NHTSA ID Number: 10173189
Manufacturer Communication Number: WUK-96R
Summary
Subaru
of America, Inc. (Subaru) is initiating a service campaign for certain 2015-2018 Forester 2.0L Turbo and 2016-2018 WRX models which may experience a loosening of the front exhaust pipe nuts.
7 Affected Products
Vehicles
NUMBER: WUK-96
DATE: 12/05/19
REVISED: 03/26/20
| APPLICABILITY: | 2015-2018MY Forester 2.0L Turbo 2016-2018MY WRX 2.0L Turbo |
| SUBJECT: | DIT Exhaust Pipe Front (EPF) Nut Torque |
INTRODUCTION:
Subaru of America, Inc. (Subaru) is initiating a service campaign for certain 2015-2018 Forester 2.0L Turbo and 2016-2018 WRX models which may experience a loosening of the front exhaust pipe nuts. On certain affected vehicles, the six (6) front exhaust pipe (EPF) nuts at the cylinder heads may not have been tightened sufficiently due to variations in production. As a result, these nuts may become loose during use and cause exhaust leakage. A leak occurring at the front exhaust pipe may result in deterioration of emission performance. As a result, affected vehicle may fail to meet emission levels certified by the EPA and/or California ARB.
AFFECTED VEHICLES:
Vehicles included in this service campaign are 2015-2018 Forester XT and 2016-2018 WRX. This recall will affect approximately 93,796 vehicles. Coverage for all affected vehicles must be confirmed by using the Vehicle Coverage Inquiry function on subarunet.com. This information is now available.
| Model Year | Carline | Affected Production Dates |
| 2015-2018 | Forester XT | 5/11/2015 – 3/20/2018 |
| 2016-2018 | WRX | 5/09/2015 – 10/04/2017 |
DESCRIPTION OF THE REPAIR:
Subaru retailers will inspect the 6 nuts securing the front exhaust pipe to the cylinder heads on all affected vehicles. If any of the 6 nuts are found to be loose or lost and / or exhaust gas leakage is identified at either of the connections to the cylinder heads, the retailer should replace the front exhaust pipe.
RETAILER RESPONSIBILITY:
Retailers are to promptly perform this repair on all affected vehicles in their inventory. Additionally, whenever a vehicle subject to this service program is taken into inventory or in for service, necessary steps should be taken to ensure the update has been made before selling or releasing the vehicle.
OWNER NOTIFICATION:
Subaru is in the process of acquiring registration data and will notify affected vehicle owners by first class mail by the end of March. Retailers will be advised when owner notification occurs.
RETAILER AFFECTED VIN LISTS:
Each Subaru retailer will receive an affected VIN list from their Zone Office. Vehicles will be assigned to retailers 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 information for vehicles affected by this service program. This information will enable retailers to follow up with owners of affected vehicles. The lists contain owners’ names and phone numbers 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 sole purpose of completing this service program.
PART INFORMATION:
EPF Exhaust Gasket Kit, p.n. X4460AA011
NOTES:
- This kit will only be required when the inspection procedure outlined below determines EPF replacement is necessary. The likelihood of a need to replace the EPF assembly is expected to be extremely low.
- If exhaust leakage is confirmed, peripheral (surrounding) parts (e.g. engine mount, oil level sensor / switch) may be damaged as a result. These parts will need to be ordered separately.
SERVICE PROCEDURE:
On certain vehicles, the six (6) nuts securing the front exhaust pipe (EPF) to the cylinder heads may not have been tightened sufficiently due to variations in production. As a result, these nuts may become loose during use resulting in exhaust leakage. Therefore, torque on these 6 nuts must be inspected on all affected vehicles. If the any of the 6 nuts are found to be loose or lost and / or exhaust gas leakage is identified at either of the connections to the cylinder heads, the front exhaust pipe must be replaced.
Use the following Flow Chart below as an overview / guideline for performing this procedure. Stepby-step instructions are also provided below.
Helpful Hints for Technicians if EPF replacement is necessary:
- After draining the cooling system, ALWAYS replace the o-ring on the radiator petcock (a new one is included in the EPF parts kit).
- Be sure to remove (and re-install) the braided ground strap from the heat shield above the front exhaust pipe connection.
- The turbocharger stay bracket, main and sub cooling fans and the water pump pulley DO NOT need to be removed.
- When installing the new o-rings on the air flow meter, they both look the same but, they have different part numbers and two different locating tabs. The tab on the turbo outlet (charge) pipe o-ring is not centered. The tab’s offset must be toward the turbocharger otherwise, it will distort as shown below. The other o-ring’s tab is centered and can be installed in either way.
- When reinstalling the Turbo / EPF assembly, only snug (do not tighten / torque) the 6 EPF flange nuts at the cylinder heads. Install the 2- 14mm hex bolts for the turbocharger stay brackets, tighten / torque them to specification 33Nm (3.4 kgf-m, 24.3 ft. lbs.) FIRST then, proceed to torque the 6 EPF flange nuts to 45.5 Nm (4.6 kgf-m, 33.5 Ft. Lbs.) TWICE and IN THE ORDER SHOWN IN STEP 2 on pg. 5.
- Loosen the 10mm hex bolt in the center of the bottom EPF heat shield before reinstalling the turbocharger oil reservoir. This will make it easier to get the reservoir back into position. Also, put the 2 long 10mm hex bolts through the reservoir, hold them in place and put the new gasket on them as shown below. This makes the gasket installation much easier.
- To insure the cooling system has been completely refilled (with NEW coolant) and any remaining air pockets removed, the use of a vacuum refilling system is strongly recommended.
IMPORTANT NOTE: As stated at the top of the Flow Chart, if inspection reveals an after-market EPF assembly (a.k.a. performance exhaust header), STOP. Reinstall the undercover and proceed to the Claim Reimbursement and Entry Procedures section for IMPORTANT information on how to process the Inspection Only claim.
Step 1: Remove the front under cover and guard. Inspect the following two areas carefully:
- Are any of the 6 EPF nuts shown in the figure below missing?
- Is there any trace of exhaust gas leakage (soot deposits) around the EPF mounting flanges at the cylinder heads? IMPORTANT: Always check for exhaust gas leakage even if all the EPF nuts are in place.
REMINDER: If after removing the engine undercover, inspection reveals an aftermarket EPF assembly (a.k.a. performance exhaust header), STOP. Reinstall the undercover and proceed to the Claim Reimbursement and Entry Procedures section for IMPORTANT information on how to process the Inspection Only claim.
NO When all 6 of the EPF nuts are in place or, if there is no trace of exhaust gas leakage, proceed to Step 2: and inspect the 6 EPF nuts for proper torque.
YES When any of the 6 EPF nuts are missing or, if there is exhaust gas leakage: proceed to Step 3: and replace the EPF assembly.
Step 2: Tighten the 6 EPF nuts to 45.5 Nm (4.6 kgf-m, 33.5 ft-lb) in the order shown below to check if any of them turn.
TIP: Marking the edge of the flanged nuts and head pipe flange first with a scribe or similar tool will help determine if one or more of them move during this inspection.
NO If none of the 6 EPF nuts turn: reinstall the front engine under cover to complete the procedure.
YES If any of the 6 EPF nuts turn: proceed to Step 3: and replace the EPF assembly.
Step 3: When inspections during Step 1) or Step 2) dictate the EPF needs to be replaced, replace it following the procedure in the applicable Service Manual. During EPF replacement, inspect the peripheral parts (engine mount, oil level switch / harness, etc.) for any heat damage from leaking exhaust.
NO If none of the peripheral parts near the EPF are damaged, replace the EPF assembly to complete the procedure.
YES If any peripheral parts near the EPF are damaged, replace them as needed along with the EPF assembly following the procedures outlined in the applicable Service Manual.
REMINDER: When reinstalling the Turbo / EPF assembly, only snug (do not tighten / torque) the 6 EPF flange nuts at the cylinder heads. Install the 2- 14mm hex bolts for the turbocharger stay bracket, tighten / torque them to specification FIRST then, proceed to torque the 6 EPF flange nuts TWICE and IN THE PROPER ORDER as specified in the applicable Service Manual.
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 normal parts ordering channels using part number MSA6P1301. Quantity 1 = 1 booklet of 50 certificates.
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 campaign 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 |
| EPF INSPECTION ONLY, A/MARKET EPF FOUND | A129-008 | 0.3 | WUK-96 | RC |
| EPF INSPECTION AND TORQUE CHECK (OK) ONLY | A129-018 | 0.4 | ||
| EPF INSPECTION AND REPLACE EPF ASSY. | A129-011 | 1.8 | ||
| EPF INSPECTION, REPL. EPF ASSY, ENGINE MOUNT AND / OR OIL LEVEL SENSOR SWITCH R&R | A129-013 | 2.9 |
IMPORTANT NOTE: When processing an inspection only claim after identifying an aftermarket
EPF, it is STRONGLY RECOMMENDED a Vehicle Modification / Damage / Aftermarket Product Report (see Section 17.8 of the Claims Policy and Procedures Manual) be completed and retained along with a photo for documentation purposes.
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.
NHTSA ID Number: 10169855
Manufacturer Communication Number: WUK-96
Summary
Subaru of America, Inc. (Subaru) is initiating a service campaign for certain 2015-2018 Forester 2.0L Turbo and 2016-2018 WRX models which may experience a loosening of the front exhaust pipe nuts. On certain affected vehicles, the six (6) front exhaust pipe (EPF) nuts at the cylinder heads may not have been tightened sufficiently due to variations in production. As a result, these nuts may become loose during use and cause exhaust leakage. A leak occurring at the front exhaust pipe may result in deterioration of emission performance. As a result, affected vehicle may fail to meet emission levels certified by the EPA and/or California ARB.
1 Associated Document
Manufacturer Communications
NUMBER: WUK-96
DATE: 12/05/19
MC-10169855-0001.pdf 1582.258KB
1 Associated Document
Manufacturer Communications
NUMBER: WUK-96R
DATE: 12/05/19
REVISED: 03/26/20
MC-10173189-0001.pdf 1583.402KB
NHTSA ID Number: 10169834
Manufacturer Communication Number: Subaru Announ
Summary
Subaru of America, Inc. (Subaru) is initiating a service campaign/ voluntary emissions recall for certain 2015-2018 Forester 2.0L Turbo and 2016-2018 WRX models which may experience a loosening of the front exhaust pip nuts.
Subarunet Announcement
To: All Subaru Retailers
From: Subaru of America, Inc.
Date: December 5, 2019
New Subaru Service Campaign/Voluntary Emissions Recall: WUK-96 DIT Exhaust Pipe Front (EPF) Nut Torque
Subaru of America, Inc. (Subaru) is initiating a service campaign/voluntary emissions recall for certain 2015-2018 Forester 2.0L Turbo and 2016-2018 WRX models which may experience a loosening of the front exhaust pipe nuts.
Affected Vehicles
This recall will affect 93,141 vehicles.
| Model Year | Carline | Affected Production Dates |
| 2015-2018 | Forester XT | 5/11/2015-3/20/2018 |
| 2016-2018 | WRX | 5/09/2015-10/04/2017 |
Coverage for this campaign must be confirmed by using the Vehicle Coverage Inquiry function on subarunet.com. This information will be available later today.
Background
On certain affected vehicles, the six (6) front exhaust pipe nuts at the cylinder heads may not have been tightened sufficiently due to variations in production. As a result, these nuts may become loose during use and cause exhaust leakage. A leak occurring at the front exhaust pipe may result in deterioration of emission performance. As a result, affected vehicle may fail to meet emission levels certified by the EPA and/or California ARB.
Description of the Remedy
Subaru retailers will inspect the 6 nuts securing the front exhaust pipe to the cylinder heads on all affected vehicles. If any of the 6 nuts are found to be loose or lost and / or exhaust gas leakage is identified at either of the connections to the cylinder heads, the retailer should replace the front exhaust pipe.
Retailer Responsibility
Any vehicles listed in any recall/campaign that are in retailer 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 the Product Campaign 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 recall is taken into retailer inventory necessary steps should be taken to ensure the recall correction has been made before selling or releasing the vehicle.
Each Subaru retailer will receive an affected VIN list from their Zone Office prior to owner notification. Affected vehicles will be assigned to retailers as follows:
- Original vehicle owners will be 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 will be 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 will be assigned to the nearest active retailer.
IMPORTANT: Retailer affected VIN lists include information for vehicles affected by this campaign. This information will enable retailers to follow up with owners of affected vehicles. The lists contain owners’ information 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 sole purpose of completing this campaign.
Owner Notification
Subaru will notify affected vehicle owners by first class mail during the first quarter of 2020. Owners with a valid email address on file will also be notified by email.
Service, Parts, and Claim Instructions
Detailed service, parts, and claim information will be available shortly in the WUK-96 Service Program Bulletin on STIS.
1 Associated Document
Manufacturer Communications
Date: December 5, 2019
NHTSA ID Number: 10169833
Manufacturer Communication Number: Subarunet Announ
Summary
Subaru of America, Inc. (Subaru) is initiating a service campaign/ voluntary emissions recall for certain 2015-2018 Forester 2.0L Turbo and 2016-2018 WRX models which may experience a loosening of the front exhaust pip nuts.
1 Associated Document
Manufacturer Communications
Date: December 5, 2019
NHTSA ID Number: 10171873
Manufacturer Communication Number: Subarunet Annou
Summary
Owner notification WUK-96 DIT exhaust pipe front (EPF) nut torque service campaign/voluntary emission recall.
Subarunet Announcement
To: All Subaru Retailers
From: Subaru of America, Inc.
Date: February 7, 2020
UPDATE: Owner Notification WUK-96 DIT Exhaust Pipe Front (EPF) Nut Torque Service Campaign/Voluntary Emissions Recall
Owner Notification
Subaru will begin to notify affected Forester vehicle owners by first class mail in phases starting on February 11, 2020. These notifications will be mailed in conjunction with the WUT05 and WUM98 notifications that affect the same vehicles. Affected VIN lists will be distributed to the Regional offices next week.
The owner notification for affected WRX vehicles will be scheduled at a later date. Retailers will be advised of that notification schedule before it begins.
Subaru of America, Inc. (Subaru) is initiating a service campaign/voluntary emissions recall for certain 2015-2018 Forester 2.0L Turbo and 2016-2018 WRX models which may experience a loosening of the front exhaust pipe nuts.
Affected Vehicles
This recall will affect 93,141 vehicles.
| Model Year | Carline | Affected Production Dates |
| 2015-2018 | Forester XT | 5/11/2015-3/20/2018 |
| 2016-2018 | WRX | 5/09/2015-10/04/2017 |
Coverage for this campaign must be confirmed by using the Vehicle Coverage Inquiry function on subarunet.com.
Background
On certain affected vehicles, the six (6) front exhaust pipe nuts at the cylinder heads may not have been tightened sufficiently due to variations in production. As a result, these nuts may become loose during use and cause exhaust leakage. A leak occurring at the front exhaust pipe may result in deterioration of emission performance. As a result, affected vehicle may fail to meet emission levels certified by the EPA and/or California ARB.
Description of the Remedy
Subaru retailers will inspect the 6 nuts securing the front exhaust pipe to the cylinder heads on all affected vehicles. If any of the 6 nuts are found to be loose or lost and / or exhaust gas leakage is identified at either of the connections to the cylinder heads, the retailer should replace the front exhaust pipe.
Retailer Responsibility
Any vehicles listed in any recall/campaign that are in retailer 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 the Product Campaign 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 recall is taken into retailer inventory necessary steps should be taken to ensure the recall correction has been made before selling or releasing the vehicle.
Service, Parts, and Claim Instructions
For detailed service, parts, and claim information, please refer to the WUK-96 Service Program Bulletin on STIS.
1 Associated Document
Manufacturer Communications
Date: February 7, 2020
MC-10171873-0001.pdf 175.743KB
NHTSA ID Number: 10171872
Manufacturer Communication Number: Subarunet Announ
Summary
Owner notification WUK-96 DIT exhaust pipe front (EPF) nut torque service campaign/voluntary emission recall.
1 Associated Document
Manufacturer Communications
Date: February 7, 2020
MC-10171872-0001.pdf 175.743KB
NHTSA ID Number: 10173193
Manufacturer Communication Number: Subarunet Announ
Summary
Update: Owner notification WUK-96 DIT exhaust pipe front (EPF) nut torque service campaign/voluntary emissions recall.
Subarunet Announcement
To: All Subaru Retailers
From: Subaru of America, Inc.
Date: March 27, 2020
UPDATE: Owner Notification WUK-96 DIT Exhaust Pipe Front (EPF) Nut Torque Service Campaign/Voluntary Emissions Recall
Owner Notification
Subaru notified the affected Forester vehicle owners by first class mail in phases throughout February. Those notifications were mailed in conjunction with the WUT05 and WUM98 notifications for the same affected vehicles.
The owner notification letters for affected WRX vehicles will be mailed next week.
Subaru of America, Inc. (Subaru) is initiating a service campaign/voluntary emissions recall for certain 2015-2018 Forester 2.0L Turbo and 2016-2018 WRX models which may experience a loosening of the front exhaust pipe nuts.
Affected Vehicles
This recall will affect 93,796 vehicles.
| Model Year | Carline | Affected Production Dates |
| 2015-2018 | Forester XT | 5/11/2015-3/20/2018 |
| 2016-2018 | WRX | 5/09/2015-10/04/2017 |
Coverage for this campaign must be confirmed by using the Vehicle Coverage Inquiry function on subarunet.com.
Background
On certain affected vehicles, the six (6) front exhaust pipe nuts at the cylinder heads may not have been tightened sufficiently due to variations in production. As a result, these nuts may become loose during use and cause exhaust leakage. A leak occurring at the front exhaust pipe may result in deterioration of emission performance. As a result, affected vehicle may fail to meet emission levels certified by the EPA and/or California ARB.
Description of the Remedy
Subaru retailers will inspect the 6 nuts securing the front exhaust pipe to the cylinder heads on all affected vehicles. If any of the 6 nuts are found to be loose or lost and / or exhaust gas leakage is identified at either of the connections to the cylinder heads, the retailer should replace the front exhaust pipe.
Retailer Responsibility
Any vehicles listed in any recall/campaign that are in retailer 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 the Product Campaign 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 recall is taken into retailer inventory necessary steps should be taken to ensure the recall correction has been made before selling or releasing the vehicle.
Service, Parts, and Claim Instructions
For detailed service, parts, and claim information, please refer to the WUK-96 Service Program Bulletin on STIS.
1 Associated Document
Manufacturer Communications
Date: March 27, 2020
MC-10173193-0001.pdf 179.336KB
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