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Engine Control Module (ECM) Reprogramming (WWX-08)

WARNING: This page is about the Outback Base, 4D Wagon, EJ251, Automatic, which is a different variant/trim than selected.
Publication date: 2006-06-01
Reference number: WWX-08

ENGINE CONTROL MODULE (ECM) REPROGRAMMING

ENGINE CONTROL MODULE (ECM) REPROGRAMMING

SERVICE CAMPAIGN BULLETIN

Reference Number(s): WWX-08, Date of Issue:  June 01, 2006
SUBARU: 2004 MY California PZEV Spec.; Subaru Legacy and Outback 2.5i NA

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 slight "on-off" throttle applications repeated in a short period of time after high load (e.g., uphill) driving, the temperature in the vehicles' catalytic converter can rise beyond its designed limits. If left uncorrected, this condition may eventually damage the catalytic converters. (Note: This campaign does not require the replacement of catalytic converters unless diagnostic trouble code (DTC) P0420 is found during the reprogramming process outlined in this bulletin. If catalytic converter damage has occurred as a result of this condition, the "CHECK ENGINE" light will illuminate to alert the driver of a malfunction. DTC P0420 indicates that catalytic converter damage has occurred and replacement is necessary.)

This condition is a software issue and has no impact on vehicle emissions or driveability.

This service program will involve reprogramming the ECM on affected vehicles. It may also involve catalytic converter replacement, but only if DTC P0420 is present.

AFFECTED VEHICLES

Affected vehicles are identified in the VIN range chart below. Note: Not all of the vehicles within the VIN range are affected. Prior to performing repairs, confirm coverage for potentially affected vehicles by using the Vehicle Coverage Inquiry in the Dealer Communication System (DCS) or by selecting the Vehicle Inquiry Icon from the SDS graphical user interface (GUI). 

MODEL   FROM TO
2004MY Sedan 4(1)200001 4(1)212125
Legacy Wagon 4(1)300001 4(1)306042
Outback 4(1)600003 4(1)646908
(1) Various characters may occupy this position of the VIN.

OWNER NOTIFICATION

SOA will prepare and mail an Owner Notification Letter to owners of affected vehicles on or around June 9, 2006.

A copy of the Owner Notification Letter is included at the end of this bulletin.

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 correction has been made before selling or releasing the vehicle.

SPECIAL TOOLS

Vehicle ECM reprogramming will require the following:

Subaru Diagnostic System (SDS)

SERVICE PROCEDURE

NOTE: If you require assistance with using the Subaru Diagnostic System (SDS), use the "Help" function icon, which will allow you to access tutorial information.

Using the appropriate Subaru Diagnostic 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 Used Interface (GUI). The Main Menu will appear.

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  1. Select "Each System Check".
    G08474684
  2. Select "Engine Control System".
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  3. Select "Diagnostic Code(s) Display".
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  4. Select "Memorized Diagnostic Code(s)".
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  5. Search results will appear. Then proceed as follows:
    G08474688

If no codes are found  , proceed to the "ECM Reprogramming Precautions and Instructions " section of this bulletin.

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 Replace the front catalytic converter assembly. When replacing the converters because of a P0420 code, replace both the "Exhaust Pipe Assy. - Center Right & Center Left". Clear codes and reprogram the ECM.
Any other code or combination of codes not listed above. Refer to applicable service manual for additional diagnostic procedures. After completing repairs, clear codes and reprogram the ECM.
NOTE: The catalytic converters should ONLY be replaced when trouble code P0420 is present and should not be replaced for any other reason.

ECM REPROGRAMMING PRECAUTIONS

Before reprogramming the ECM, the following precautions must be observed:

  1. Keep the vehicle at least 150 feet (50 meters) from high voltage power lines.
  2. Keep the vehicle at least 30 feet (10 meters) from any machinery that creates high voltage.
  3. Keep the vehicle at least 6 feet (2 meters) away from other vehicles that may generate electrical "noise". (Example: Other vehicle being checked for ignition spark, etc.)
  4. Keep the vehicle at least 6 feet (2 meters) away from any electrical device that can generate an electronic wave, such as mobile phones, pagers, radios, etc.
  5. Turn off all electronic devices that can generate electromagnetic waves (mobile phones, pagers, etc. - no radios).
  6. Turn off the vehicle's electrical devices before reprogramming (every light, seat heater, audio system. Do not use the cigarette lighter, power seat switch, etc. during reprogramming).
  7. Do not attempt ECM reprogramming if the vehicle's under hood temperature is below 32° F (0° Celsius).

ECM REPROGRAMMING INSTRUCTIONS

IMPORTANT: Use ONLY the A/C Power Supply for the SDS Notebook during the reprogramming process.

Prior to initiating the ECM reprogramming function, work through the open driver's window; do not open the driver's door during the reprogramming process; this will turn on the interior light creating a voltage surge. Any voltage surge will erase all ECM information and permanently damage the ECM. 

Turn the ignition switch to the "On" position. Do not start the engine.

With the Subaru Diagnostic System (SDS) still connected, select the Select Monitor Icon from the SDS Graphical Used Interface (GUI). The Main Menu will appear.

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  1. Select "Each System Check".
    G08474690
  2. Select "Engine Control System".
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  3. From the Engine Diagnosis menu, select "OBD System".
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  4. From the OBD Menu, select "Getting of vehicle information".
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  5. The Calibration Identification (CID) will be displayed. Write down the first eight (8) digits of the Calibration Identification. (You will need the CID in step  7).
    NOTE: Take note that the "0" in the CID is the number zero, and not the capital letter "O"; the "1" is the number one, and not the lower case letter "l".
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  6. Return to the Main Menu and select "Reprogram".
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  7. The "Search FlashWrite" screen will be displayed. Select and check the CID option under the Search Condition heading. Enter the 8 digit CID (previously written down in step  5) in the "CID #" field. Select "Search".
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  8. The "Search FlashWrite" screen will appear with the Search Result. The applicable Pack Number and related vehicle information will appear on the first line. Select this line and ensure the information is highlighted. Write down the "Decryption keyword" found on the "Details" portion of the screen. (You will need the "Decryption keyword" in step  13.) Select "Continue". Note: If the Pack Number and related vehicle information does not appear on the screen, there are no updates for this vehicle or it has already been reprogrammed. A message will appear, "No reflash file available."
    G08474697

    Special note about Pack Files: Beginning with this Service Program, the identification format for Pack Files will change. New Pack Files will be assigned a part number equivalent to the applicable Subaru ECM Part number. The suffix will be changed and indicate the latest update. Any new Pack File with this new part number format will include all previously available logic changes. 

    VEHICLE EMISSION SYSTEM TRANSMISSION OLD ECM PART NUMBER NEW ECM / PACK FILE PART NUMBER
    2004 Legacy & Outback 2.5L Sedan/Wagon CAL Spec PZEV MT 22611AJ10A
    22611AJ10B    		 22611AJ10C
    2004 Legacy 2.5L
    Sedan/Wagon    		 CAL Spec PZEV AT 22611AG83A
    22611AG83B
    22611AG83C    		 22611AG83D
    2004 Outback 2.5L
    Sedan/Wagon    		 CAL Spec PZEV AT 22611AG84A
    22611AG84B
    22611AG84C    		 22611AG84D
  9. The "Cautions" screen will appear. Carefully read the information displayed. Ensure that all vehicle electrical accessories are turned off. Connect the vehicle's green D-check connectors located under the dash near the steering column. Note: The engine cooling fans may cycle until the reprogramming procedure is completed and the D-check connector is disconnected.
  10. Select "Next".
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  11. The "FlashWrite" screen will appear with a message "Select The Reprogramming Device You Are Using". Select "Subaru Select Monitor III (SSMIII)" option. Select "Pass-Thru".
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  12. The "Pass-Thru" screen will appear. Follow the instructions listed  and select "Next".
    G08474700
  13. The "Pass-Thru Reprogramming" screen will appear. Enter the Decryption Keyword (previously written down in step  8) and select "Next".
    G08474701
  14. The "Pass-Thru Reprogramming" screen will appear. A message "This ECU (Electronic Control Unit) is suitable for reprogramming" will appear. The current and new ECU part numbers will be displayed. (Once the ECU has been successfully reprogrammed, the new part number will be assigned to the unit.) Select "Execute"
    G08474702
  15. The "Pass-Thru Reprogramming" screen will appear and reprogramming will begin.
    G08474703
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  16. Once the reprogramming has completed, the "Pass-Thru Reprogramming" screen will appear. You will be instructed to turn the ignition switch to the "Off" position. After the ignition is turned "Off", click on the "Ignition Switch Off" check box and select "Next". 
    G08474705
  17. The "Pass-Thru Reprogramming" screen will appear. You will be instructed to turn the ignition switch to the "On" position. After the ignition is turned "On", click on the "Ignition Switch On" check box and select "Next". 
    G08474706
  18. The "Pass-Thru Reprogramming" screen will appear with a message indicating "Reprogramming is now complete". Select "Finish".
    G08474707
  19. Turn off the SDS notebook:
    • Turn the ignition switch to the "off" position.
    • Unplug the DLC cable from the vehicle.
    • Unplug the green D-check connectors.
    • Start the vehicle to insure proper performance.

STATE EMISSION TESTING ADVISORY

After ECM reprogramming, the OBD 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 11-72-04, dated 08/04/04 or the applicable Subaru Technical Service Manual 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.

A quantity of labels has been sent each dealer along with their affected VIN list. Additional labels are available through the Customer Dealer Services Department (CDS) at 1-866-782-2782.

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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.

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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 enter the applicable claim information through their Dealer Communications System.

ECM Reprogramming Only -  Use the applicable claim submission information for Reprogramming the ECM.

For ECM Reprogramming enter labor operation 455-288.

Replacement of the Catalytic Converter Combination Pipe -  Use the applicable claim submission information when trouble code P0420 was found and the Catalytic Converter Combination Pipe is replaced. Replacement part will be reimbursed at dealer cost plus the applicable handling allowance.

CLAIM TYPE CAMPAIGN CODE LABOR LABOR TIME LABOR DESCRIPTION
RC WWX-08 455 - 288 0.6 Reprogram ECM
447 - 301 0.8 Catalytic Converter Combination Pipe R&R (When DTC P0420 was found.)

OWNER NOTIFICATION LETTER

Subaru of America, Inc. 

Subaru Plaza 

P.O. Box 6000 

Cherry Hill, NJ 08034-6000 

www.subaru.com 

Service Program WWX-08 

Engine Control Module Reprogramming 

June 2006 

Dear Subaru Owner: 

We would like to thank you for selecting a 2004 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 slight "on-off" throttle applications repeated in a short period of time after high load (e.g., uphill) driving, the temperature in your vehicle's catalytic converter can rise beyond its designed limits. If left uncorrected, this condition may eventually damage the catalytic converter. (The "CHECK ENGINE" light will illuminate to alert you if catalytic converter damage has occurred). To prevent catalytic converter damage from occurring, Subaru has developed a modification to the Engine Control Module software logic that will improve management of temperatures within the catalytic converter.

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 the Engine Control Module software reprogrammed to help maintain your vehicle's optimum performance and prevent possible catalytic converter damage. Your Subaru dealer will perform this repair at no cost to you. The approximate time to perform this repair 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 scheduling other appointments.

Please present this letter to your Subaru Dealer on the day of your service appointment.

RESIDENTS OF CALIFORNIA 

The Department of Motor Vehicles in the State of California requires that all emission related service program repairs be completed before a vehicle registration is renewed. Your dealer will provide you with a "Vehicle Emission Recall - Proof of Correction" certificate after the service program repair has been completed. You should retain this certificate because the California Department of Motor Vehicles may require you to provide proof the service program repair has been completed.

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 immediately 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 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.) 

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