WTG-67 – Engine No-Start Condition in Cold Climates – 2015 Subaru Legacy & Outback

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Bulletin Number: WTG-67; Revised: 08/30/16 Page 1 NUMBERS: WTG-67R DATE: 08/23/16 REVISED: 08-30-16 APPLICABILITY: 2015 MY Legacy and Outback SUBJECT: Engine No-Start Condition in Cold Climates ATTENTION: GENERAL MANAGER q PARTS MANAGER q CLAIMS PERSONNEL q SERVICE MANAGER q IMPORTANT – All Service Personnel Should Read and Initial in the boxes provided, right. © 2016 Subaru of America, Inc. All rights reserved. CAUTION: VEHICLE SERVICING PERFORMED BY UNTRAINED PERSONS COULD RESULT IN SERIOUS INJURY TO THOSE PERSONS OR TO OTHERS. Subaru Service Bulletins are intended for use by professional technicians ONLY. They are written to inform those technicians of conditions that may occur in some vehicles, or to provide information that could assist in the proper servicing of the vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do the job correctly and safely. If a condition is described, DO NOT assume that this Service Bulletin applies to your vehicle, or that your vehicle will have that condition. SUBARU OF AMERICA, INC. IS ISO 14001 COMPLIANT ISO 14001 is the international standard for excellence in Environmental Management Systems. Please recycle or dispose of automotive products in a manner that is friendly to our environment and in accordance with all local, state and federal laws and regulations. Continued… 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 SERVICE PROGRAM BULLETIN Bulletin Number: WTG-67; Revised: 08/30/16 Page 2 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 Continued… Bulletin Number: WTG-67; Revised: 08/30/16 Page 3 TOOLS REQUIRED: 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). Continued… Bulletin Number: WTG-67; Revised: 08/30/16 Page 4 *VERY 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. Continued… Bulletin Number: WTG-67; Revised: 08/30/16 Page 5 IMPORTANT: Relay identification: Continued… Bulletin Number: WTG-67; Revised: 08/30/16 Page 6 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 WTG-67 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. Bulletin Number: WTG-67; Revised: 08/30/16 Page 7 OWNER NOTIFICATION LETTER Subaru Service Program WTG-67 August 2016 This notice applies to the VIN identified in the address section printed below. 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. Bulletin Number: WTG-67; Revised: 08/30/16 Page 8 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. Notice to Lessors: Under Federal law the lessor of a vehicle who receives this letter must provide a copy of it to the vehicle lessee(s) within 10 business days from receipt. The lessor must 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.) A subsidiary of Fuji Heavy Industries Ltd.

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Subarunet Announcement To: All Subaru Retailers From: Subaru of America, Inc. Date: August 23, 2016 Subject: New Service Programs: WTG‐67 and WTH‐68 – Relay replacement In the interest of customer satisfaction, Subaru of America, Inc. is initiating two service programs for certain 2015 and 2016 model year Legacy and Outback vehicles, for the repair procedure previously published in TSB number 07‐89‐15R. Description Subaru has redesigned several ignition relays in order to provide improved cold weather re‐starting performance. Under certain extreme cold weather conditions, after the engine is shut off, ice crystals may form inside the relay which may temporarily prevent the driver from re‐starting the vehicle. The newly‐designed IG1, IG2, ACC1, and ACC2 relays were incorporated into production during mid‐ February, 2015. The newly‐designed EGI Main Relay was incorporated into production during mid‐ October, 2015.  The WTG‐67 service program will involve replacing all five relays in certain 2015 model year vehicles (IG1, IG2, ACC1, ACC2, and the EGI Main Relay).  The WTH‐68 service program will involve replacing only one relay in certain 2015 model year vehicles, and certain 2016 model year vehicles (EGI Main Relay). Affected Vehicles Not all vehicles listed below are covered by these service programs. 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 relays as described in the bulletins are not included in these service programs. Be sure to confirm which service program applies to the vehicle being serviced. Service Program Vehicle Models Production Date Range WTG‐67 (replace five relays) 2015 Legacy and Outback December 2013 – February 2015 WTH‐68 (replace one relay) 2015‐2016 Legacy and Outback December 2013 – October 2015 Repair Please refer to Service Program Bulletins WTG67 and WTH68 which are now posted on STIS. Owner Notification Subaru is in the process of obtaining the current registration data for the affected vehicles. Owner notification will occur by early September. Retailers will be notified when owner notification begins. 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 these service programs. 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 these service programs.

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