Engine No-Start Condition In Cold Climates (WTG-67R)

Publication date: 2016-08-30
Reference number: WTG-67R
Supersedes refnos: WTG-67

ENGINE NO-START CONDITION IN COLD CLIMATES

TECHNICAL SERVICE BULLETIN

Reference Number(s): WTG-67R, Date of Issue: August 30, 2016

SUBARU:

2015 Legacy and Outback

Superceded Bulletin(s): WTG-67, Date of Issue: August 23, 2016

APPLICABILITY

2015 MY Legacy and Outback

This repair procedure was previously published in TSB number 07-89-15R . In the interest of customer satisfaction, Subaru of America, Inc. (Subaru) is now initiating a service program for certain 2015 model year Legacy and Outback vehicles as described in this service program bulletin.

INTRODUCTION

During ocean transportation of the IG, ACC and EGI Main relays, moisture may be absorbed into them from exposure to very high ambient humidity conditions. During normal operation, this moisture is heated by the relay's electric coils and evaporated while the engine is running however, it may not all be eliminated. If the vehicle is used in extreme cold temperatures (-20C / -4F), ice crystals may form on the relay's contacts due to rapid heat radiation after the engine is turned off. As a result, these ice crystals can insulate and prevent electricity from flowing and lead to a contact failure. Should this occur, the engine may fail to start immediately. For example: if the engine is started under extreme cold temperatures, shut-off and left to "soak" for approximately 20 minutes and then restarted, the described relay freezing / no-start condition may occur requiring several attempts to start the engine.

AFFECTED VEHICLES

Not all vehicles listed below are covered by this service program. Coverage for all affected vehicles must be confirmed by using the Vehicle Coverage Inquiry function on subarunet.com. This data is now available.

Please note that any vehicles with claim history of replacing the five relays described in this bulletin are not included in this service program.

Vehicle Model	Production Date Range
2015 Legacy and Outback	December 2013 - February 2015

OWNER NOTIFICATION

Notification letters will be sent by first class mail to owners of all potentially affected vehicles by early September, 2016. A copy of the letter is included at the end of this bulletin.

RETAILER AFFECTED VIN LISTS

Each Subaru retailer will receive an affected VIN list from their Zone Office when owner notification begins. Vehicles will be assigned to retailers in the affected VIN list as follows:

Original vehicle owners are assigned to the original selling retailer when their current address is within a 100-mile radius of that retailer.
If the original selling retailer is inactive, the VIN has been assigned to the nearest active retailer.
For any new owners or when original owners live more than 100 miles from the original selling retailer, the VIN has been assigned to the nearest active retailer.

IMPORTANT: Retailer affected VIN lists include owner name and address information for vehicles affected by this service program. This information will enable retailers to follow up with owners of potentially affected vehicles. The lists contain owners' names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is unlawful. Accordingly, retailers are required to limit the use of these lists for the purpose of completion of this service program.

RETAILER PROGRAM RESPONSIBILITY

Any vehicles listed in a service program that are in retailer stock must be:

Immediately identified.
Tagged or otherwise marked to prevent their delivery or use prior to inspection and/or repair.
Repaired in accordance with the repair procedures outlined in this Service Program Bulletin.

Retailers are to promptly perform the applicable service procedures to correct all affected vehicles in their inventory (used, demo & SSLP). Additionally, whenever a vehicle subject to this service program is taken into retailer inventory, or in for service, necessary steps should be taken to ensure the service program correction has been made before selling or releasing the vehicle.

PRODUCTION CHANGE INFORMATION

The new IG1, IG2, ACC1, and ACC2 relays were incorporated into production during mid-February, 2015 starting with the following VINs: Legacy: F*048310 Outback: F*296775

The new EGI Main Relay was incorporated into production during mid-October, 2015 starting with the following VINs: Legacy: G*017247 Outback: G*237505

TOOLS REQUIRED

1/4" Drive Ratchet
6" 1/4" Drive Extension
Plastic Trim Tool
#2 Philips Screw Driver
10mm and 12mm sockets

PART INFORMATION

The new relay part numbers are:

82501AL000, qty. 4 required: IG1, IG2, ACC1, ACC2 RELAY ASSEMBLY)
25232AA130, qty. 1 required: EGI-MAIN RELAY

SERVICE PROCEDURE

The 4 IG1, IG2, ACC1, ACC2 relays are located in the vehicle's interior fuse box (F/B). The EGI Main Relay is located in the under-hood fuse box (M/B).

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 3-10mm 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, left).

*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 room 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.
Using the reference photos below as a guide, inspect the EGI Main Relay in the M/B. Replace the relay if inspection reveals M07 on the top cover.

IMPORTANT: Relay identification:

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 vehicle and verify all the combination meter warning lights cycle on / off normally.
Confirm the HVAC and all electrical systems operate as designed to complete the procedure.

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

CLAIM REIMBURSEMENT AND ENTRY PROCEDURES

Credit to perform this service program will be based on the submission of properly completed repair order information. Retailers may submit claims through Vehicle Claim Entry on subarunet.com.

Labor Description	Labor Operation #	Labor Time	Fail Code	Claim Type
REPLACE ALL 5 RELAYS; IG1, IG2, ACC1, ACC2 & EGI MAIN	A186-003	0.6	WTG-67	RC

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.

OWNER NOTIFICATION LETTER

August, 2016

Dear Subaru Owner:

We would like to thank you for your selection of a Subaru vehicle. We take pride in our products and are committed to your continued satisfaction.

Subaru has redesigned several ignition relays in order to provide improved cold weather re-starting performance for certain 2015 model year Legacy and Outback vehicles.

You received this notice because our records indicate that you currently own one of these vehicles. In the interest of your continued satisfaction, we would like to replace these relays in your vehicle at no cost to you to avoid any future potential concerns.

DESCRIPTION

Under certain extreme cold weather conditions, after the engine is shut off, ice crystals may form inside the relays which may temporarily prevent you from re-starting the vehicle.

REPAIR

Subaru will replace your vehicle's ignition relays at no cost to you.

WHAT YOU SHOULD DO

You should immediately contact your Subaru retailer (dealer) for an appointment to have this repair performed.

HOW LONG WILL THE REPAIR TAKE?

The time to replace the relays is approximately 35 minutes. However, it may be necessary to leave your vehicle for a longer period of time on the day of your scheduled appointment to allow your Subaru retailer flexibility in scheduling.

CHANGED YOUR ADDRESS OR SOLD YOUR SUBARU?

If you have moved or sold your vehicle, please complete the enclosed prepaid postcard and mail it to us. Or if you prefer to update this information online, please go to www.subaru.com, select 'Customer Support,' then select 'Address Update' or 'Ownership Update' from the drop down menu.

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.wtg67.service-campaign.com.

If you need additional assistance, please contact us directly:

By e-mail: Go to www.subaru.com, Customer Support and select "Contact Us"
By telephone: 1-800-SUBARU3 (1-800-782-2783)
Monday through Thursday between 7:30 a.m. and 8:00 p.m. ET

Friday between 10:30 a.m. and 5:00 p.m. ET

Saturday between 9:00 a.m. and 3:30 p.m. ET
By U.S. Postal mail: Write us at Subaru of America, Inc., Attn: Customer-Retailer Services Department, P.O. Box 6000, Cherry Hill, NJ 08034-6000

Please contact us immediately if the Subaru retailer fails or is unable to make the necessary repairs free of charge.

Your continued satisfaction with your Subaru is important to us. Please understand that we have taken this action in the interest of 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 to have this repair performed.

Sincerely,

Subaru of America, Inc.