Fuel Injector- Design Change Misfire DTC P030* / Engine Knocking / DTC P219C P219D P219E P219F – 2018-2021 Subaru Crosstrek 2.0L DI & PHEV 2017-2021 Impreza 2.0L DI

NHTSA ID Number: 10201811

Manufacturer Communication Number: 09-81-21

Summary

This bulletin announces design changes made to the fuel injector assembly in response to misfire DTC P030x, engine knocking, and/or DTCs P219C-D-E-F.

 


NUMBER: 09-81-21
DATE:  09/24/21

 

INTRODUCTION:

This bulletin announces design changes made to the fuel injector assembly in response to the DTCs listed above. Changes have been made to the internal needle flange to enhance durability. In some cases, the needle flange may develop excessive internal wear causing restricted fuel flow which can result in engine vibration and / or engine misfire DTC(s). This condition can also result in DTC P219C/D/E/F. Since a similar concern and / or DTC(s) may result from carbon buildup, it is critical to confirm if the condition continues after two carbon cleanings with P.E.A. are completed before proceeding with any part replacement.

 

PRODUCTION CHANGE INFORMATION:

  • The new fuel injector assemblies were incorporated into Crosstrek production starting with VIN M8330452.
  • The Production Change Information for Impreza is TBD.

 

PART INFORMATION:

Injector Assembly Part Number Flow Rate Number
16611AA971 “4”
16611AA981 “5”
16611AA991 “6”

 

VERY IMPORTANT:

  • Using the illustration below for identification reference, always replace an injector assembly with the same flow rate number as originally equipped.

 

REMINDER: Always order the most up-to-date replacement parts based on the specific VIN being repaired.

 

SERVICE PROCEDURE / INFORMATION:

REMINDER:  Customer satisfaction and retention starts with performing quality repairs.

NOTE:  Subaru Select Monitor data may be required for processing Warranty Claims related to these procedures.

Follow the proper diagnostics for any of the DTCs listed using the procedures provided in the applicable Service Manual. BEFORE any injector assembly replacement, it is important to perform a carbon deposit cleaning procedure FIRST as outlined in TSB 09-74-21. Doing so (if successful) can prevent unnecessary injector replacements which may not resolve the condition. If injector replacement is still determined to be required, the cleaning procedure will remove carbon from surrounding combustion chamber components for any newly installed injector(s).

STEP 1) Is DTC P219C/D/E/F current or stored in the ECM memory?

Yes

Proceed to STEP 8.

No

Proceed to next STEP.

NOTE: DTC’s found stored in the ECM MUST be recorded and entered into the note section of the claim. This is a REQUIREMENT for Warranty claim submission.

 

STEP 2) Confirm DTC P030* is current or stored in the ECM memory.

 

STEP 3) Verify any engine vibration or knocking condition has been experienced by the customer.

 

STEP 4) If an injector(s) is determined to be the fault source, perform the P.E.A. carbon cleaning
procedure as per 09-74-21 along with a post-cleaning road test. Start with STEP 1C of TSB 09-74-21. Follow balance of steps for DINA models. If more than one PEA cleaning is required, change the engine oil.

 

STEP 5) Has the condition been resolved?

Yes

No additional work is needed. See Warranty / Claim Information section of this bulletin.

No

Proceed to next STEP.

 

STEP 6) Perform a second P.E.A. carbon cleaning procedure as per 09-74-21 followed by a road
test. Perform an engine oil and filter change following this second cleaning.

 

STEP 7) Has the condition been resolved?

Yes

No additional work is needed. See Warranty / Claim Information section of this bulletin.

No

Proceed to next STEP.

 

STEP 8) Identify the injector assembly(s) by confirming the vendor part number and flow rate number engraved on the injector body as shown in the Parts Information section above. Replace the injector(s) as necessary with the NEW part(s) having the matching flow rate. Remove any carbon build-up found during replacement: Engine > FUEL INJECTION (FUEL SYSTEMS) > Fuel Injector.

IMPORTANT:  Do Not replace fuel injector(s) without performing two P.E.A. carbon cleaning procedures FIRST.

CRITICAL:  When replacing injector(s), NEVER reuse parts identified in the applicable Service Manual as one-time-use items:  Engine > FUEL INJECTION (FUEL SYSTEMS) > General Description > COMPONENT. This area of the Service Manual uses a black star (★) in the illustrations to indicate one-time use parts.

 

IMPORTANT NOTE: Whenever reconnecting the ground cable terminal to the battery sensor, torque to 7.5Nm (5.5 ft.-lbs. or 66 inch-lbs.) while supporting the sensor with the other hand as outlined in the applicable Service Manual under: STARTING/CHARGING SYSTSEMS > Battery Sensor.

 


9 Affected Products

Vehicles

MAKE MODEL YEAR
SUBARU CROSSTREK 2018-2021
SUBARU IMPREZA 2017-2021

 


1 Associated Document

Manufacturer Communications

NUMBER: 09-81-21
DATE: 09/24/21

https://www.nhtsa.gov/recalls?nhtsaId=10201811

MC-10201811-0001.pdf 1220.231KB

MC-10201811-0001

 


 

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