Recall - Catalytic Converter Replacement/ECM Update: Overview
NUMBER: WQD-40DATE: January 2013
APPLICABILITY:
2008-09MY PZEV Legacy, Outback & Forester
SUBJECT:
Catalytic Converter Replacement & Engine Control Module (ECM) Reprogramming
This Campaign applies to vehicles with motor vehicle registration in the following states:
2008MY: California, Connecticut, Maine, Massachusetts, New York, Pennsylvania, Rhode Island, and Vermont.
2009MY: California, Connecticut, Maine, Massachusetts, New York, Pennsylvania, Rhode Island, Vermont, New Jersey, Oregon and Washington.
INTRODUCTION
Subaru of America, Inc. has determined vehicles affected by this Service Program require front catalytic converter replacement and ECM reprogramming.
For vehicles affected by this Service Program, efficiency of the front catalytic converter may degrade over time. If the catalytic converter efficiency degrades beyond an acceptable level, the vehicle may be releasing air pollutants which exceed California standards. To correct this condition, it will be necessary to replace the front catalytic converter and reprogram the ECM software logic, improving management of the catalytic converter. This software change will not adversely affect fuel economy or performance of the vehicle.
AFFECTED VEHICLES
^ 2008-2009MY 2.5L PZEV Legacy, Outback and Forester
Affected vehicles are identified in the VIN range chart. NOTE: Not all vehicles in the VIN ranges are affected. Prior to performing repairs, confirm coverage by using the Vehicle Coverage Inquiry function at Subarunet.com. Affected VINs will be added to the Vehicle Coverage table according to the "Schedule Date" found under the heading "Owner Notification".
OWNER NOTIFICATION
SOA will prepare and mail Owner Notification Letters to owners of affected vehicles according to the schedule:
A copy of the owner notification letter can be found in this bulletin.
DEALER PROGRAM RESPONSIBILITY
Dealers are to promptly perform the applicable service procedures defined in this bulletin to correct all affected vehicles in their inventory (new, used and demo). Additionally, whenever a vehicle subject to this Service Program is taken into dealer new or used inventory, or is in the dealership for service, necessary steps should be taken to ensure the Service Program correction has been made before selling or releasing the vehicle.
New or used vehicles listed in a Service Program that are in dealer 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 this Service Program Bulletin
PARTS INFORMATION
Catalytic converter replacement will be required.
Due to limited part availability, dealers are requested to order catalytic converter kits as needed. It is suggested parts be ordered at the time a customer contacts a dealer to schedule an appointment. This will ensure the necessary parts are available on the day a customer brings their vehicle in for service.
The kit contains the following components:
SPECIAL TOOLS
Vehicle ECM reprogramming will require the following:
Subaru Diagnostic System (SDS)
^ SDS Toughbook
^ Subaru Select Monitor III (SSMIII Application Software)
^ Subaru Diagnostic Interface Box (SDI)
^ USB Data Link Cable and Reprogramming Cable.
Note:
If you require assistance with using the Subaru Diagnostic System (SDS), use the "Help" function, which will allow you to access the tutorial information.
SERVICE PROCEDURE
^ This service procedure involves replacement of the front catalytic converter assembly and reprogramming of the ECM with updated logic to correct an OBDII system deficiency.
^ The catalytic converter must be replaced BEFORE reprogramming the ECM.
^ IMPORTANT:
Both procedures must be done during the same repair visit.
1. Front Catalytic Converter Replacement
Replace the front catalytic converter following the procedures outlined in the applicable Subaru Service Manual and any related Technical Service Bulletins. When replacing the converter, the A/F and O2 sensors should be reused.
Note:
To avoid potential damage to the threaded portions of the sensors, allow the converter to cool down before attempting to remove them. Application of a spray-type penetrating lubricant to the thread areas and allowing it to soak in for at least a minute or more is recommended to help ease sensor removal. Be sure to wipe away all excess lubricant. Before installing the sensors into the replacement converter, application of a small amount of nickle based anti-seize compound to the sensor threads is also recommended.
2. ECM Reprogramming Instructions
Information regarding ECM reprogramming procedures can be found by accessing the Help menu located at the top of the Main Menu screen of the SSMIII application.
^ Verify the status of the "CHECK ENGINE" malfunction indicator light (MIL) located on the vehicle's instrument cluster.
^ If no malfunction is indicated, proceed with reprogramming the ECM.
^ If a malfunction is indicated by the MIL remaining continually "on" or "flashing", diagnose the cause and perform any necessary repairs. Once repairs have been completed, clear all DTCs then reprogram the ECM.
NOTES:
^ In the event the cause of the check engine light illumination is not covered by applicable warranties, the cost of repairs is the vehicle owner's responsibility.
^ Under no circumstances should the ECM be reprogrammed until the proper corrections have been made and the catalytic converter replaced.
Confirm your SSM III contains the applicable SSMIII FlashWrite File Update which includes the reprogramming PAK files shown in the chart below. PAK files will be released and automatically sent electronically to dealer equipment on or prior to the dates indicated in the "Date Available" column found in the following table.
Version Numbers
^ Software: 1.36.50.7 or later
^ Interface Box: 1.7.7 or later
^ Interface Box CF Card: 1.8.0 or later
For the WQD-40 Service Program, special Look-Up CID Numbers have been established to identify proper Pack File applicability. New ECM / Pack File Part Numbers and the tentative availability dates are also included in the chart below.
IMPORTANT:
The Pack Files for this Service Program will not appear when searching FlashWrite if the current ECM CID number or Vehicle Spec. parameters are used. These files are only accessible by using the Look-Up CID Numbers from the chart.
Once the applicable Pack File has been identified, proceed with the remainder of the established ECM reprogramming procedure.
These Pack Files are to be used solely for completion of the WQD-40 Service Program.
NOTE:
Should the ECM become inoperative or un-responsive during the reprogramming procedure;
1. Disconnect both the positive (+) and negative (-) battery terminals for at least 2 or more seconds.
2. Touch the cable ends together for a few moments, and then re-connect the terminals to the battery.
3. Start the reprogramming procedure over again from the beginning.
STATE EMISSION TESTING ADVISORY
After ECM reprogramming, the OBDII system's readiness code monitors will set to "incomplete". Normally, the vehicle needs to be driven under a variety of conditions before the readiness code monitors will indicate "complete". (See State I/M Program Advisory Bulletin number 11-120-12, dated 9-20-2012 for details.)
SERVICE PROGRAM IDENTIFICATION LABEL
Type or print the necessary information on a Service Program identification label. The completed label should be attached to the vehicle's upper radiator support.
Additional labels are available through the Subaru Claims Helpline.
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 the Subaru Claims Helpline.
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES
Credit to perform this service program will be based on the submission of properly completed repair order information. Dealers may submit claims through Vehicle Claim Entry on Subarunet.com.
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