WQD-40 – Catalytic Converter Replacement & Engine Control Module (ECM) Reprogramming – 2008-2009 Subaru Legacy, Outback & Forester PZEV

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Bulletin Number: WQD-40; Date: January 2013 Page 1
Continued…
This Campaign applies to vehicles with motor vehicle registration in the following
states:
2008MY: California, Connecticut, Maine, Massachusetts, New York,
Pennsylvania, Rhode Island, and Vermont.
2009MY: California, Connecticut, Maine, Massachusetts, New York,
Pennsylvania, Rhode Island, Vermont, New Jersey, Oregon and Washington.
INTRODUCTION
Subaru of America, Inc. has determined vehicles affected by this Service Program require
front catalytic converter replacement and ECM reprogramming.
For vehicles affected by this Service Program, efficiency of the front catalytic converter may
degrade over time. If the catalytic converter efficiency degrades beyond an acceptable level,
the vehicle may be releasing air pollutants which exceed California standards. To correct this
condition, it will be necessary to replace the front catalytic converter and reprogram the ECM
software logic, improving management of the catalytic converter. This software change will not
adversely affect fuel economy or performance of the vehicle.
AFFECTED VEHICLES
• 2008-2009MY 2.5L PZEV Legacy, Outback and Forester
Affected vehicles are identified in the VIN range chart below. NOTE: Not all vehicles in
the VIN ranges are affected. Prior to performing repairs, confirm coverage by using the
Vehicle Coverage Inquiry function at Subarunet.com. Affected VINs will be added to
the Vehicle Coverage table according to the “Schedule Date” found on page 2 under the
heading “Owner Notification”.
Model From To
2008MY
Legacy Sedan 8*200366 8*227207
Outback 8*300017 8*367425
Forester 8*700009 8*733308
2009MY
Legacy Sedan 9*210001 9*236941
Outback 9*310001 9*348624
Forester 9*700011 9*797855
* Various Characters may occupy this position
NUMBER: WQD-40
DATE: January 2013
APPLICABILITY: 2008-09MY PZEV Legacy,
Outback & Forester
SUBJECT: Catalytic Converter Replacement
& Engine Control Module (ECM)
Reprogramming
SERVICE PROGRAM BULLETIN
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.
Bulletin Number: WQD-40; Date: January 2013 Page 2
Continued…
OWNER NOTIFICATION
SOA will prepare and mail Owner Notification Letters to owners of affected vehicles
according to the following schedule:
Model
Year
Vehicle
Registration
State
Vehicle Transmission Schedule Date
2008
CA Legacy & Outback AT 1/14/13
CA Legacy & Outback MT **
CA Forester AT & MT **
Other CA
Emission States **
2009
CA Legacy & Outback AT 1/14/13
CA Legacy & Outback MT **
CA Forester AT & MT **
Other CA
Emission States **
** Refer to the phase-in table found on pg. 9 for more information regarding the owner
notification schedule dates.
A copy of the owner notification letter can be found starting on pg. 7 of this Bulletin.
DEALER PROGRAM RESPONSIBILITY
Dealers are to promptly perform the applicable service procedures defined in this bulletin to
correct all affected vehicles in their inventory (new, used and demo). Additionally, whenever
a vehicle subject to this Service Program is taken into dealer new or used inventory, or is in
the dealership for service, necessary steps should be taken to ensure the Service Program
correction has been made before selling or releasing the vehicle.
New or used vehicles listed in a Service Program that are in dealer 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 this Service Program
Bulletin
PARTS INFORMATION
Catalytic converter replacement will be required.
Due to limited part availability, dealers are requested to order catalytic converter kits as
needed. It is suggested parts be ordered at the time a customer contacts a dealer to schedule an
appointment. This will ensure the necessary parts are available on the day a customer brings
their vehicle in for service.
Model Description Part Number
All WQD40 Catalytic Converter Kit SOA635112
Bulletin Number: WQD-40; Date: January 2013 Page 3
Continued…
The kit contains the following components:
Quantity Description Part Number
1 Pipe Comp-Exh Fr 44620AD99A
1 Gskt & Seal Set-Eng 10105AB600
SPECIAL TOOLS
Vehicle ECM reprogramming will require the following:
Subaru Diagnostic System (SDS)
• SDS Toughbook
• Subaru Select Monitor III (SSMIII Application Software)
• Subaru Diagnostic Interface Box (SDI)
• USB Data Link Cable and Reprogramming Cable.
Note: If you require assistance with using the Subaru Diagnostic System (SDS), use the
“Help” function, which will allow you to access the tutorial information.
SERVICE PROCEDURE
• This service procedure involves replacement of the front catalytic converter
assembly and reprogramming of the ECM with updated logic to correct an OBDII
system deficiency.
• The catalytic converter must be replaced BEFORE reprogramming the ECM.
• IMPORTANT: Both procedures must be done during the same repair visit.
1. Front Catalytic Converter Replacement
Replace the front catalytic converter following the procedures outlined in the applicable
Subaru Service Manual and any related Technical Service Bulletins. When replacing the
converter, the A/F and O2 sensors should be reused.
Note: To avoid potential damage to the threaded portions of the sensors, allow the converter
to cool down before attempting to remove them. Application of a spray-type penetrating
lubricant to the thread areas and allowing it to soak in for at least a minute or more is
recommended to help ease sensor removal. Be sure to wipe away all excess lubricant. Before
installing the sensors into the replacement converter, application of a small amount of nickle
based anti-seize compound to the sensor threads is also recommended.
2. ECM Reprogramming Instructions
Information regarding ECM reprogramming procedures can be found by accessing the Help
menu located at the top of the Main Menu screen of the SSMIII application.
• Verify the status of the “CHECK ENGINE” malfunction indicator light (MIL)
located on the vehicle’s instrument cluster.
• If no malfunction is indicated, proceed with reprogramming the ECM.
• If a malfunction is indicated by the MIL remaining continually “on” or “flashing”,
diagnose the cause and perform any necessary repairs. Once repairs have been
completed, clear all DTCs then reprogram the ECM.
Bulletin Number: WQD-40; Date: January 2013 Page 4
Continued…
NOTES:
• In the event the cause of the check engine light illumination is not covered by
applicable warranties, the cost of repairs is the vehicle owner’s responsibility.
• Under no circumstances should the ECM be reprogrammed until the proper
corrections have been made and the catalytic converter replaced.
Confirm your SSM III contains the applicable SSMIII FlashWrite File Update which includes
the reprogramming PAK files shown in the chart below. PAK files will be released and
automatically sent electronically to dealer equipment on or prior to the dates indicated in the
“Date Available” column found in the following table.
Version Numbers
• Software: 1.36.50.7 or later
• Interface Box: 1.7.7 or later
• Interface Box CF Card: 1.8.0 or later
For the WQD-40 Service Program, special Look-Up CID Numbers have been established to
identify proper Pack File applicability. New ECM / Pack File Part Numbers and the tentative
availability dates are also included in the chart below.
IMPORTANT: The Pack Files for this Service Program will not appear when searching
FlashWrite if the current ECM CID number or Vehicle Spec. parameters are used. These files
are only accessible by using the Look-Up CID Numbers from the chart below.
Model
Year Vehicle
Engine /
Emission
Spec.
Transmission
Type
Look-Up
CID Number
for WQD-40
New ECM/Pack
File Part Number
Date
Available
2008
Legacy &
Outback
2.5L NA CA
Spec. PZEV
4AT WQD4005 22611BC05A.pak 1/14/2013
5MT WQD4004 22611BC04A.pak 2/25/2013
Forester 2.5L NA CA
Spec. PZEV
4AT WQD4007 22611BC070.pak TBD
5MT WQD4006 22611BC060.pak TBD
2009
Legacy &
Outback
2.5L NA CA
Spec. PZEV
4AT WQD4005 22611BC05A.pak 1/14/2013
5MT WQD4004 22611BC04A.pak 2/25/2013
Forester 2.5L NA CA
Spec. PZEV
4AT WQD4009 22611BC090.pak TBD
5MT WQD4008 22611BC080.pak TBD
Bulletin Number: WQD-40; Date: January 2013 Page 5
Continued…
Once the applicable Pack File has been identified, proceed with the remainder of the
established ECM reprogramming procedure.
These Pack Files are to be used solely for completion of the WQD-40 Service
Program.
NOTE: Should the ECM become inoperative or un-responsive during the
reprogramming procedure;
1. Disconnect both the positive (+) and negative (-) battery terminals for at least
2 or more seconds.
2. Touch the cable ends together for a few moments, and then re-connect the
terminals to the battery.
3. Start the reprogramming procedure over again from the beginning.
STATE EMISSION TESTING ADVISORY
After ECM reprogramming, the OBDII system’s readiness code monitors will set to
“incomplete”. Normally, the vehicle needs to be driven under a variety of conditions before
the readiness code monitors will indicate “complete”. (See State I/M Program Advisory
Bulletin number 11-120-12, dated 9-20-2012 for details.)
SERVICE PROGRAM IDENTIFICATION LABEL
Type or print the necessary information on a Service Program identification label. The
completed label should be attached to the vehicle’s upper radiator support.
Additional labels are available through the Subaru Claims Helpline at 1-866-782-2782.
WQD-40
Bulletin Number: WQD-40; Date: January 2013 Page 6
Continued…
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 the Subaru Claims Helpline at 1-866-782-2782.
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES
Credit to perform this service program will be based on the submission of properly
completed repair order information. Dealers may submit claims through Vehicle Claim
Entry on Subarunet.com.
LABOR DESCRIPTION LABOR
OPERATION
CLAIM
TYPE FAIL CODE LABOR
TIME
Catalytic Converter
Replacement and
ECM Reprogramming
A143-601 RC WQD-40 0.9
Bulletin Number: WQD-40; Date: January 2013 Page 7
Continued…
OWNER NOTIFICATION LETTER
Subaru of America, Inc.
Subaru Plaza
P.O. Box 6000
Cherry Hill, NJ 08034-6000
www.subaru.com
Dear Subaru Owner:
We would like to thank you for your selection of a 2008-2009 model year Subaru Legacy,
Outback or Forester vehicle equipped with a 2.5 Liter engine and a California Partial Zero
Emission Vehicle (PZEV) system. At Subaru, we take pride in our products and are committed
to your continued satisfaction.
Subaru has determined that the efficiency of your vehicle’s front catalytic converter may
degrade over time. If the catalytic converter efficiency degrades beyond an acceptable level,
your vehicle may be releasing air pollutants that exceed California standards. To correct this
condition, Subaru will replace the front catalytic converter and reprogram the Engine Control
Module software logic to improve management of the catalytic converter. This software
change will not adversely affect fuel economy or the performance of your vehicle.
WHAT WE ARE ASKING YOU TO DO PROMPTLY
We ask that you schedule an appointment with your Subaru Dealer as soon as possible to have
your vehicle’s front catalytic converter replaced and Engine Control Module software reprogrammed.
Doing so will help ensure your vehicle’s full protection under the emission warranty
as failure to do so may be considered a lack of proper maintenance. This will take approximately
1 hour to complete. However, it may be necessary for you to leave your car longer on
the day of your appointment to allow your dealer flexibility in scheduling. Your Subaru dealer
will perform this modification at no cost to you.
Please present this letter to your Subaru Dealer on the day of your service appointment.
CALIFORNIA REGISTERED OWNERS
The California Air Resources Board requires that emission related campaigns be completed
prior to California’s vehicle registration renewal process; without this repair, you will not
be able to register your vehicle during your next annual registration. Upon completion of
this campaign, your California dealer will complete and provide you a “Proof of Correction
Certificate.” If required, present the certificate to the California Department of Motor
Vehicles (the “DMV”) when renewing your California registration as proof of campaign
completion. If the DMV does not request the certificate, we recommend that you keep it for
your records.
Service Program WQD-40
Engine Control Module Reprogramming
Vehicles Registered in the States of
CA, CT, MA, ME, NJ, NY, OR, PA, RI, VT, WA
January 2013
Bulletin Number: WQD-40; Date: January 2013 Page 8
Continued…
In addition, the State of California requires that every vehicle must pass an emission test
(SMOG Check) every two years and before it is sold. Without the service we are providing at
no charge, your vehicle may not pass this test.
CHANGED YOUR ADDRESS OR SOLD YOUR SUBARU?
If you have changed your address, or if you have sold your Subaru, 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 Contact Us then select Update Address from the drop
down menu.
IF YOU NEED FURTHER ASSISTANCE
To locate the nearest Subaru Dealer you can access our website at www.subaru.com and select
“Find a Dealer”.
For additional information and the most Frequently Asked Questions, please go to:
• http:////www.wqd40.service-campaign.com
If you need additional assistance, please contact us directly:
• 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
• E-mail: Go to www.subaru.com and select “Contact Us”.
• U.S. Postal mail: Write us at Subaru of America, Inc., Attn: CDS Department,
P.O. Box 6000, Cherry Hill, NJ 08034-6000.
Please contact us immediately if the dealer fails or is unable to make the necessary repairs
free of charge.
Your continued satisfaction with Subaru is important to us. This update is intended to ensure
your vehicle’s optimal performance. We appreciate your understanding in this matter and
regret any inconvenience this may cause you.
Sincerely,
Subaru of America, Inc.
Notice to Lessors: The lessor of a vehicle who receives this letter is requested to provide a copy of it to the vehicle lessee(s)
within 10 business days from receipt. The lessor should 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.
Bulletin Number: WQD-40; Date: January 2013 Page 9
Continued…
PHASE-IN TABLE
STATE MY CARLINE TRANS
Phase 1 (1/14/13)
CA 2008 Legacy Auto
CA 2009 Legacy Auto
CA 2008 Outback Auto
CA 2009 Outback Auto
Phase 2 (2/25/13)
MA 2008 Outback Auto
OR 2009 Legacy Auto
OR 2009 Outback Auto
WA 2009 Legacy Auto
WA 2009 Outback Auto
Phase 3 (3/18/13)
CA 2008 Legacy Manual
CA 2009 Legacy Manual
CA 2008 Outback Manual
CA 2009 Outback Manual
CT 2008 Legacy Auto
CT 2009 Legacy Auto
CT 2008 Outback Auto
CT 2009 Outback Auto
MA 2008 Legacy Auto
OR 2009 Legacy Manual
OR 2009 Outback Manual
WA 2009 Legacy Manual
WA 2009 Outback Manual
Phase 4 (4/15/13)
CA 2008 Forester Auto
CA 2008 Forester Manual
CT 2008 Legacy Manual
CT 2009 Legacy Manual
CT 2008 Outback Manual
CT 2009 Outback Manual
MA 2008 Forester Auto
MA 2008 Forester Manual
MA 2008 Legacy Manual
MA 2009 Legacy Auto
MA 2009 Legacy Manual
MA 2008 Outback Manual
MA 2009 Outback Auto
MA 2009 Outback Manual
Bulletin Number: WQD-40; Date: January 2013 Page 10
Continued…
STATE MY CARLINE TRANS
Phase 5 (5/13/13)
CA 2009 Forester Auto
OR 2009 Forester Auto
OR 2009 Forester Manual
Phase 6 (6/17/13)
CA 2009 Forester Manual
CT 2008 Forester Auto
CT 2008 Forester Manual
ME 2008 Legacy Manual
ME 2009 Legacy Manual
ME 2008 Outback Manual
ME 2009 Outback Manual
WA 2009 Forester Auto
WA 2009 Forester Manual
Phase 7 (7/15/13)
CT 2009 Forester Auto
MA 2009 Forester Auto
Phase 8 (8/12/13)
CT 2009 Forester Manual
MA 2009 Forester Manual
ME 2008 Forester Auto
ME 2008 Forester Manual
ME 2009 Forester Auto
ME 2009 Forester Manual
NJ 2009 Forester Auto
NJ 2009 Forester Manual
Phase 9 (9/16/13)
ME 2008 Legacy Auto
ME 2009 Legacy Auto
ME 2008 Outback Auto
ME 2009 Outback Auto
NJ 2009 Legacy Auto
NJ 2009 Legacy Manual
NJ 2009 Outback Auto
NJ 2009 Outback Manual
NY 2008 Forester Auto
NY 2008 Forester Manual
PA 2008 Legacy Manual
PA 2009 Legacy Manual
PA 2008 Outback Manual
PA 2009 Outback Manual
Bulletin Number: WQD-40; Date: January 2013 Page 11
Continued…
STATE MY CARLINE TRANS
Phase 10 (10/14/13)
NY 2009 Forester Auto
PA 2008 Forester Auto
PA 2008 Forester Manual
Phase 11 (11/11/13)
NY 2009 Forester Auto
NY 2009 Forester Manual
NY 2008 Legacy Manual
NY 2009 Legacy Manual
NY 2008 Outback Manual
NY 2009 Outback Manual
RI 2008 Legacy Auto
RI 2008 Legacy Manual
RI 2009 Legacy Auto
RI 2009 Legacy Manual
RI 2008 Outback Auto
RI 2008 Outback Manual
RI 2009 Outback Auto
RI 2009 Outback Manual
VT 2008 Legacy Manual
VT 2009 Legacy Manual
VT 2008 Outback Manual
VT 2009 Outback Manual
Phase 12 (12/9/13)
NY 2008 Outback Auto
RI 2008 Forester Auto
RI 2008 Forester Manual
RI 2009 Forester Auto
RI 2009 Forester Manual
VT 2008 Forester Auto
VT 2008 Forester Manual
VT 2009 Forester Auto
VT 2009 Forester Manual
Phase 13 (1/13/14)
NY 2008 Legacy Auto
NY 2009 Legacy Auto
PA 2009 Outback Auto
VT 2008 Legacy Auto
VT 2008 Outback Auto
Bulletin Number: TBD; Date: January 2013 Page 12
STATE MY CARLINE TRANS
Phase 14 (2/10/14)
NY 2009 Outback Auto
PA 2008 Outback Auto
VT 2009 Legacy Auto
VT 2009 Outback Auto
Phase 15 (3/10/14)
PA 2009 Forester Auto
PA 2009 Forester Manual
Phase 16 (4/7/14)
PA 2008 Legacy Auto
PA 2009 Legacy Auto

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Subarunet Announcement
To: All Subaru Dealers
From: Subaru of America, Inc.
Date: January 10, 2013
Subject: Subaru Service Program WQD-40: Front Catalytic Converter Replacement & Engine Control Module (ECM) Reprogramming
This Campaign applies to PZEV Legacy, Outback & Forester vehicles with motor vehicle registration in the following states:
2008MY: California, Connecticut, Maine, Massachusetts, New York, Pennsylvania, Rhode Island, and Vermont.
2009MY: California, Connecticut, Maine, Massachusetts, New York, Pennsylvania, Rhode Island, Vermont, New Jersey, Oregon and Washington.
Subaru of America, Inc. has determined that vehicles affected by this Service Program require front catalytic converter replacement and ECM reprogramming.
For vehicles affected by this Service Program, efficiency of the front catalytic converter may degrade over time. If the catalytic converter efficiency degrades beyond an acceptable level, the vehicle may be releasing air pollutants that exceed California standards. To correct this condition, it will be necessary to replace the front catalytic converter and reprogram the Engine Control Module software logic which improves management of the catalytic converter. This software change will not adversely affect fuel economy or performance of the vehicle.
Replacement parts and ECM reprogramming PAK files will not be available for all models at the time this Service Program is initially released. PAK files will be available in accordance with the schedule found on page 4 of the WQD-40 bulletin. Additionally, because this program affects a high volume of vehicles within the affected states, mailing of owner notification letters will be phased according to the following schedule. This schedule coincides with replacement part and PAK file availability.
Model Year
Vehicle Registration State
Vehicle
Transmission
Scheduled Date
2008
CA
Legacy & Outback
AT
1/14/13*
CA
Legacy & Outback
MT
2/25/13
CA
Forester
AT & MT
TBD
Other CA Emission States
TBD
2009
CA
Legacy & Outback
AT
1/14/13*
CA
Legacy & Outback
MT
2/25/13
CA
Forester
AT & MT
TBD
Other CA Emission States
TBD
* Included with the January version of SSMlll released to all dealers on 1/4/13.
Additional Information Concerning this Service Program:
•
Service Program Bulletin: The WQD-40 bulletin will be posted on the Techinfo.Subaru.com website on 1/10/13. The Bulletin contains additional information concerning identification of affected vehicles, reprogramming procedures, and claim submission procedures.
•
Reprogramming software: PAK files will be released in accordance with the schedule found on page 4 of the WQD-40 bulletin.
Thank you for your cooperation in this matter.
Subaru of America, Inc.

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