ring nut with the special tool. As it
tightens, the up and down movement of the fuel pump assembly will be reduced. Once this
up and down movement can no longer be felt (one full turn), it is VERY IMPORTANT
to make sure the indexing arrow of the fuel pump assembly stays aligned with the arrow in
the center of the starting point hash marks. At this point, the ring nut should only need final
tightening to get the middle line into the range of (between) the Finishing Point Range hash
marks. REMINDER: As the final tightening is completed, make sure the indexing arrow is
still aligned with the arrow in the center of the starting point hash marks. If not, loosen the
ring nut reposition the pump properly and re-tighten.
•
TIP: To help stop the pump from turning while tightening the ring nut, make sure the new
gaskets and all the surfaces they contact (top of fuel tank, top and bottom of the fuel pump
flange and both sides of the top seal plate) are thoroughly cleaned of any residual gasoline or
other contamination and completely dry. Areas to focus on are shown in red below.
•
On Impreza, start the ring nut with the indexing arrow
centered between the hash marks. Tighten the ring
to 96 ft. lbs. IMPORTANT: As the specified torque
approaches, confirm the indexing arrow on the fuel
pump stays between the hash marks. When successful
alignment and torque are achieved, perform the height
adjustment check procedure below.
Pump Indexing
Arrow
Height Adjustment Checks:
•
CRITICAL: These height measurement checks
MUST be made as a final check to confirm the ring nut
is not cross-threaded.
•
Ascent: 23.8 +/- 2.5 mm (.937 +/- .098 in.) measured
in 3 positions around the ring nut. The best tool for
doing this measurement is a digital caliper as shown
below. Measure from the top edge of the ring nut
“teeth” to the top surface of the tank.
•
Impreza: After the specified torque is reached,
measure the height using a digital caliper as shown
below between the flats adjacent to the ring nut
“teeth” to the top surface of the tank in 3 places. All 3
measurements must be between 1.5 mm of each other.
ASCENT
IMPREZA
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 18 of 49
NOTE: In cases where the ring nut does not thread properly onto the fuel tank, it will be necessary
to “jump” one thread to avoid cross-threading of the ring nut and tank. To do this, begin threading
the ring nut onto the tank at a minimal angle until slight turning resistance is felt. The ring nut thread
starting points are identified by the triangle arrow ∆ on the Impreza ring and the set of 3 lines close
together on the Ascent ring nut (Green arrows in photo below and highlighted with black marker on
the parts). Once the resistance is felt, apply a quick, downward, non-percussive force to the side of
the ring opposite from where the threads were started. A slight “pop” sound should be heard. Once
the pop has been heard and while keeping downward pressure on the ring nut, continue threading the
ring nut onto the tank until it can no longer be turned by hand. Proceed with the remainder of the
tightening and height adjustment procedures as described above.
ASCENT RING
IMPREZA RING
Other differences (between the Legacy / Outback procedure) to be aware of:
LEGACY / OUTBACK PUMP
1. The fuel pump is secured to the filter
assembly with 3 retaining claws instead of 5.
2. Instead of having 2 fuel line connections on
the pump assembly, Impreza and Ascent only
use 1.
3. Impreza does not utilize a “saddle” type fuel
tank therefore, there is also no jet pump.
IMPREZA / ASCENT PUMP
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 19 of 49
4. Both models utilize a large o-ring seal between the
fuel pump assembly and the tank instead of a rubber
gasket. Ascent uses an additional blue plastic sealing
washer between the lock ring and top of the fuel pump
assembly.
5. Ascent has a jet pump fuel line connection to the fuel
chamber inside the tank. When removing this line, if
desired, it can be secured either with tape or a piece of
Mechanic’s wire under the connector slider to keep it
from dropping inside the fuel tank.
END OF IMPREZA & ASCENT TIPS
FUEL PUMP REPLACEMENT for 2019MY IMPREZA Models:
IMPORTANT PRECAUTIONS:
•
Place “NO OPEN FLAMES” signs near the working area.
•
Be careful not to spill any fuel, especially when working inside the vehicle.
•
Catch any leaking fuel from the removed fuel tube(s) using a small drain pan or cloths.
•
If the fuel level in the tank is 2/3 full or more, drain the fuel to below 2/3 full before starting
this procedure to avoid spilling any fuel.
•
To prevent static electricity discharge / spark, always discharge any static electricity before
starting this procedure using an anti-static cord and / or touching a grounded metal part of the
vehicle body (e.g. door striker).
•
Insure there is plenty of ventilation by opening windows of the vehicle and the service area.
•
ALWAYS remove the fuel cap to release any accumulated evaporative / vapor pressure.
As mentioned earlier, select Fuel Filter REMOVAL in the applicable Service Manual to get the
complete, detailed procedure for separating the fuel pump / filter sock from the complete fuel pump
assembly. The following instructions will follow the Service Manual with additional photos to help
clarify the step where applicable.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 20 of 49
For this Campaign procedure, the
connector cable (9) does not need
to be replaced.
However, if either of the following
conditions are found, replace it.
• Cracking of the harness insulation or
• Deformation / discoloration of any
connector or terminal.
1. Park the vehicle where the work will be performed. Release the fuel pressure:
•
Locate and remove the fuel pump fuse in the under-hood fuse box (M/B).
•
Start the engine and allow it to run until it stalls. NOTE: Even after the engine stalls, there
will still be a small amount of residual pressure left in the fuel system. Crank the engine
another 5 seconds with the starter.
2. Enter the driver seat and lower all windows. Using the fuel gauge in the Combination Meter,
check the fuel level.
•
If the fuel gauge shows two thirds (2/3) or more: go to STEP 3
•
If the fuel gauge shows less than two thirds: go to STEP 4.
3. (STEP 3A:) If the fuel level is above 2/3, use the following
procedure and fuel pipe adapter 18471AA000 (required tool) for
connecting to the female fuel supply connection at the fuel rail. On
Impreza, removing the intake air duct makes the connection point
easier to access. Connect the adapter and clamp a length of fuel
hose to the other end. Empty the hose into a safety container as
shown in the photo sequence below.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 21 of 49
Once the drain hose assembly is securely in place, connect the SSM4, turn the ignition ON and
from the Active test item menu, select Fuel Pump Control to operate the fuel pump. Drain the
fuel tank down until the fuel gauge reads at or below 2/3 full.
(STEP 3B:) Once available, the PREFERRED method for draining fuel will be to use the
special adapter p.n. 42099FL030. CAREFULLY remove the rear seat cushion assembly
and fuel pump access cover. Apply a length of door edge guard, flexible tubing or electrical
tape around the pump access opening as protection from cuts / abrasions from any sharp edges.
Release the quick disconnect fitting at the fuel pump outlet pipe. While covering the fuel pipe
with a clean shop cloth to catch any residual pressurized fuel, slide the fuel delivery pipe off
the fuel pump outlet. Insert the plastic temporary plug supplied in the kit into the removed fuel
delivery pipe. The one-time use temporary plug is included in the replacement fuel pump parts
kit. This plug is not required if the fuel pump assembly is being replaced due to the very short
disconnection time.
•
Connect a sufficient length of 5/16” rubber fuel hose to the male hose barb portion of the
adapter fitting. Always secure it with a small hose clamp to prevent leakage. Remove the
plastic plug from the adapter and connect the adapter / hose assembly to the male fuel
discharge tube of the fuel pump as shown below. Put the other end of the rubber fuel hose
securely into a safety container to collect the drained fuel. Once the drain hose assembly
is securely in place, connect the SSM4, turn the ignition ON and from the Active test item
menu, select Fuel Pump Control to operate the fuel pump. Drain the fuel tank down until the
fuel gauge reads at or below 2/3 full.
Remove
Plug and
Discard
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 22 of 49
4. Disconnect the ground terminal from battery and wait 60 seconds before proceeding.
5. If not already done in STEP 3, CAREFULLY remove the rear seat cushion assembly, set it aside
in a clean, safe place. While pushing the corners of the rear seat cushion from above, pull the
knobs of the retaining hooks forward. Lift up on the front of the cushion assembly to disengage
the rear hooks and remove it.
REMINDER: ALWAYS remove the fuel tank filler cap to release any remaining vapor pressure.
CAUTION:
• The Airbag system satellite safing sensor is located under the front center of the rear seat cushion.
Be careful not to apply any strong impacts to the sensor when working with the rear seat cushion
removed.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 23 of 49
6. Fuel Pump Assembly Removal:
•
CAREFULLY remove the fuel pump access cover while paying close attention to avoid
damaging the foam seal between the cover and vehicle body. Replace the seal if damaged
with p.n. 96077FL00A (rare case).
•
Apply a length of door edge guard, flexible tubing or electrical tape around the pump access
opening as protection from cuts / abrasions from any sharp edges.
•
Release the quick disconnect fitting at the fuel pump outlet pipe, and while covering the pipe
and connector with a clean shop cloth to catch any residual pressurized fuel, slide the fuel
delivery pipe off the fuel pump outlet tube. Insert the plastic temporary plug into the fuel
delivery pipe connector. The one-time use temporary plug is included in the replacement fuel
pump parts kit.
•
Disconnect the harness connector from the pump.
•
CAREFULLY using HAND TOOLS ONLY and the Ring
Nut Wrench tool shown here, remove the plastic retaining
ring securing the fuel pump assembly in the fuel tank.
NOTE: Make sure the removed fuel delivery pipe is ON
TOP of the tool as shown and not pinched under it.
Ring Nut
Wrench
Removed Pipe
on TOP of Tool
•
CAREFULLY remove the fuel pump assembly from the
fuel tank. Use a vacuum tool with a reservoir, squeeze bottle or an equivalent tool to remove
residual fuel from the fuel chamber of the pump assembly along with a small catch pan to
prevent spilling fuel as the pump assembly is removed. IMPORTANT: Do not let the fuel
level sensor arm or float contact the tank opening during removal.
•
Once the fuel pump assembly has been removed, install the applicable plastic plug tool into
the fuel tank opening to prevent contamination from entering the tank and fuel vapors from
accumulating in the vehicle interior. If the plug is not available, cover the opening with a
clean shop cloth. The plug is not required when replacing the complete fuel pump assembly
due to the very short time the tank will be open for that repair.
7. After disconnecting the pump and sending unit harness connectors from the underside of the top
flange, CAREFULLY remove the fuel sending unit from the pump chamber.
IMPORTANT: If any damage e.g. distorted or melting plastic connectors, overheated wiring or
terminals is identified, the harness MUST be replaced. Release the retaining clip (a plastic trim
tool is being used here) and slide the sending unit upward. NEVER touch the contact surface of
the sending unit and use care to avoid bending or otherwise damaging the float arm and contact
point.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 24 of 49
8. CAREFULLY disconnect both the fuel pump and fuel sending unit harness connectors and
remove the wiring from the retaining clips. Note the wire routing prior to disassembly for
reference during reassembly.
•
Compress the spring (fuel filter assembly) and remove / discard the (one-time use) c-clip.
•
IMPORTANT: When releasing the retaining claws as described in the following steps,
move them only as far as needed to disengage them. If any
break, the affected component must be replaced.
•
Using a flat-blade screwdriver wrapped with protective tape (or
equivalent), release the connector for the fuel tube at the bottom of
the fuel chamber. Remove the fuel tube from the side of the fuel
chamber as shown.
•
CAREFULLY disengage three claws of the fuel pump holder
from the fuel chamber assembly. Remove the fuel pump and filter
assembly from the chamber.
Fuel Pump Holder
•
CAREFULLY remove the fuel pump holder from the fuel filter
assembly.
•
Disengage the 3 claws at the bottom of the fuel pump.
•
Using the flat tip screwdriver or similar tool wrapped with a
protective tape, press on the fuel pump and remove the fuel
pump from the fuel filter assembly.
IMPORTANT: Remove the
o-ring and spacer from
the original fuel pump.
The spacer is reused. Put
the removed pump in a
vise and crush it as shown
here to eliminate any
chance of it being reused.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 25 of 49
•
Transfer the white plastic spacer (B) to the new pump and install the new o-ring (A) from the
kit to hold the spacer in place. Lubricate the new o-ring with gasoline.
•
IMPORTANT: Always confirm the original o-ring came out
of the filter assembly during disassembly. If not, use a rubbertipped or plastic (non-marring) pick tool to CAREFULLY
remove it without scratching the filter assembly bore. Transfer
the white plastic spacer (B) to the new pump and install the
new o-ring (A) from the kit to hold the spacer in place. It is
CRITICAL for the bushing and NEW o-ring to be installed
on the new pump in the proper order. Always lubricate the
new o-rings with gasoline.
Plastic
Non-Marring
Pick Tool
(C)
(A)
(B)
9. Install the new fuel pump into the fuel filter assembly. Using
the image here as a guide, lay the partially reassembled pump
assembly on the bench horizontally and insert the new pump
into the fuel filter assembly. Using both hands, CAREFULLY
press the new pump and filter assemblies together until a “click”
is heard from ALL of the new fuel pump’s retaining claws. If
the new pump does not fully seat and lock into position, make
sure the old o-ring (A) is not still in the bore as shown above.
•
Refit the fuel pump holder to the fuel filter assembly.
•
Reinstall the fuel filter assembly into the fuel chamber. Make sure the fuel tube and the
spring are properly positioned as shown in the photo and illustration below.
•
Confirm the 3 claws securing the fuel filter assembly into the fuel
chamber are fully engaged.
•
Secure the fuel tube to the outside of the fuel chamber and
reconnect it at the bottom.
•
Push the fuel filter assembly in the direction of the arrow to
compress, and install the new clip supplied in the kit.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 26 of 49
10. CAREFULLY refit the fuel level sensor assembly to the fuel chamber. Put the (thinner) fuel
lever sensor wires into the 2 retaining clips first followed by the fuel pump wires IN THAT
ORDER.
•
CRITICAL: ALL surfaces of the new pump assembly o-ring, top gasket, underside of the
ring nut along with the surfaces described and shown below: fuel tank neck rim (A) pump
flange top and bottom faces (B) and (C) must be thoroughly wiped clean and completely dried
BEFORE re-installation. This will help prevent the pump from turning with the ring nut during
final tightening.
(A) Fuel Tank Rim
•
(B) Pump Flange Top Face
(C) Underside of Pump Flange
Use CAUTION to keep the fuel level sensor arm from contacting the fuel tank opening. If
the arm were to become bent, the fuel gauge may not read properly.
11. CAREFULLY reinstall the fuel pump assembly into
the tank in the proper position / orientation as shown
below. ALWAYS use the new gasket included in
the kit. Position the indexing arrow ∆ between the
molded-in hash marks (blue arrows) on the fuel tank.
•
Install the new ring nut included in the kit. The
new ring nut has a triangle index mark ∆ (shown
in black here for illustration purposes) similar to
the fuel pump to indicate the ring nut thread
starting point (if needed).
•
NOTE: In a case where there is
difficulty getting the ring nut threads
started onto the fuel tank threads,
align the starting points, install the
ring nut wrench then press down
firmly by hand on the ring nut wrench
to “jump” the ring nut thread past the
interference point. A “pop” sound
will occur, the ring nut should now be
parallel to the top of the fuel tank and
able to be tightened by hand.
Pump Indexing
Arrow
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 27 of 49
12. CAUTION: SLOWLY tighten the new ring nut to 130 Nm (96 ft.
lbs.) while paying close attention to make sure the fuel pump does not
rotate along with the ring nut. If the pump were to turn more than 45
degrees, the fuel level sensor will likely be damaged. When properly
tightened, the index mark on the ring nut ∆ should align with the fuel
pump indexing arrow ∆ (Center Line (A).
13. CRITICAL: Using a caliper with depth gauge, measure the dimension
in 3 positions between the top of the ring nut and the top of fuel tank
as shown in the illustration and photo (inset) below. The difference
between the three measurements cannot exceed ±1.5mm or .060 inch.
CAUTION:
•
If the difference between any of the three measurements exceeds ±1.5mm or .060 inch, loosen and
re-tighten the ring nut to correct any cross-threading.
•
If the ring nut or fuel pump gasket are deformed, cracked or damaged, they MUST be replaced.
14. Remove and discard the plastic temporary plug from the fuel delivery pipe and re-connect the
pipe to the fuel pump outlet tube. Make sure the connector is all the way onto the outlet tube then
lock the slider. Tug on the fuel delivery pipe to be sure it is fully locked in place.
IMPORTANT REMINDERS: Discard the plastic fuel line plug as it is a one-time use item.
Reusing the plug may damage the connector’s internal o-ring and cause a fuel leak.
•
Ensure both the pipe and tube are clean and dry
•
If the slider does not move easily, confirm the pipe is engaged on the tube
•
ALWAYS confirm the pipe is fully engaged after connecting and check for any leaks
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 28 of 49
15. REMINDER: Discard the removed temporary plug as it is a one-time use item. Reusing the plug
may damage the connector’s internal o-ring and cause a fuel leak.
16. Reconnect the harness connector to the fuel pump.
17. Reconnect the ground cable to the battery. Torque to 7.5 Nm (5.5 ft. lbs.).
18. Turn on the ignition switch to run the fuel pump. The engine does not need to be started. Check
closely for any leaks around ALL fuel delivery tube connections removed as part of this repair
(including those under the hood if fuel was drained) and around the ring nut.
19. Reinstall the inspection cover.
20. Reinstall the seat cushion assembly while making sure the seat belt buckles are properly
positioned. IMPORTANT NOTE: If any of the plastic clips securing the seat cushion to the
body were displaced when removing the seat cushion, they MUST be replaced.
21. Return any removed fuel back to the vehicle.
22. Deodorize the vehicle interior as necessary.
END OF IMPREZA SERVICE PROCEDURE
FUEL PUMP REPLACEMENT for 2019MY ASCENT Models:
IMPORTANT PRECAUTIONS:
•
Place “NO OPEN FLAMES” signs near the working area.
•
Be careful not to spill any fuel, especially when working inside the vehicle.
•
Catch any leaking fuel from the removed fuel tube(s) using a small drain pan or cloths.
•
If the fuel level in the tank is 2/3 full or more, drain the fuel to below 2/3 full before starting
this procedure to avoid spilling any fuel.
•
To prevent static electricity discharge / spark, always discharge any static electricity before
starting this procedure using an anti-static cord and / or touching a grounded metal part of the
vehicle body (e.g. door striker).
•
Insure there is plenty of ventilation by opening windows of the vehicle and the service area.
•
ALWAYS remove the fuel cap to release any accumulated evaporative / vapor pressure.
As mentioned earlier, select Fuel Filter REMOVAL in the applicable Service Manual to get the
complete, detailed procedure for separating the fuel pump / filter sock from the complete fuel pump
assembly. The following instructions will follow the Service Manual with additional photos to help
clarify the step where applicable.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 29 of 49
1. Park the vehicle where the work will be performed. Release the fuel pressure:
•
Locate and remove the fuel pump fuse in the under-hood fuse box (M/B).
•
Start the engine and allow it to run until it stalls. NOTE: Even after the engine stalls, there
will still be a small amount of residual pressure left in the fuel system. Crank the engine
another 5 seconds with the starter.
2. Enter the driver seat and lower all windows. Using the fuel gauge in the Combination Meter,
check the fuel level.
•
If the fuel gauge shows two thirds (2/3) or more: go to STEP 3
•
If the fuel gauge shows less than two thirds: go to STEP 4.
3. (STEP 3A:) Use this procedure only when the tools in Step 3B below are
unavailable. If the fuel level is above 2/3, use the following procedure and
fuel pipe adapter 18471AA000 (required tool) for connecting to the female
fuel supply connection at the fuel rail. On Ascent, removing the intercooler
is required to access the connection point. Connect the adapter and clamp a
length of fuel hose to the other end. Empty the hose into a safety container
as shown in the photo sequence below.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 30 of 49
IMPORTANT: When removing the intercooler, the intake duct gaskets p.n. 14497AA080 and
p.n. 21896AA130 are both 1-time use and MUST be replaced. Remove the Intercooler and duct
as an assembly. Do not separate them.
14497AA080
21896AA130
Once the drain hose assembly is securely in place, connect the SSM4, turn the ignition ON and
from the Active test item menu menu, select Fuel Pump Control to operate the fuel pump. Drain
the fuel tank down until the fuel gauge reads at or below 2/3 full.
(STEP 3B:) Once available, the PREFERRED method for draining fuel will be to use the
special adapter p.n. 42099FL030. After CAREFULLY removing the retaining bolt trim covers,
CAREFULLY remove the right rear seat assembly following the procedure in the applicable
Service Manual and set it aside in a safe place. REMINDER: Always protect the surrounding
trim and painted surfaces when removing and reinstalling the seat assembly. Using a helper for
this step is also STRONGLY recommended. Remove the section of floor mat covering the fuel
pump access cover. With the access cover removed, apply a length of door edge guard, flexible
tubing or electrical tape around the pump access opening as protection from cuts / abrasions
from any sharp edges. Release the quick disconnect fitting at the fuel pump outlet pipe. While
covering the fuel pipe with a clean shop cloth to catch any residual pressurized fuel, slide
the fuel delivery pipe off the fuel pump outlet. Insert the plastic temporary plug supplied in the
kit into the removed fuel delivery pipe. The one-time use temporary plug is included in the
replacement fuel pump parts kit. This plug is not required if the fuel pump assembly is being
replaced due to the very short disconnection time.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 31 of 49
•
Connect a sufficient length of 5/16” rubber fuel hose to the male hose barb portion of the
adapter fitting. Always secure it with a small hose clamp to prevent leakage. Remove the
plastic plug from the adapter and connect the adapter / hose assembly to the discharge tube
of the fuel pump as shown below. Put the other end of the rubber fuel hose securely into
a safety container to collect the drained fuel. Once the drain hose assembly is securely in
place, connect the SSM4, turn the ignition ON and from the Active test item menu, select
Fuel Pump Control to operate the fuel pump. Drain the fuel tank down until the fuel gauge
reads at or below 2/3 full.
Remove
Plug and
Discard
4. While holding the battery sensor firmly with one hand to avoid damage, loosen and disconnect
the ground terminal and harness connector.
REMINDER: ALWAYS remove the fuel tank filler cap to release any remaining vapor pressure.
5. If not already done in STEP 3, CAREFULLY remove the retaining bolt trim covers and
CAREFULLY remove the right rear second row seat assembly following the procedure in
the applicable Service Manual. ALWAYS disconnect the seat heater connection (if equipped)
before lifting the seat. IMPORTANT NOTE: the side impact sensor is under the carpeting of
the center seating area. Avoid hard impacts to this area during seat removal and installation.
REMINDER: Always protect the surrounding trim and painted surfaces when removing and
reinstalling the seat assembly. Using a helper for this step is also STRONGLY recommended.
Set seat aside in a clean, safe place.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 32 of 49
•
Remove the section of floor mat covering the fuel pump access cover. CAREFULLY
remove the fuel pump access cover while paying close attention to avoid damaging the
foam seal between the cover and vehicle body. Replace the seal if damaged with p.n.
96077FL00A (rare case). With the access cover removed, release the quick disconnect fitting
at the fuel pump outlet pipe. While covering the fuel pipe with a clean shop cloth to catch
any residual pressurized fuel, slide the fuel delivery pipe off the fuel pump outlet. Insert
the one-time use plastic temporary plug into the removed fuel delivery pipe. The plug is
included in the replacement fuel pump parts kit.
6. Fuel Pump Assembly Removal:
•
Disconnect the harness connector from the pump.
•
CAREFULLY using HAND TOOLS ONLY and the Ring Nut Wrench tool shown here,
remove the plastic retaining ring nut securing the fuel pump assembly into the fuel tank.
NOTE: Make sure the removed fuel delivery pipe is ON TOP of the tool as shown and not
pinched under it.
•
CAREFULLY remove the fuel pump assembly from the fuel tank. Use a vacuum tool with
a reservoir, squeeze bottle or an equivalent tool to remove residual fuel from the fuel
chamber of the pump assembly along with a small catch pan to prevent spilling fuel as the
pump assembly is removed. IMPORTANT: Do not let the fuel level sensor arm or float
contact the tank opening during removal.
•
IMPORTANT NOTE: Ascent has a jet pump fuel tube
connection to the fuel chamber inside the fuel tank. When
removing this line, if desired, it can be secured either with
tape or a piece of Mechanic’s wire under the connector
slider to keep it from dropping inside the fuel tank.
•
Once the fuel pump assembly has been removed, install
the applicable plastic plug tool into the fuel tank opening
to prevent contamination from entering the tank and fuel
vapors from accumulating in the vehicle interior. If the
plug is not available, cover the opening with a clean shop
cloth. The plug is not required when replacing the complete fuel pump assembly due to the
very short time the tank will be open for that repair.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 33 of 49
7. After disconnecting the pump and sending unit harness connectors from the underside of the top
flange, CAREFULLY remove the fuel sending unit from the pump chamber.
IMPORTANT: If any damage e.g. distorted or melting plastic connectors, overheated wiring or
terminals is identified, the harness MUST be replaced. Release the retaining clip (a plastic trim
tool is being used here) and slide the sending unit upward. NEVER touch the contact surface of
the sending unit and use care to avoid bending or otherwise damaging the float arm and contact
point.
•
CAREFULLY disconnect both the fuel pump and fuel sending unit harness connectors and
remove the wiring from the retaining clips. Note the wire routing prior to disassembly for
reference during reassembly.
•
Compress the spring (fuel filter assembly) and remove / discard the (one-time use) c-clip.
•
IMPORTANT: When releasing the retaining claws as described in the following steps,
move them only as far as needed to disengage them. If any break, the affected component
must be replaced.
•
Using a screwdriver wrapped with protective tape (or equivalent), release the retaining claw
for the tube at the bottom of the fuel chamber then disengage the
fuel tube from the outside of the outside of the chamber.
•
CAREFULLY disengage three claws of the fuel pump holder
from the fuel chamber assembly. Remove the fuel pump and
filter assembly from the chamber.
•
Using a screwdriver wrapped with protective tape (or
equivalent), remove the tube assembly from the fuel chamber
assembly, and separate the fuel filter assembly and fuel chamber
assembly as shown below.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 34 of 49
•
After separating the fuel filter from the fuel chamber assembly,
inspect the fuel chamber to confirm the o-ring is not still in the
bore as shown here. If the o-ring remains, use a rubber -tipped
or plastic (non-marring) pick tool to CAREFULLY remove it
without scratching the fuel chamber bore.
•
Remove the fuel pump holder then
disengage the 3 claws securing the fuel
pump to the filter assembly.
•
Using the flat tip screwdriver (or equivalent) wrapped with a
protective tape, press on the fuel pump and remove the fuel pump
from the fuel filter assembly.
•
IMPORTANT: Confirm the o-ring is not stuck in the fuel filter
bore after removing the fuel pump. If needed, use a rubber-tipped
or plastic (non-marring) pick tool to CAREFULLY remove it
without scratching the filter assembly bore.
Plastic
Non-Marring
Pick Tool
•
IMPORTANT: Remove the
o-ring and spacer from
the original fuel pump.
The spacer is reused.
Put the removed pump
in a vise and crush it as
shown above to eliminate
any chance of it being
reused.
Transfer the white plastic spacer (B) to the new pump and install the new o-ring (A) from the kit to
hold the spacer in place. It is CRITICAL for the bushing and NEW o-ring to be installed on the
new pump in the proper order. Always lubricate the new o-rings with gasoline.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 35 of 49
8. Install the new fuel pump into the fuel filter assembly.
Using the image here as a guide, lay the partially
reassembled pump assembly on the bench horizontally and
insert the new pump into the fuel filter assembly. Using
both hands, CAREFULLY press the new pump and filter
assemblies together until a “click” is heard from ALL of
the new fuel pump’s retaining claws. If the new pump
does not fully seat and lock into position, make sure the
old o-ring (A) is not still in the bore as shown above.
•
Install the fuel filter assembly to the fuel chamber
assembly. Position tube (A) and spring (B) for the fuel
filter assembly as shown in the figure.
•
Confirm the fuel tube routing and make sure all the claws
securing the fuel chamber to the fuel filter assembly are
fully engaged as shown in the photos shown below.
NOTE: In the images below, a section of the fuel chamber has been
cut away to make the fuel pipe routing visible for reference. Normally, these fuel pipes are inside the
chamber and not visible except at the top.
ALWAYS inspect closely for any seepage or leaks around ALL fuel delivery tube connections removed
as part of this repair (including those under the hood if fuel was drained) and around the ring nut.
Retaining Claw
•
Secure the fuel tube to the
outside of the fuel chamber
and reconnect it at the
bottom.
•
Push the fuel filter assembly
in the direction of the arrow
to compress, and install the
new clip supplied in the kit.
IMPORTANT: Confirm this fuel hose runs
UNDER the retaining claw when installing
the pump / filter assembly back into the
fuel chamber as shown here.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 36 of 49
9. CAREFULLY refit the fuel level sensor assembly to the fuel chamber. Put the (thinner) fuel
lever sensor wires into the 2 retaining clips first followed by the fuel pump wires IN THAT
ORDER.
10. CRITICAL: ALL surfaces of the new pump assembly o-ring, top gasket, underside of the ring
nut along with the surfaces described and shown below: fuel tank neck rim (A) pump flange top
and bottom faces (B) and (C) must be thoroughly wiped clean and completely dried BEFORE
re-installation. This will help prevent the pump from turning with the ring nut during final
tightening.
(A) Fuel Tank Rim
•
(B) Pump Flange Top Face
(C) Underside of Pump Flange
Use CAUTION to keep the fuel level sensor arm from contacting the fuel tank opening. If
the arm were to become bent, the fuel gauge may not read properly.
11. CAREFULLY reinstall the fuel pump assembly into the tank using the new gasket included in
the kit.
•
CRITICAL: DO NOT OVERLOOK RECONNECTING THE JET PUMP FUEL TUBE AT
THE BOTTOM OF THE FUEL CHAMBER.
•
After connecting the jet pump fuel tube, CAREFULLY lower the fuel pump assembly into
the tank and in the orientation shown in the photo below.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 37 of 49
Pump
Indexing
Arrow
IMPORTANT: This photo shows
the NEW ring nut and (Blue) seal
plate included in the kit already
in place. The ASCENT ring nut
thread starting point is identified
by the 3 “teeth” close together
(RED circled). Align the center
(Green) tooth (position mark) with
the triangle ∆ mark between the
molded-in hash marks on the tank
(Blue arrows).
•
IMPORTANT: ALWAYS use the new gasket and blue ring nut seal plate included in the kit.
•
The photo above shows the thread STARTING POINTS for the ring plate and fuel tank.
There is a second set of molded-in hash marks 90 degrees CLOCKWISE from the starting
point hash marks which are the FINISHING POINT (End Range) hash marks shown as (c) in
the illustration below.
•
IMPORTANT: Before tightening the ring nut:
▪ Make sure the fuel delivery tube is ON TOP of the tool and not pinched under it
▪ Make sure the tool fits down fully and squarely onto the ring nut.
•
Using the ring nut tool, and the illustrations below as a guide, SLOWLY tighten the ring nut
ONE FULL TURN then continue until (b) is within the range of the End Range hash marks
(c). NOTE: (b) MUST be within the End Range hash marks for the ring nut to be fully
tightened.
•
CRITICAL: While tightening the ring nut, make sure the fuel pump does not rotate with
the ring nut otherwise, the fuel level sensor and the jet pump fuel tube may become damaged.
Always keep the Pump Indexing Arrow; (e) below and the fuel tank ring nut start mark (a)
below aligned.
STARTING POINT MARKS
END RANGE MARKS
Front of Vehicle
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 38 of 49
Fuel Tube on TOP of Tool
LEGEND FOR THE ABOVE ILLUSTRATIONS:
(a)
(b)
(c)
(d)
(e)
(f)
•
Front of Vehicle
Ring nut installation position start mark (on fuel tank)
Position mark (on ring nut)
Ring nut installation position end range hash marks (on fuel tank)
Fuel pump installation position range hash marks (on fuel tank)
Position (Index) mark (for fuel pump)
Toward FRONT of vehicle
NOTE: In a case where there is difficulty getting the ring nut threads started onto the fuel
tank threads, align the starting points, install the ring nut wrench then press down firmly
by hand on the ring nut wrench to “jump” the ring nut thread past the interference point. A
“pop” sound wil occur, the ring nut should now be parallel to the top of the fuel tank and able
to be tightened normally.
CRITICAL: Using a caliper with depth gauge, measure the dimension in 3 positions between the top
of the ring nut and the top of fuel tank as shown in the illustration below. Confirm the measured
values of dimensions (D) are 23.8 ± 2.5 mm (0.937±0.098 in.).
LEGEND:
(A)
(B)
(C)
(D)
Caliper with depth gauge
Ring nut
Fuel tank
Dimension of ring nut and
top of fuel tank
(E) Measuring point
(F) Toward FRONT of
vehicle
CAUTION:
•
If the difference between any of the three measurements exceeds ±1.5mm or .060 inch, loosen
and re-tighten the ring nut to correct any cross-threading.
•
If the ring nut or fuel pump gasket are deformed, cracked or damaged, they MUST be replaced.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 39 of 49
•
Remove and discard the plastic temporary plug from the fuel delivery pipe and re-connect the
pipe to the fuel pump outlet tube. Make sure the connector is all the way onto the outlet tube
then lock the slider. Tug on the fuel delivery pipe to be sure it is fully locked in place.
IMPORTANT REMINDERS: Discard the removed temporary fuel line plug as it is a one-time use
item. Reusing the plug may damage the connector’s internal o-ring and cause a fuel leak.
•
Ensure both the pipe and tube are clean and dry
•
If the slider does not move easily, confirm the pipe is engaged on the tube
•
ALWAYS confirm the pipe is fully engaged after connecting and check for any leaks
12. Reconnect the harness connector to the fuel pump.
13. Reconnect the ground cable and harness connector to the battery sensor. While supporting the
sensor with one hand, torque the 12mm ground cable nut to 7.5 Nm (5.5 ft. lbs.).
14. Turn on the ignition switch to run the fuel pump. The engine does not need to be started. Check
closely for any leaks around ALL fuel delivery tube connections removed as part of this repair
(including those under the hood if fuel was drained) and around the ring nut.
15. Reinstall the inspection cover.
16. Reinstall the r/rear second row seat and trim in reverse order of removal. Torque the retaining
bolts to 53 Nm (39 ft. lbs.) Make sure the seat belt buckles are properly positioned.
17. Return any removed fuel back to the vehicle.
18. Deodorize the vehicle interior as necessary.
END OF ASCENT SERVICE PROCEDURE
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 40 of 49
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 #
WRD-20 Complete Fuel Pump Assembly
Replacement
B186-943
WRD-20 Fuel Pump Kit Replacement
B186-941
Drain Fuel Tank To 2/3 (if required)
Drain Fuel Tank To 2/3 (if required), Includes
Intercooler R&R
Applicability
Labor
Time
Legacy, Outback, Impreza
0.7
Ascent
0.9
Legacy, Outback, Impreza
0.9
Ascent
1.1
Legacy, Outback, Impreza
0.2
Ascent
0.5**
C186-945
Fail
Code
Claim
Type
WRD-20
RC
**NOTE: .5 can be claimed on Ascent only when intercooler R&R is required to use the 18471AA000 fuel pipe adapter for
draining the fuel tank. Once the 42099FL030 adapter is available to drain the tank by connection at the fuel pump, the
Labor Time will be reduced to .2 hrs.
IMPORTANT NOTES:
•
Each retailer will be supplied two (2) of each of the following special tools at “no charge”
when they become available.
○ 42099FL030
Fuel Pipe Adapter
○ 42099CA010
Fuel Tank Cap Legacy / Outback
○ 42099FL020
Fuel Tank Cap Ascent/ Impreza
○ SOA635161
•
Hose- Fuel See APPENDIX A starting on pg. 43 for more information.
Each retailer will receive a miscellaneous credit on their parts statement for:
○ Bulk 5/16” Fuel Hose, 10 ft- Quantity of four (4)
○ Brass Hose Adapter- Quantity of four (4)
○ Fuel Hose Clamps- Quantity of eight (8)
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 41 of 49
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
WRD-20
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: WRD-20R; Revised: 07/16/20
Page 42 of 49
APPENDIX A
Alternate Procedure for Draining the Fuel Tank using Hose Adapter SOA635161.
The following information provides photo instruction for using the SOA635161 fuel adapter hose (1
of the 2 supplied) and 42099AE000 fuel line release tool to drain fuel from the tank when necessary.
The adapter connects to the hard metal fuel supply pipe in the engine compartment. In addition, a
readily available barbed hose connection nipple, 5’ length of 5/16” fuel hose, 2 small fuel line hose
clamps and a gasoline safety can are required.
SOA635161 Fuel Hose Adapter (1 of 2 Supplied)
42099AE000 Fuel Line Release Tool
Assemble the drain hose by inserting one end of the barbed nipple into the special tool adapter hose.
Insert the other end of the nipple into one end of the 5’ length of 5/16” fuel hose. IMPORTANT:
For extra safety, hose clamps are recommended on BOTH these connections. Put the other end of the
bulk fuel hose into the gasoline safety can. In-Use photos of the drain hose assembly are supplied
below.
Locate and remove the fuel pump fuse in the under-hood fuse box (M/B). Release the fuel pressure
by starting the engine and allowing it to run until it stalls. NOTE: Even after the engine stalls, there
will still be a small amount of residual pressure left in the fuel system. Crank the engine another 5
seconds with the starter to reduce it.
Use the 42099AE000 release tool as shown here to
remove the fuel supply hose from the hard metal
supply pipe coming from the tank.
IMPORTANT: Place a shop cloth over the
connection point while sliding the hose off the supply
pipe and another in the area underneath the connection
point to catch any remaining fuel in the hose or pipe
when the connection is opened.
42099AE000
Additional important steps for this procedure are supplied after the reference photos below. They
detail the connection points and proper hose routing for each application when draining fuel from
Legacy / Outback, Impreza and Ascent using one of the SOA635161 fuel hose adapter tools.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 43 of 49
LEGACY / OUTBACK (locations are the same for 2.5L and 3.6L models):
Top view, looking down over l/side of engine compartment. Close-up of hose adapter installed
between strut tower and brake fluid reservoir.
Overall top view to better show connection point location.
Hose installation complete and ready for draining.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 44 of 49
IMPREZA:
Top view, looking down over r/front of engine compartment. Close-up of hose adapter installed.
Overall top view to better show connection point location between intake duct and brake piping.
Hose installation complete and ready for draining.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 45 of 49
ASCENT:
Top view, looking down over r/front of engine compartment. Close-up of hose adapter installed.
Overall top view to better show connection point location.
Hose installation complete and ready for draining.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 46 of 49
•
After connecting the drain hose assembly securely, reinstall the fuel pump fuse, connect the
SSM4 and turn the ignition ON.
•
From the Active Test item menu, select Fuel Pump Relay to operate the fuel pump. Drain the
fuel tank down until the fuel gauge reads at or below 2/3 full.
•
Remove the fuel line adapter using the fuel line release tool from the metal fuel supply pipe
while holding a shop cloth under the connection to catch any residual fuel spillage.
•
Hold the fuel line adapter and hose up together with a shop cloth as you move it away from
the car to prevent any spillage. Allow any residual fuel in the hose to drain into the storage
container.
•
Ensure the metal fuel supply pipe and vehicle fuel line are both clean and dry.
•
Reconnect the engine fuel line connector back onto the metal fuel supply pipe and confirm it
is fully engaged by lightly tugging on it.
•
Proceed with fuel pump replacement as outlined previously in this bulletin by vehicle type.
IMPORTANT: Be sure to check this fuel connection for any leaks once the fuel pump replacement
is complete. There must be NO fuel leaks of any type from this or ANY fuel line connection.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 47 of 49
URGENT
IMPORTANT SAFETY RECALL
This notice applies to the VIN below
Subaru of America, Inc
PO Box 9103
Camden, NJ 08101-9877
844-373-6614
www.subaru.com
Subaru Safety Recall WRD-20
NHTSA Recall ID 20V-218
June 2020
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 2019
model year Ascent, 2019 model year Impreza, 2019 model year Legacy and 2019 model year Outback vehicles.
You received this notice because our records indicate that you currently own one of these vehicles.
REASON FOR THIS SAFETY RECALL
Your vehicle may be equipped with a low-pressure fuel pump assembled with an impeller that may become deformed.
Over time, the impeller may become deformed enough to interfere with the body of the fuel pump, potentially causing
the low-pressure fuel pump to become inoperative.
SAFETY RISK
If the low-pressure fuel pump becomes inoperative, the check engine warning light or malfunction indicator light may
illuminate, and/or the engine may run rough. An inoperative fuel pump may result in the engine stalling without the
ability to restart the vehicle, increasing the risk of a crash.
WHAT SUBARU WILL DO
Subaru will replace the fuel pump at no cost to you.
What You Should Do
You should contact any authorized Subaru retailer (dealer) for an appointment to have this safety recall repair
performed, at no cost to you.
HOW LONG WILL THE REPAIR TAKE?
The time required to replace the fuel pump for Impreza, Legacy and Outback vehicles is approximately 1 hour and 10
minutes. The time required to replace the fuel pump for Ascent vehicles is approximately 1 hour and 40 minutes. 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.
For your convenience, your retailer may provide you with a loaner or rental vehicle, at no cost to you, until the repair is
complete.
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 repair we are providing at no charge, your vehicle may not pass this test.
Continued...
Bulletin Number: WRD-20R; Revised: 07/16/20
Page 48 of 49
OWNER INFORMATION
Government regulations require that recall notifications be sent to the last known owner of record. That information
is based primarily on state registration and title data. If you are a lessor of this vehicle, federal 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 “Quick Links” menu.
IF YOU HAVE PREVIOUSLY PAID FOR A REPAIR
If you have already paid for repairs associated with this condition, you may be eligible for reimbursement.
Reimbursement consideration will be based on the amount an authorized Subaru retailer in your area would charge for
the same repair.
Please send the original service repair order, which has the name of the repair facility, date of repair, mileage at the
time of repair, complete 17-digit vehicle identification number (VIN), and your name, with correct mailing address and
telephone number to the address listed below.
Subaru of America, Inc.
Customer Advocacy Department, Attention: WRD-20 Recall
P.O. Box 9103, Camden, NJ 08101-9877
Please send original receipts only and retain a photocopy for your records. Please be assured that we will attempt
to process your reimbursement request as quickly as possible, but it may take up to 60 days for this process to be
completed.
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, please go to: http://www.wrd20.service-campaign.com.
If you need additional assistance, please contact us directly:
•
By e-mail: Go to www.subaru.com and select “Customer Support”
•
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 Advocacy Department
P.O. Box 9103, Camden, NJ 08101-9877
To subscribe to the NHTSA Recall Notification email System, please go to:
https://www-odi.nhtsa.dot.gov/nhtsa/subscriptions.
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 (NHTSA), 1200 New Jersey
Ave., SE, Washington, DC 20590 or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (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 and urge you to schedule an appointment as soon as possible.
Sincerely,
Subaru of America, Inc.
Notice to Lessors:
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: WRD-20R; Revised: 07/16/20
Page 49 of 49