Recall - ECM Update For Catalyst Efficiency (Non-Ca.): Overview
NUMBER: WVH-18DATE: June 2009
APPLICABILITY:
2005MY PZEV Spec. Subaru Legacy and Outback
SUBJECT:
Engine Control Module (ECM) Reprogramming
This Campaign only applies to vehicles with motor vehicle registration in the States of California, Massachusetts, Maine, New York and Vermont. For affected vehicles registered in any other state, see Service Program WVI-19.
Introduction
Subaru of America, Inc. (SOA) has determined that vehicles affected by this Service Program require ECM reprogramming along with catalytic converter efficiency testing and possible replacement.
Under certain unique driving patterns, such as repeated acceleration and deceleration and/or continuous uphill driving at higher speeds (about 75 mph), the catalytic converters of affected vehicles may develop high internal temperatures that exceed design parameters. If left uncorrected,
this condition may eventually degrade the efficiency of the catalytic converters. (The "CHECK ENGINE" light will illuminate to alert the driver if catalytic converter efficiency has degraded beyond an acceptable level and the vehicle may be releasing air pollutants which may exceed California standards.) To prevent this condition, a modification to the
Engine Control Module software logic has been developed that will improve management of temperatures within the catalytic converters.
This condition is a software issue and has no impact on vehicle drivability.
AFFECTED VEHICLES
2005 MY Subaru Legacy and Outback with CAL PZEV Spec Emission System and motor vehicle registration in the States of California, Massachusetts, Maine, New York or Vermont only.
Affected vehicles are identified in the following VIN range chart. NOTE: Prior to performing repairs, confirm coverage for potentially affected vehicles by using the Vehicle Coverage Inquiry in the Dealer Communication System (DCS).
OWNER NOTIFICATION
SOA will prepare and mail an Owner Notification Letter to owners of affected vehicles on or around June 15, 2009.
A copy of the Owner Notification Letter is included at the end of this bulletin.
DEALER PROGRAM RESPONSIBILITY
Dealers are to promptly service all vehicles subject to this service program at no charge to the vehicle owner regardless of mileage, age of the vehicle, or ownership.
For affected vehicles sold after the date on the dealer's computer list, dealers are to contact those owners and provide them with a copy of the owner notification letter. They should also arrange to make the required correction according to the instructions in the service procedure section of this bulletin.
Dealers are also to promptly perform the applicable service procedures defined in this bulletin to correct all affected vehicles in their inventory (new, used, 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.
REPAIR PARTS
There is only a small possibility that catalytic converter replacement will be required. Part replacement is only necessary when indicated by the Catalytic Converter Efficiency Test Procedure results described in the Service Procedure section of this bulletin. In order to maintain an adequate part supply, SOA requests that Dealers only order parts necessary to supply anticipated demand -- about 15% of your affected VIN list.
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 icon, which will allow you access the tutorial information.
SERVICE PROCEDURE
This service procedure will involve completing the following three (3) steps:
1) Check ECM memory for diagnostic trouble codes. Clear any codes found after diagnosis is completed.
2) Perform Catalytic Converter Efficiency Testing. Replace applicable pipe assembly only if indicated during Efficiency Test Procedure.
3) Reprogram ECM with updated Pack file.
1) Check ECM memory for diagnostic trouble codes.
Using the appropriate Subaru Diagnostics System (SDS) components, check for stored diagnostic trouble codes as follows:
Select the Select Monitor Icon from the SDS Graphical User Interface (GUI).
The Main Menu will appear
1) Select Each System Check.
2) Select Engine Control System.
3) Select Diagnostic Code(s) Display.
4) Select Memorized Diagnostic Code(s).
5) Search results will appear; proceed as follows:
If no codes are found, proceed to the "Catalytic Converter Efficiency Test Procedure" section of this bulletin.
If trouble codes are found, refer to the table for the correct repair procedure. Make any necessary repairs and clear all codes prior to reprogramming the ECM.
2) Catalytic Converter Efficiency Test Procedure
Note:
The following procedure only applies to vehicles affected by this Service Program and should not be used for any other models.
Check for right and/or left front catalyst deterioration using the SSMIII as follows:
^ Drive the vehicle for more than 3 minutes at 45 mph or less to warm up the catalytic converters.
^ Increase the vehicle speed to 50 through 60 mph and drive at least 5 minutes maintaining a steady throttle. (It is not necessary, but we recommend using the cruise control to maintain a steady throttle.)
^ Prior to turning the ignition off, follow the procedure below to access the "catalyst deterioration index" readings.
1. From main menu of SSMIII, select the Each System Check
2. Select the Engine Control System
3. The following menu window will be displayed
4. At this screen, press the "Alt" + "Ctrl" + "C" Keys at the same time on the SDS Toughbook.
5. The following window should be displayed.
6. Record the following information on the R.O.: Catalyst RH= ?.? and LH= ?.?, indexes, approximate vehicle speed used during test drive, and date the data was recorded (RO date). This information may be required at the time of claim submission.
Note:
If the catalyst readings (RH or LH) are zero, something during the 50mph driving cycle occurred to stop the catalyst test. This could be from not maintaining a speed over 50mph, not keeping the throttle steady, etc. Repeat the driving test cycle.
Once the deterioration index for catalyst 1 (RH) and catalyst 2 (LH) have been determined, proceed as follows:
Plot the intersection of the RH and LH deterioration indexes in the appropriate position of the following Catalyst Deterioration Chart. Determine the correct repair procedure identified in the corresponding field found on the chart and proceed accordingly. In all cases, the ECM
should be reprogrammed with the updated Pack File.
Note:
If the index coordinates intersect directly on the line between Field's proceed as follows:
"A" and "B", Reprogram ECM only.
"A" and "C", Reprogram ECM only.
"B" and "C", replace right catalytic converter only.
"B" and "D", replace right catalytic converter only.
"C" and "D", replace left catalytic converter only.
NOTE:
Catalytic converter(s) should ONLY be replaced when indicated during the Catalytic Converter Efficiency Test Procedure. They should not be replaced for any other reason.
3) ECM Reprogramming Instructions
Note:
ECM reprogramming should be performed after finishing all the procedures below:
1) Diagnosis of trouble codes.
2) Testing of catalytic converter efficiency.
3) Replacement of applicable Pipe Assy and clearing trouble codes, only if necessary.
Confirm your SSMIII contains the April 2009 software update.
Upgrade Version Numbers
^ Software: 1.18.36.11 or higher
^ Interface Box: 1.6.4 or higher
^ Interface Box CF Card: 1.2.45 or higher
Use the following Pack file to reprogram the ECM:m the ECM:
STATE EMISSION TESTING ADVISORY
After ECM reprogramming, the OBD 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 11-72-04, dated 8/4/04 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.
A quantity of labels has been sent to each dealer along with their affected VIN list. Additional labels are available through the Customer Dealer Services Department (CDS).
CALIFORNIA "VEHICLE EMISSION RECALL - PROF OF CORECTION" 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.
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 enter the applicable claim information through their Dealer Communications System.
If catalytic converter replacement was necessary, enter the Catalyst 1 (RH) and 2 (LH) deterioration index readings in the comments field at the time of claim submission.
Disclaimer