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

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: 12/15/22

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. From (the release date of this bulletin) through 12/31/2022, 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:

Diagram 1

Diagram 1

Diagram 1

 

Diagram 2

Diagram 2

Diagram 2

 

Diagram 3

Diagram 3

 

Service Procedure / Flowchart:

Service Procedure / Flowchart:

 

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.

disconnect the ground terminal from the battery sensor

 

STEP 3: Remove the left rear side sill cover on the  driver’s side of the vehicle.

Remove the left rear side sill cover on the driver’s side of the vehicle

 

STEP 4: Remove the left front side sill cover from the driver’s side of the vehicle.

Remove the left front side sill cover from the driver’s side of the vehicle

 

STEP 5: Disconnect all electrical connections from the connector holder.

Disconnect all electrical connections from the connector holder

 

STEP 6: Remove the two heater ground bolts.

Remove the two heater ground bolts

 

STEP  7: 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.

Release the connector holder cover mounting clip security tabs

 

STEP 8: Move the connector holder aside to allow room for workspace.

Move the connector holder aside to allow room for workspace

 

STEP 9: 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.

Thread the thread chaser into both of the ground bolt holes

 

STEP 10: 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.

Using a small flat head screwdriver, release the holding claw on the back of the connector holder

Using a small flat head screwdriver, release the holding claw on the back of the connector holder

 

STEP 11: CAREFULLY inspect the PTC heater ground terminal and peripheral parts for any damage. See the example images of overheat damage below.

CAREFULLY inspect the PTC heater ground terminal and peripheral parts for any damage

 

 

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 12: 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 13: Pull the front left side cover in  the horizontal direction to release the  holding claws. Once released remove the cover.

 

Pull the front left side cover in the horizontal direction

 

STEP 14: CAREFULLY pull the trim panel toward the rear of the vehicle to release the mounting claws. Once released, remove the panel.

CAREFULLY pull the trim panel toward the rear of the vehicle

 

STEP 15: 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.

Remove the mounting screw and pull the lower cover toward

 

STEP 16: Disconnect the data link connector.

Disconnect the knee airbag module connector. CAREFULLY remove the knee airbag module.

Disconnect the data link connector

 

STEP 17: Remove the mounting screw.

Release the mounting claws. Remove the duct by pulling in the direction of the left front door.

Remove the mounting screw

 

STEP 18: 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.

Disconnect the electrical connections

 

STEP 19: Using needle nose pliers, pinch the claw of the connector holder and remove the ground terminal.

Using needle nose pliers, pinch the claw of the connector holder and remove the ground terminal

 

STEP 20: Release the locking tab using a flathead screwdriver. Disconnect all electrical connections and remove the connector holder.

Release the locking tab

 

STEP 21: 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.

Install the new connector holder

 

STEP 22: 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.

Disconnect the original ground wire connection

 

STEP 23: Route the new ground wire along the instrument panel harness as shown below.

Route the new ground wire along the instrument panel harness

 

STEP 24: Align and attach the ground terminal of the new ground wire to the connector holder.

Align and attach the ground terminal

 

STEP 25: Install the new ground bolts and torque to 13Nm.

IMPORTANT: CONFIRM bolts are torqued to 13Nm.

Install the new ground bolts

 

STEP 26: 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.

Confirm there is no movement with the ground terminal

 

STEP 27: Connect all the previously removed  connectors to the connector holder.

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

Connect all the previously removed connectors to the connector holder

 

STEP 28: 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.

Using cable ties, secure the new ground wire at the six locations

 

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

STEP 29: Using side cutting pliers,

CAREFULLY cut the ORIGINAL ground wire and remove the terminal.

cut the ORIGINAL ground wire and remove the terminal

 

STEP 30: Seal the cut end of the original ground wire with electrical insulation tape. The wire can then be taped to the new ground wire.

Seal the cut end of the original ground wire with electrical insulation tape

 

STEP 31: Cut the opposite end of the ORIGINAL ground wire and remove the connector.

Cut the opposite end of the ORIGINAL ground wire and remove the connector

 

STEP 32: Seal the cut end of the original ground wire with electrical insulation tape. The wire can then be taped to the new ground wire.

Seal the cut end of the original ground wire with electrical insulation tape

 

STEP 33: 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.

 


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

 


7 Associated Documents

Recall Acknowledgement

RCAK-22V907-6253.pdf 646.319KB

RCAK-22V907-6253

 


Defect Notice 573 Report

RCLRPT-22V907-5845.PDF 214.751KB

RCLRPT-22V907-5845

 


Subaru – Subarunet Announcement – December 2022

RCMN-22V907-8669.pdf 210.516KB

RCMN-22V907-8669

 


SubaruAscent Recall Announcement – December 2022

RMISC-22V907-1444.pdf 126.867KB

RMISC-22V907-1444

 


Remedy Instructions and TSB

RCRIT-22V907-2969.pdf 15354.098KB

RCRIT-22V907-2969

 


Subaru – Subarunet Announcement – December 2022

RCMN-22V907-6697.pdf 188.33KB

RCMN-22V907-6697

 


Remedy Instructions and TSB

RCRIT-22V907-1342.pdf 15359.308KB

RCRIT-22V907-1342

 


Latest Recalls Documents

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

 


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

MC-10228778-0001

 


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

MC-10228784-0001

 


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

MC-10228783-0001

 


 

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