078915R

ATTENTION:
CLAIMS PERSONNEL q
IMPORTANT - All
Service Personnel
Should Read and
Initial in the boxes
provided, right.
SERVICE MANAGER
© 2015 Subaru of America, Inc. All rights reserved.
GENERAL MANAGER q
PARTS MANAGER
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q
SERVICE INFORMATION
APPLICABILITY:
SUBJECT:
NUMBER: 07-89-15R
DATE: 02-10-15
REVISED: 01-04-16
2015-16MY Legacy and Outback Models
Interior Fuse Box (F/B) “IG” and “ACC” Relay
Under-Hood Fuse Box (M/B) Main Relay
Replacement for Engine Will Not Crank / Start Condition
INTRODUCTION
If you receive a customer concern of a no crank / no start condition during very cold temperatures, the
IG1, IG2, ACC1, ACC2 and/or the EGI Main relays may be the root cause and require replacement.
It is generally reported that the car starts normally after an overnight soak. After the initial start, the
customer drives a short distance then shuts the car off (example: at a gas pump or coffee shop). After
the time that it takes to pump their gas or get their coffee, they return to the car and it will not start.
The customer may also notice the instrument cluster and/or interior lights are not illuminating along
with the HVAC being inoperative. The source of this condition has been identified as condensation
flash-freezing inside the relays. This bulletin provides a service procedure for replacement of all 5
relays, 4 of which are located together in the vehicle’s interior fuse box (F/B) and the EGI Main relay
which is located in the under-hood Main fuse box (M/B).
PRODUCTION CHANGE INFORMATION
The new IG1, IG2, ACC1, and ACC2 relays were incorporated into production starting with the
following VINs:
Legacy: F*048310		
Outback: F*296775
The new EGI Main Relays were incorporated into production October 5, 2015 starting with the
following VINs:
Legacy: G*017247		
Outback: G*237505
PART INFORMATION
The new relay part numbers are: 8 2501AL000 (qty. 4, IG1, IG2, ACC1, ACC2 RELAY ASSEMBLY)
25232AA130 (qty. 1, EGI-MAIN RELAY)
TOOLS REQUIRED
•
1/4” Drive Ratchet
•
6” 1/4” Drive Extension
•
Plastic Trim Tool
•
#2 Phillips Screw Driver
•
10mm and 12mm sockets
Continued...
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.
Bulletin Number: 07-89-15R Revised: 01/04/16
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.
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SERVICE PROCEDURE
*VERY IMPORTANT: To prevent damage to the F/B itself or the relay connections inside it,
the F/B MUST be removed from the vehicle and allowed to stabilize to a reasonable temperature
PRIOR to relay removal. DO NOT attempt to remove the relays with the F/B still installed in the
vehicle.
•
Remove the 12mm nut and disconnect the negative cable from the battery temperature
sensor.
•
Release the 3 push clips securing the under dash cover and push it up towards the pedals /
bulkhead to get it out of the way.
•
Using a plastic trim tool, CAREFULLY remove the trim cover on the end of the instrument
panel. Once removed, you will have access to the 1 Philips screw at the bottom, just above
the hood release lever which secures the lower dash trim panel.
•
The remaining fasteners securing the lower dash trim panel are simply claws which will
release easily. Once the trim panel is removed, unplug the harness connectors and put the
panel aside.
•
There are three - 10mm hex fasteners securing the F/B to the dash structure; a bolt at the
bottom and 2 nuts at the top on studs. Remove the 3 fasteners and start CAREFULLY
unplugging harness connectors as you drop the F/B down, gaining more access as each
harness connector is released. There are 16 harness connectors plugged into the F/B. Use a
plastic trim tool to release the hinged yellow cover for the connector in the upper right corner
(green arrow in photo below).
Continued...
Bulletin Number: 07-89-15R Revised: 01/04/16
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*IMPORTANT REMINDER: To prevent damage to the F/B itself or relay connections inside it, the
F/B MUST be removed from the vehicle and allowed to stabilize to reasonable temperature PRIOR to
relay removal. DO NOT attempt to remove the relays with the F/B still installed in the vehicle.
•
Using a large pair of needle-nosed pliers, remove the 4 black relays by PULLING
STRAIGHT UP on them in a motion perpendicular to the F/B as shown in the photos below.
DO NOT WIGGLE THEM as damage to the relay connectors or the F/B itself may result.
•
Once ALL 4 of the black relays have been replaced, reinstall the F/B and re-assemble in the
opposite order of removal.
NOTE: Always make sure all of the harness connectors are fully locked back in place (audible
“click”) as each one is plugged back into the F/B.
IMPORTANT: Relay identification:
The photos above show the IG1, IG2, ACC1 and ACC2 relays. The EGI Main Relay photos are
shown below.
OLD: M07
NEW: M09
Continued...
Bulletin Number: 07-89-15R Revised: 01/04/16
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•
Remove the under-hood M/B cover and CAREFULLY replace the EGI Main Relay
indicated in the illustration below.
EGI Main Relay
Under-hood Main Fuse Box (M/B)
NOTE: Make sure all of the harness connectors are fully locked back in place (audible “click”) as
each one is plugged back into the F/B.
•
Reconnect the battery cable and torque the 12mm nut to 5.5 ft. lbs.
•
Start the car and verify all the combination meter warning lights cycle on / off normally.
•
For the power window Auto Up / Down feature to operate, the system will need to be
re-initialized on BOTH front doors.
•
Confirm the HVAC and all electrical systems operate as designed to complete the repair.
WARRANTY / CLAIM INFORMATION
For vehicles within the Basic New Car Limited Warranty period or covered by a Subaru Added
Security Classic or Gold plan, this repair may be submitted using the following claim information:
LABOR DESCRIPTION
Interior Fuse Box (F/B) R&R and Relay
Replacement Procedure
LABOR
OPERATION #
FAIL
CODE
LABOR
TIME
A860-062
UQW-48
0.6
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.
Bulletin Number: 07-89-15R Revised: 01/04/16
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