SERVICE PROGRAM BULLETIN
Contents
1. Bulletin Number WVI 19 R Date August 2009 Page 10 CHANGED YOUR ADDRESS OR SOLD YOUR SUBARU If you have changed your address or if you have sold your Subaru please complete the enclosed prepaid postcard and mail it to us IF YOU NEED FURTHER ASSISTANCE To locate your nearest Subaru Dealer you can access our web site at www Subaru com and go to the dealer locator function Or you may call us at 1 800SUBARU3 1 800 782 2783 during normal business hours Please call or write using the address at the top of this letter us imme diately if the dealer fails or is unable to complete this procedure free of charge Your continued satisfaction with Subaru is important to us This update is intended to assure your vehicle s optimal performance We appreciate your understanding in this matter and regret any inconvenience this may cause you Sincerely Subaru of America Inc Notice to Lessors The lessor of a vehicle who receives this letter is requested to provide a copy of it to the vehicle lessee s within 10 business days from receipt The lessor should 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 vehicles title of any five or more leased vehicles A leased vehicle is2. Subaru Diagnostic System SDS use the Help function icon which will allow you access the tutorial information Continued Bulletin Number WVI 19 R Date August 2009 Page 2 SERVICE PROCEDURE This service procedure will involve completing the following two 2 steps 1 Check ECM memory for diagnostic trouble codes 2 Reprogram ECM with updated Pack file 1 Check ECM memory for diagnostic trouble codes Using the appropriate Subaru Diagnostics System SDS components connect to the vehicle s Diagnostic Link Connector DLC located in the vehicle s lower left dash panel Select the Select Monitor Icon from the SDS Graphical User Interface GUI The Main Menu will appear 1 Select Each System Check 2 Select Engine Control System 3 Select Diagnostic Code s Display 4 Select Memorized Diagnostic Code s 5 Search results will appear Proceed as follows If no codes are found proceed to the ECM Reprogramming Instructions section of this bulletin beginning on this page below If trouble codes are found refer to the following table for the correct repair procedure Make any necessary repairs and clear all codes prior to reprogramming the ECM DIAGNOSTIC TROUBLE CODE REPAIR PROCEDURE P0420 Proceed to Catalytic Converter Efficiency Test Procedure on page 4 Reprogram the ECM Any other code or combination of Refer to applicable service manual for additional codes not listed above diagnosti
3. condition is a software issue and has no impact on vehicle drivability AFFECTED VEHICLES 2005 MY Subaru Legacy and Outback with CAL PZEV Spec Emission System and motor ve hicle registration in any state except California Massachusetts Maine New York or Vermont Affected vehicles are identified in the VIN range chart below NOTE Prior to performing repairs confirm coverage for potentially affected vehicles by using the Vehicle Coverage Inquiry in the Dealer Communication System DCS MODEL FROM TO 2005MY 5 200006 5 230146 Wagon Outback 9 300006 9 393924 Various characters may occupy this position of the VIN Continued CAUTION VEHICLE SERVICING PERFORMED BY UNTRAINED PERSONS SUBARU OF AMERICA INC IS ISO COULD RESULT IN SERIOUS INJURY TO THOSE PERSONS OR TO OTHERS 14001 COMPLIANT Subaru Service Bulletins are intended for use by professionaltechniciansONLY They The international standard for excellence are written to inform those technicians of conditions that may occur in some vehicles or in Environmental Management Systems to provide information that could assist in the proper servicing of the vehicle Properly Please recycle or dispose of automotive trained technicians have the equipment tools safety instructions and know how to products in a manner that is friendly to our do the job correctly and safely If a condition is described DO NOT assume that this environment and in accordance with all Service
4. illuminated with DTC P0420 in the ECM memory The catalytic converter efficiency test must also indicate replacement 1s necessary For all other vehicles the Catalytic Converter Warranty Extension applies DEALER PROGRAM RESPONSIBILITY Dealers are to promptly service all vehicles subject to this service program at no charge to the vehicle owner regardless of mileage age of the vehicle or ownership For affected vehicles sold after the date on the dealer s computer list dealers are to contact those owners and provide them with a copy of the owner notification letter They should also arrange to make the required correction according to the instructions in the service procedure section of this bulletin Dealers are also to promptly perform the applicable service procedures defined in this bulletin to correct all affected vehicles in their inventory new used 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 correc tion has been made before selling or releasing the vehicle SPECIAL TOOLS Vehicle ECM reprogramming will require the following Subaru Diagnostic System SDS e SDS Toughbook e Subaru Select Monitor II SSMIII Application Software e Subaru Diagnostic Interface Box SDI e USB Data Link Cable and Reprogramming Cable Note If you require assistance with using the
5. ATTENTION IMPORTANT All GENERAL MANAGER iJ Service Personnel PARTS MANAGER 4 Should Read and CLAIMS PERSONNEL q Initial in the boxes SERVICE MANAGER O provided right APPLICABILITY 2005MY PZEV Spec Subaru Legacy NUMBER WYVI 19 R and Outback DATE August 2009 SUBJECT Engine Control Module ECM Reprogramming This Campaign applies to vehicles in any state except those with motor vehicle registrations in the States of California Massachusetts Maine New York or Vermont For affected vehicles registered in these states see Service Program WVH 18 INTRODUCTION Subaru of America Inc SOA has determined that vehicles affected by this Service Program require ECM reprogramming Under certain unique driving patterns such as repeated acceleration and deceleration and or continuous uphill driving at higher speeds about 75 mph the catalytic converters of af fected vehicles may develop high internal temperatures that exceed design parameters If left uncorrected this condition may eventually degrade the catalytic converters The CHECK ENGINE light will illuminate to alert the driver if catalytic converter degradation has already occurred and that the vehicle may be releasing air pollutants which exceed Federal emission standards To prevent this condition a modification to the Engine Control Module software logic has been developed that will improve management of temperatures within the catalytic converters This
6. Bulletin applies to your vehicle or that your vehicle will have that condition local state and federal laws and regulations Bulletin Number WVI 19 R Date August 2009 Page 1 OWNER NOTIFICATION SOA will prepare and mail an Owner Notification Letter to owners of affected vehicles on or around June 15 2009 A copy of the Owner Notification Letter 1s included at the end of this bulletin CATALYTIC CONVERTER WARRANTY EXTENSION For owners of affected vehicles SOA is extending warranty coverage for catalytic converters under the Subaru Federal Specification Emissions Extended Defect Limited Warranty to a period of 10 years or 100 000 miles whichever occurs first Warranty coverage begins on the date the vehicle was delivered to the first retail purchaser If the vehicle was used as a demon strator or company vehicle before being sold at retail warranty coverage begins on the date the vehicle was first placed in such service Note In the event an affected vehicle requires catalytic converter replacement as determined by the test procedure described in this Bulletin the repair will be covered for those vehicles beyond the extended catalytic converter warranty coverage period of 10 years or 100 000 miles provided this Service Program has not been previously performed This coverage only applies if the vehicle arrives at the dealer for the first time to have the WVI 19 procedure performed with over 100 000 miles and the Check Engine light
7. STATE EMISSION TESTING ADVISORY After ECM reprogramming the OBD system s readiness code monitors will set to incom plete 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 72 04 dated 8 4 04 for details Continued Bulletin Number WVI 19 R Date August 2009 Page SERVICE PROGRAM IDENTIFICATION LABEL Type or print the necessary information on a Service Program identification label The com pleted label should be attached to the vehicle s upper radiator support A quantity of labels has been sent to each dealer along with their affected VIN list Additional labels are available through the Customer Dealer Services Department CDS at 1 866 782 2782 SUBARU Campaign Code COMPLETED DIST DEALER NO SERIAL NO DO NOT REMOVE CLAIM REIMBURSEMENT AND ENTRY PROCEDURES Credit to perform this Service Program will be based on the submission of properly com pleted repair order information Dealers may submit claims through Vehicle Claim Entry on Subarunet ECM Reprogramming Only Use the applicable claim submission information for Reprogramming the ECM e For ECM Reprogramming only CLAIM TYPE CAMPAIGN LABOR CODE LABOR DESCRIPTION CODE TIME WVI 19 A145 580 0 6 Reprogram ECM ECM Reprogramming and Catalytic Converter Replacement e For vehicles within t
8. a vehicle leased to another person for a term of at least four months A subsidiary of Fuji Heavy Industries Ltd Bulletin Number WVI 19 R Date August 2009 Page 11
9. c procedures After completing repairs clear codes and reprogram the ECM 2 ECM Reprogramming Instructions Confirm your SSMIII contains the April 2009 software update Upgrade Version Numbers e Software 1 18 36 11 or higher e Interface Box 1 6 4 or higher e Interface Box CF Card 1 2 45 or higher Use the following Pack file to reprogram the ECM VEHICLE TRANSMISSION NEW ECM PACK FILE PART NUMBER 2005MY Legacy amp Outback 2 5L NA CA Spec PZEV 2261 1AH92G pak 2005MY Outback 2 5L NA CA Spec PZEV 22611 AH94F pak 2005MY Legacy 2 5L NA CA Spec PZEV 22611AJ49F pak Continued Bulletin Number WVI 19 R Date August 2009 Page 3 CATALYTIC CONVERTER EFFICIENCY TEST PROCEDURE Note The following procedure is only necessary when troubleshooting for DTC P0420 This procedure only applies to vehicles affected by this Service Program and should not be used for any other models Check for right and or left front catalyst deterioration using the SSMIII as follows e Drive the vehicle for more than 3 minutes at 45 mph or less to warm up the catalytic converters e Increase the vehicle speed to 50 through 60 mph and drive at least 5 minutes maintaining a steady throttle It is not necessary but we recommend using the cruise control to maintain a steady throttle e Prior to turning the ignition off follow the procedure below to access the catalyst deterioration index readings 1 From main menu of SSMIII
10. he 10 year 100 000 mile Catalytic Converter Extended Warranty period the Catalyst 1 RH and 2 LH deterioration index readings are REQUIRED in the comments field at the time of the warranty WC claim submission CLAIM TYPE CAMPAIGN LABOR CODE LABOR DESCRIPTION CODE TIME RC WVI 19 A145 680 1 0 ECM reprogramming and Catalytic Converter efficiency testing for DTC P0420 Use Subaru Warranty Wizard for claim coding information e For vehicles beyond the 10 year 100 000 mile catalytic converter extended warranty period the Catalyst 1 RH and 2 LH deterioration index readings are REQUIRED in the comments field at the time of the recall RC claim submission Continued Bulletin Number WVI 19 R Date August 2009 Page 8 Note Coverage only applies for vehicles beyond the 10 year 100 000 mile catalytic converter extended warranty period when all of the following conditions exist See the Catalytic Converter Warranty Extension section on page 2 of this Bulletin for additional details 1 The Vehicle has not previously had the WVI 19 Service Program performed 2 The Vehicle is beyond the 10 year 100 000 mile Catalytic Converter Extended Warranty coverage period 3 The Check Engine light is illuminated with DTC P0420 in the ECM memory 4 The catalytic converter efficiency test indicates replacement is necessary CLAIM TYPE CAMPAIGN LABOR CODE LABOR DESCRIPTION CODE TIME WVI 19 B 145 680 1 0 Cata
11. lytic converter efficiency testing and ECM reprogramming ne 145 682 0 6 Replace left front catalytic converter add aas 145 681 0 6 Replace right front catalytic converter add 145 684 0 8 Replace both left amp right front catalytic converters add Continued Bulletin Number WVI 19 R Date August 2009 Page 9 OWNER NOTIFICATION LETTER Subaru of America Inc Subaru Plaza P O Box 6000 Cherry Hill NJ 08034 6000 www subaru com Service Program WVI 19 June 2009 Engine Control Module Reprogramming Vehicles Registered in States other than CA MA ME NY or VT Dear Subaru Owner We would like to thank you for selecting a 2005 Subaru Legacy or Outback with a 2 5 Liter engine equipped with a California Partial Zero Emission Vehicle PZEV emission system At Subaru we take pride in our products and are committed to your continued satisfaction During a quality review we discovered that under certain unique driving patterns such as re peated acceleration and deceleration and or continuous uphill driving at higher speeds about 75 mph your vehicle s catalytic converters may develop high internal temperatures that exceed design parameters If left uncorrected this condition may eventually degrade the efficiency of the catalytic converters The Check Engine light will illuminate to alert you if the catalytic converter efficiency has degraded beyond an acceptable level and if your vehicle may be relea
12. mation may be required at the time of claim submission Note If the catalyst readings RH or LH are zero something during the 5Omph driving cycle occurred to stop the catalyst test This could be from not maintaining a speed over 5Omph not keeping the throttle steady etc Repeat the driving test cycle Catalyst deterioration diagnosis Record these numbers Catalyst RH deterioration index 1 2 Then Press OK Catalyst2 LH deterioration index 1 7 Once the deterioration index for catalyst 1 RH and catalyst 2 LH have been determined proceed as follows Plot the intersection of the RH and LH deterioration indexes in the appropriate position of the following Catalyst Deterioration Chart Determine the correct repair procedure identified in the corresponding field found on the chart and proceed accordingly In all cases the ECM should be reprogrammed with the updated Pack file Note If the index coordinates intersect directly on the line between Field s proceed as follows A and B Reprogram ECM only A and C Reprogram ECM only B and C replace right catalytic converter only B and D replace right catalytic converter only C and D replace left catalytic converter only NOTE Catalytic converter s should ONLY be replaced when indicated during the Catalytic Converter Efficiency Test Procedure They should not be replaced for any other reason NOTE 2 ECM
13. reprogramming should be performed after finishing all the procedures below only when troubleshooting for P0420 was necessary 1 Diagnosis of trouble codes 2 Testing of catalytic converter efficiency 3 Repl t of applicable Pipe A d clearing trouble codes Replacement of applicable Pipe Assy and clearing trouble codes Continued Bulletin Number WVI 19 R Date August 2009 Page 6 Catalyst Deterioration Chart Field D Replace RH amp LH Catalytic Converters amp Reprogram ECM Field C Replace LH Catalytic Converter amp Reprogram ECM fare te ele ee Gitte l l L 74 QAM VIVUTGTITENIVE F 4 bh 4 l PS A A E A ATAT A Gag A ea Clee S R Field B Replace RH Pfft Catalytic Converter amp Reprogram ECM Lo F 4 f 5 ee ee ey ree ee gt lt ab lt 2 c E O aw Same O ab ab m I _ Sp gt 9 _ ae L ES c 9 L re ab Fidd N HOR Reprogram Pr Nopp pe a ZC ae E ih ee ek An ee se E 0 0 05 1 0 1 5 2 0 2 5 3 0 35 40 45 5 0 5 5 60 65 7 0 7 5 8 0 Right Hand RH Catalyst Deterioration Index If catalytic converter replacement is necessary refer to the following parts list Pipe Assy LH MT 44101AG20A WVH18 WVI19 GSKT Kit RH 10105AB300 WVH18 WVI19 GSKT Kit LH 10105AB310
14. s ing air pollutants that exceed Federal emission standards To prevent this condition Subaru has developed a modification to the Engine Control Module software logic that will improve man agement of temperatures within the catalytic converters This software change will not adversely affect the performance of your vehicle WHAT WE ARE ASKING YOU TO DO PROMPTLY We suggest that you schedule an appointment with your Subaru Dealer as soon as possible to have your vehicle s Engine Control Module software reprogrammed The approximate time to perform this update is 40 minutes However it may be necessary for you to leave your car for a longer period on the day of your scheduled appointment to allow your dealer flexibility in sched uling other appointments Your Subaru dealer will perform this repair at no cost to you Please present this letter to your Subaru Dealer on the day of your service appointment WARRANTY EXTENSION If you have this Service Program repair performed promptly Subaru will extend the Federal Ex tended Emissions Defect Warranty coverage on your vehicle s front catalytic converters to a pe riod of 10 years or 100 000 miles whichever occurs first Warranty coverage begins on the date the vehicle was delivered to the first retail purchaser If the vehicle was used as a demonstrator or company vehicle before being sold at retail warranty coverage begins on the date the vehicle was first placed in such service Continued
15. select the Each System Check All system Diagnosis Each System Check Saved Data Display Immobilizer Reprogram Converti Save measurement data on driving recorder Oscilloscope Quit Continued Bulletin Number WVI 19 R Date August 2009 Page 4 2 Select the Engine Control System System Selection Menu Engine Control System Transmission Control System Cruise Control system Brake Control System Image Processing Preview Control integ unit mode Radar sensor Impact Sensor Power Steering System Tire pressure monitor Airbag System Occupant Detection System Back 3 The following menu window will be displayed Engine Diagnosis Current Data Display amp Save Diagnostic Code s Display Cancel Code s Display Clear Memory System Operation Check Mode Dealer Check Mode Procedure OBD System Entry VIN Driving recorder Roughness monitor Select save sampling tems Back 4 At this screen press the Alt Ctrl C Keys at the same time on the SDS Toughbook Bulletin Number WVI 19 R Date August 2009 Continued Page 5 5 The following window should be displayed Catalyst deterioration diagnosis Be a aee N start catalyst deterioration diagnosis Cancel 6 Record the following information on the R O Catalyst RH and LH indexes approximate vehicle speed used during test drive and date the data was recorded RO date This infor
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