WRL-22 PTC Heater Ground Bolt – 2019-2022 Subaru Ascent

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December 8, 2022 NHTSA CAMPAIGN NUMBER: 22V907000

Improperly Fastened Ground Bolts May Cause Fire

A melting ground terminal increases the risk of a fire.

 

NHTSA Campaign Number: 22V907

Manufacturer Subaru of America, Inc.

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 271,694

 

Summary

Subaru of America, Inc. (Subaru) is recalling certain 2019-2022 Ascent vehicles. The ground bolt that secures the ground terminal of the Positive Temperature Coefficient (PTC) heater may have been improperly fastened, which could result in melting of the ground terminal and surrounding components.

 

Remedy

Owners are advised to park their vehicle away from structures and to avoid leaving the vehicle unattended while the engine is running. An owner who notices or smells smoke coming from the dash or driver’s footwell area should immediately stop operating the vehicle and turn the ignition switch to the “Off” position. Dealers will replace the PTC heater ground bolts and if necessary, replace the ground wire and the connector holder, free of charge. Owner notification letters are expected to be mailed February 6, 2023. Owners may contact Subaru’s customer service at 1-844-373-6614. Subaru’s number for this recall is WRL-22.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Subaru has a Recall

 


NUMBER: WRL-22R
DATE:
12/12/22
NHTSA: 22V-907
REVISED: 02/20/23

APPLICABILITY: 2019-2022MY Ascent
SUBJECT: PTC Heater Ground Bolt

 

Subaru of America, Inc. (Subaru) is initiating a new safety recall for certain 2019-2022 model year Ascent vehicles.

 

DESCRIPTION OF THE DEFECT AND SAFETY RISK

The ground bolt that secures the ground terminal of the Positive Temperature Coefficient (PTC) heater may have been improperly fastened during vehicle production. This potential condition may result in the melting of the ground terminal and surrounding components when the PTC heater is in operation, increasing the risk of a fire.

 

REMEDY

For all potentially affected vehicles, Subaru retailers will replace the PTC heater ground bolts and, if necessary, replace the ground wire harness and connector holder at no cost to the customer.

  • As a precautionary measure, it is highly recommended that owners park their vehicle away from any garage, car port or other structure until this repair is completed.
  • Additionally, owners should never leave the vehicle unattended while the engine is running until this repair is completed.
  • If an owner notices or smells melting plastic or smoke coming from the dash or driver’s footwell area, the ignition should be placed in the “off” position and the vehicle should not be operated. If this occurs, the owner should immediately contact Subaru’s Roadside Assistance or the nearest Subaru retailer for assistance.

 

AFFECTED VEHICLES

A total of 271,694 U.S. vehicles will be included in this recall as listed below. Not all vehicles in the production range listed above are affected by this recall. Coverage must be confirmed by using the Vehicle Coverage Inquiry function on subarunet.com prior to repair. This information is now available.

Model Year Carline Production Date Range
2019-2022 Ascent February 23, 2018 – April 28, 2022

The VIN status for this recall will display as ‘Open-Limited Parts Available’ until the owner notification letters are mailed, at which time the status will be updated to ‘Open.’ Repairs can begin prior to the owner notification.

 

RETAILER RESPONSIBILITY

Please be advised that it is a violation of Federal law for a dealer to deliver a new motor vehicle covered by a recall under a sale or lease until the defect is remedied. Therefore, any Authorized Subaru Retailer failing to perform the applicable service procedures to correct all affected vehicles in their inventory prior to the vehicle being placed in service may be subject to civil penalties of up to $22,423 per violation (i.e., for each vehicle), as provided in 49 CFR §578.6 and will also be in breach of the Subaru Dealer Agreement.

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). 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.

 

OWNER NOTIFICATION

Subaru is in the process of obtaining current vehicle registration data and will notify affected vehicle owners by first class mail within 60 days. Retailers will be advised when owner notification is scheduled.

 

PART INFORMATION:

Up to two kits may be required for this procedure. The bolt kit is required on ALL vehicles. The harness kit is required if the inspection results confirm further harness work is required.

Part Description Kit Part Number Qty Application Ordering Method
WRL-22 Bolt Kit SOA635174 1 Required on ALL vehicles Ordered through PRIME
WRL-22 Harness Kit SOA635175 1 Required on vehicles needing further harness work after inspection Currently on HOLD. The PIC team will release the ordered parts when contacted & provided with a valid VIN and QMR number

 

Bolt Kit (SOA635174) Components

Part Description Qty Image
BOLT

(Ground Bolt)

2 BOLT (Ground Bolt)

 

Harness Kit (SOA635175) Components

Part Description Qty Image
INST PNL HARN USA

(PTC Heater Ground Wire)

1 INST PNL HARN USA (PTC Heater Ground Wire)
CONNECTOR HOLDER LH 1 CONNECTOR HOLDER LH

 

REQUIRED TOOLS:

Tool Description Application Image
Thread Chaser (M6 x 1.0) For cleaning the female thread of the ground terminal. Thread Chaser (M6 x 1.0)
Tap (M6 x 1.0) For repairing female thread of the ground terminal. Tap (M6 x 1.0)
Tap Holder To be used with tap. Tap Holder

 

QMR INFORMATION:

The following are required when a harness kit (SOA635175) repair is necessary (arcing or melting found at the ground point):

  1. There is a QMR submission requirement should a repair require the harness kit (SOA635175).
    • A TechShare QMR must be issued including photo(s) clearly showing the melting or arcing condition found at the ground point necessitating the repair.
    • Include the VOR parts order number for the related harness kit (SOA635175) in the QMR comments. This will be used to prioritize release of parts as they become available.
  2. ALL claim submissions for repairs requiring a harness kit (SOA635175) will require attachment of photos to the claim submission documenting the condition found requiring a harness kit repair.

 

COMPONENT DESCRIPTION/CONFIGURATION:

 

Service Procedure / Flowchart:

Service Procedure / Flowchart:

NOTE**: If a torque of 13Nm cannot be achieved, a QMR must be submitted. Contact Techline for further instruction.

 

SERVICE PROCEDURE / INFORMATION:

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

STEP 1: Refer to the applicable Service Manual and review: General Description > Repair Contents > Action required before & after Battery Disconnect. Additionally, record any stored seat position(s) before proceeding. Relearn any seat position memory after work is complete. If the power rear gate (PRG) height has been customized, that position must also be noted and relearned.

STEP 2: CAREFULLY disconnect the ground terminal from the battery sensor.

 

STEP 3:  Remove the mounting nut securing the left front side sill cover. CAREFULLY detach the front section of the left rear side sill cover. While holding the front section, use your other hand to detach and remove the left front side sill cover.

 

 

CAUTION: ALWAYS remove the cover when it is or has reached room temperature. Any attempts of removal in cold ambient temperatures may result in unwanted breakage DO NOT use excessive force when pulling the cover upward. This may cause damage to the cover.

STEP 4: Disconnect all electrical connections from the connector holder

 

STEP 5: Remove the two heater ground bolts.

 

STEP 6: Release the connector holder cover mounting clip security tabs.

CAUTION: To prevent any damage, DO NOT attempt to remove the connector holder WITHOUT releasing the security tabs first.

 

STEP 7: Move the connector holder aside to allow room for workspace.

 

STEP 8: Thread the thread chaser into both of the ground bolt holes. Use a torque wrench to turn the thread chaser. If the turning torque is 7Nm or higher, clean the threads with a tap and recheck the turning torque. Once the turning torque is less than 7Nm, continue to the next STEP.

 

STEP 9: Using a small flat head screwdriver, release the holding claw on the back of the connector
holder. With the claw released, remove the PTC heater ground terminal from the connector holder.

 

STEP 10: CAREFULLY inspect the PTC heater ground terminal and peripheral parts for any damage. See the example images of overheat damage below.

 

IMPORTANT: If any damage is found, a QMR will be required with detailed photos of the damage attached and the repair parts order information noted in the comments section.

 

STEP 11: Has any damage been found with the PTC heater ground terminal and/or the peripheral parts?

YES – Proceed to STEP 13.

NO – Proceed to STEPS 25, 26, & 27. Then proceed to STEP 33.

STEP 12: Pull the front left side cover in  the horizontal direction to release the  holding claws. Once released remove the cover.

 

STEP 13: CAREFULLY pull the trim panel toward the rear of the vehicle to release the mounting claws. Once released, remove the panel.

 

STEP 14: Remove the mounting screw and pull the lower cover toward the rear of the vehicle to release the mounting clips. Once released, disconnect all electrical connections and remove the panel.

 

STEP 15: Disconnect the data link connector. Disconnect the knee airbag module connector. CAREFULLY remove the knee airbag module.

 

STEP 16: Remove the mounting screw. Release the mounting claws. Remove the duct by pulling in the direction of the left front door.

 

STEP 17: Disconnect the electrical connections at the front of the fuse box. Remove the mounting nuts and screw. Move the fuse box toward the floor to allow for workspace.

 

STEP 18: Using needle nose pliers, pinch the claw of the connector holder and remove the ground terminal.

 

STEP 19: Release the locking tab using a flathead screwdriver. Disconnect all electrical connections and remove the connector holder.

 

STEP 20: Install the new connector holder supplied in harness kit (SOA635175). Connect all the electrical connections in the reverse order of disassembly. Secure the connector holder to the vehicle body with the mounting clip.

CAUTION: DO NOT install the mounting bolts at this time.

 

STEP 21: Disconnect the original ground wire connection. Connect the new ground harness supplied in the harness kit (SOA635175).

NOTE: The original ground wire will remain in place. The ends will be trimmed  in later STEPS.

 

STEP 22: Route the new ground wire along the instrument panel harness as shown below.

 

STEP 23: Align and attach the ground terminal of the new ground wire to the connector holder.

 

STEP 24: Install the new ground bolts and torque to 13Nm.

IMPORTANT: CONFIRM bolts are torqued to 13Nm.

 

STEP 25: Confirm there is no movement with the ground terminal. Check for any loose contact by attempting to move the terminal with your fingers in an up/down direction. There is no need to pull the ground cable when checking for loose contact.

CAUTION: Any loose connection could cause a possible thermal event.

 

STEP 26: Connect all the previously removed  connectors to the connector holder.

NOTE: If performing bolt replacement ONLY,  proceed to STEP 33.

 

STEP 27: Using cable ties, secure the new ground wire at the six locations indicated in the images below. The original harness wire strap locations can be used as reference. Confirm the tension of the ground wire is evenly distributed.

NOTE: 12-inch wire straps are recommended for the best results.

 

CAUTION: Always trim the edges of the cable ties to prevent any interference with other parts.

STEP 28: Using side cutting pliers, CAREFULLY cut the ORIGINAL ground wire and remove the terminal.

 

STEP 29: Seal the cut end of the original ground wire with electrical insulation tape. The wire can then be taped to the new ground wire.

 

STEP 30: Cut the opposite end of the ORIGINAL ground wire and remove the connector.

 

STEP 31: Seal the cut end of the original ground wire with electrical insulation tape. The wire can then be taped to the new ground wire.

 

STEP 32: Reinstall all removed parts in the reverse order of disassembly.

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

 

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.

 

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Chronology :

January 9, 2020 – Air tools introduced to the production line (replacing battery tool)

January 11, 2020 – Subaru received the first technical report exhibiting smoke from the driver’s side interior cabin

September 29, 2021 – Subaru received the first technical report involving fire damage. While a vehicle inspection identified the area of origination, a root cause could not be determined due to the significant damage caused by the fire.

February 24, 2022 – Subaru received the first technical report exhibiting smoke on a vehicle produced after the

Jan 9, 2020 tool change

April 29, 2022 – Subaru changed line tooling to DC tools capable of detecting torque and rotation angle

May 2022 – Subaru received the first technical report from the U.S. market involving fire damage on a vehicle produced after the Jan 9, 2020 tool change.

May-July 2022 Subaru conducted testing and evaluation to determine the specific conditions required to generate the heat necessary to cause the melting conditions being observed. It was determined that contact surface area was the primary condition. Low torque was a secondary condition.

August 15-30, 2022 – Subaru conducted a field evaluation study to understand the potential scope of the issue beyond the few incidents that were reported.

December 1, 2022 – Out of an abundance of caution, Subaru decided to conduct a voluntary safety recall.

Subaru is only aware of 11 technical reports in the U.S. market. Subaru is not aware of any crashes or injuries resulting from this condition.

 


4 Affected Products

Vehicle

MAKE MODEL YEAR
SUBARU ASCENT 2019-2022

 


15 Associated Documents

Recall Acknowledgement

RCAK-22V907-6253.pdf 646.319KB

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Defect Notice 573 Report

RCLRPT-22V907-5845.PDF 214.751KB

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Subaru – Subarunet Announcement – December 2022

RCMN-22V907-8669.pdf 210.516KB

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SubaruAscent Recall Announcement – December 2022

RMISC-22V907-1444.pdf 126.867KB

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Remedy Instructions and TSB

RCRIT-22V907-2969.pdf 15354.098KB

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Subaru – Subarunet Announcement – December 2022

RCMN-22V907-6697.pdf 188.33KB

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Remedy Instructions and TSB

RCRIT-22V907-1342.pdf 15359.308KB

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Subaru – Subarunet Announcement – January 2023

RCMN-22V907-4876.pdf 208.075KB

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Subaru – Recall Campaign – January 2023

RCMN-22V907-0453.pdf 15333.547KB

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Remedy Instructions and TSB

RCRIT-22V907-2218.pdf 2943.369KB

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Remedy Instructions and TSB

RCRIT-22V907-9194.pdf 5005.103KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V907-5451.pdf 218.36KB

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Subaru – PTC Heater Ground Bolt Training – February 2023

RCMN-22V907-5046.pdf 184.613KB

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Subaru – Product Campaign Bulletin – February 2023

RCMN-22V907-7221.pdf 5392.44KB

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ISSUED Renotification Notice

RCRN-22V907-7823.pdf 824.234KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V907&docType=RCL

 


NHTSA ID Number: 10232227

Manufacturer Communication Number: WRL-22R

Summary

Subaru of America, Inc. (Subaru) is initiating a new safety recall for certain 2019-2022 model year Ascent vehicles.

 

1 Associated Document

Manufacturer Communications

NUMBER: WRL-22R
DATE: 12/12/22
NHTSA: 22V-907
REVISED: 02/20/23

https://www.nhtsa.gov/recalls?nhtsaId=10232227

MC-10232227-0001.pdf 5392.415KB

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NHTSA ID Number: 10231298

Manufacturer Communication Number: WRL-22R

Summary

Subaru of America, Inc. (Subaru) is initiating a new safety recall for certain 2019-2022 model year Ascent vehicles.

 

1 Associated Document

Manufacturer Communications

NUMBER: WRL-22R
DATE: 12/12/22
NHTSA: 22V-907
REVISED: 01/30/23

https://www.nhtsa.gov/recalls?nhtsaId=10231298

MC-10231298-0001.pdf 5005.103KB

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NHTSA ID Number: 10228783

Manufacturer Communication Number: WRL-22

Summary

Subaru of America, Inc. (Subaru) is initiating a new safety recall for certain 2019-2022 model year Ascent vehicles. (PTC Heater)”

 

1 Associated Document

Manufacturer Communications

NUMBER: WRL-22R
DATE: 12/12/22
NHTSA: 22V-907
REVISED: 12/15/22

https://www.nhtsa.gov/recalls?nhtsaId=10228783

MC-10228783-0001.pdf 15359.308KB

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NHTSA ID Number: 10231280

Manufacturer Communication Number: SubaruNet Announ

Summary

UPDATE Safety Recall: WRL-22 PTC Heater Ground Bolt (Owner notification)

 

1 Associated Document

Manufacturer Communications

Date: January 5, 2023
UPDATE Safety Recall: WRL-22 PTC Heater Ground Bolt

https://www.nhtsa.gov/recalls?nhtsaId=10231280

MC-10231280-0001.pdf 204.058KB

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NHTSA ID Number: 10228784

Manufacturer Communication Number: SubaruNet Announ

Summary

Service, Parts, and Claim Instructions For detailed service, parts, and claim instructions, please refer to the WRL-22 Product Campaign Bulletin which is now available on STIS.

 

1 Associated Document

Manufacturer Communications

Date: December 13, 2022
UPDATE Safety Recall: WRL-22 PTC Heater Ground Bolt

https://www.nhtsa.gov/recalls?nhtsaId=10228784

MC-10228784-0001.pdf 210.516KB

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NHTSA ID Number: 10228778

Manufacturer Communication Number: SubaruNet Announ

Summary

Subaru of America, Inc. (Subaru) is initiating a new safety recall for certain 2019-2022 model year Ascent vehicles. (WRL-22)

 

1 Associated Document

Manufacturer Communications

Date: December 9, 2022
New Safety Recall: WRL-22 PTC Heater Ground Bolt

https://www.nhtsa.gov/recalls?nhtsaId=10228778

MC-10228778-0001.pdf 187.084KB

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NHTSA ID Number: 10231314

Manufacturer Communication Number: SubaruNet Announ

Summary

WRL-22 PTC Heater Ground Bolt left side sill cover removal.

 


Subarunet Announcement

To: All Subaru Retailers From: Subaru of America, Inc.

Date: January 24, 2022

UPDATE Safety Recall: WRL-22 PTC Heater Ground Bolt

 

Updated, Service Procedure

Higher than expected breakage of the Left rear side sill cover (aka. driver’s side door-sill trim) has been occurring during this service procedure. The latest update to the WRL-22 Technical Service Bulletin addresses this, and provides recommendations for accessing the PTC heater, without the need to fully remove the Left rear side sill cover. It is recommended that retailers implement this new procedure as soon as possible. Edits to the TSB are shown below.

 

The updated TSB has been uploaded to STIS.

 

STEP 3: Remove the mounting nut securing the left front side sill cover. CAREFULLY detach the front section of the left rear side sill cover. While holding the front section, use your other hand to detach and remove the left front side sill cover.

 

CAUTION: ALWAYS remove the cover when it is or has reached room temperature. Any attempts of removal in cold ambient temperatures may result in unwanted breakage. DO NOT use excessive force when pulling the covers. This may cause damage to the covers.

 

  • As a precautionary measure, it is highly recommended that owners park their vehicle away from any garage, car port or other structure until this repair is completed.
  • Additionally, owners should never leave the vehicle unattended while the engine is running until this repair is completed.
  • If an owner notices or smells smoke coming from the dash or driver’s footwell area, the ignition should be placed in the “off” position and the vehicle should not be operated. If this occurs, the owner should immediately contact Subaru’s Roadside Assistance or the nearest Subaru dealer for assistance.

 


1 Associated Document

Manufacturer Communications

Date: January 24, 2022
UPDATE Safety Recall: WRL-22 PTC Heater Ground Bolt

https://www.nhtsa.gov/recalls?nhtsaId=10231314

MC-10231314-0001.pdf 264.745KB

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  • [Weaving process]: Weaving process, with firm connection and good softness, fine wires arranged and braided evenly, low heat, large angle bending, high conductivity and convenient use.
  • [Widely used]: Vehicle Grounding Cable Straps are used for cable tray grounding, distribution box grounding, etc. Engine Ground Strap is a component that connects the engine block and the frame.
  • [Package includes]: 3 pieces of 10 "x 1/2" and 2 pieces of 13 "x 1/2" engine grounding strips to meet your daily needs.
  • [About us]: We strive to constantly innovate, meet customer needs, provide customers with better products, and create a perfect product experience. Our goal is to serve every detail and bring convenience to every family.
Bestseller No. 8
UGSHY 20 PCS Automotive Body Bolt and U-nut Clamp Kit, Hood Guard Spiral, Bumper Fender Liner Push Pull Metal Rust-Resistant U Retainer, Universal for Most Cars Fastening Accessories (Black)
  • Metal Material: This screw is made of high-quality metal, which is durable, wear-resistant, smooth overall, high-strength and not easy to slip. The surface has been specially treated to enhance durability, resist rust, and stand the test of time.
  • Product Parameters: You will receive 10 x screws, 10 x U-clips, bolt size is 0.7" x 0.8", U-clip size is 1" x 0.3". Each body bolt clamp is carefully designed to make it the ideal automotive body clamp for a variety of applications. Body fastening accessories suitable for most cars.
  • Function: It can achieve an effective fixing effect. The combination of long bolt and U-shaped nut ensures precise tightening and provides a safe grip that you can rely on. Reduces the risk of assembly errors and enhances the overall integrity of vehicle body components.
  • Exquisite Craftsmanship: The bolt tail section is flat and smooth, with no burr residue. The spiral thread is deep and burr-free, and the force is evenly distributed. The screw teeth are sharper and less likely to slip during rotation.
  • Applications: Widely used in door trims, fenders, bumpers, radiator guards, side skirts, grilles, hood splash guard fixings. Holds vehicle components securely in place for a perfect fit.
Bestseller No. 9
10pcs Universal Automotive Ground Straps, 10/12 inch Engine Ground Strap Kit Braided Copper Ground Straps Automotive Ground Strap Wire Ground Strap Connectors for Most Cars (Silver)
  • Product Size: There are 5 pieces of automotive ground straps with a size of 250mm/10 inch, and the other 5 with a size of 300mm/12 inch. Different specifications meet your different needs.
  • Premium Material: This engine ground strap kit is made of copper, sturdy and durable, wear resistant and hard to break, can ensure a strong connection and a long service life.
  • Excellent Conductivity: These material of these ground wire straps provide excellent and maximum electrical conductivity, the ground strap has good stability, and can be used with confidence.
  • Unique Design: Our ground straps for car adopt braiding design, which is firm in connection, good in softness, offers superior durability and flexibility, and easy to use so you can get your vehicle grounded quickly and easily.
  • Wide Application: The ground cable strap is suitable for most types of vehicles, help you connect the engine to the frame, widely used in cars, appliances, transformers, junction boxes, etc. Provide you with a good user experience.
Bestseller No. 10
5PCS Universal Automotive Ground Strap, 3Pcs 10" x 1/2" & 2Pcs 13" x 1/2" Braided Tinned Copper Engine Ground Strap, Professional Vehicle Grounding Cable Straps, Engine Ground Strap for Most Cars
  • [Material]: Engine Ground Strap is made of tinned copper, Provide excellent current delivery, oxidation resistance and corrosion resistance, and long service life.
  • [Weaving process]: Weaving process, with firm connection and good softness, fine wires arranged and braided evenly, low heat, large angle bending, high conductivity and convenient use.
  • [Scope of application]: This Automotive Ground Strap is used for cable tray grounding, distribution box grounding, etc.Engine Ground Strap is a component that connects the engine block and the frame.
  • [Package include]: You will get: 3 pieces of 10 "x 1/2" and 2 pieces of 13 "x 1/2" Vehicle Grounding Cable Straps to meet your daily needs .Each strap is built from center to center of lugs holes.
  • [About us]: As people's requirements for car comfort and wisdom become higher and higher, we strive to constantly innovate, meet customer needs, provide better products, and create perfect product experience for customers.

Last update on 2024-06-18 / Affiliate links / Images from Amazon Product Advertising API

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