Recall - Side Curtain Air Bag Module Replacement: Overview
NUMBER: WWR-02DATE: 06/2004
APPLICABILITY:
2005MY Legacy Sedan and Outback Sedan Vehicles
SUBJECT:
Side Curtain Air Bags
INTRODUCTION
Subaru of America, Inc. (SOA) has determined that affected vehicles, listed below, were produced with a Side Curtain Air Bag that may not fully deploy rapidly enough when activated in a side impact collision.
This recall will involve replacement of both Side Curtain Air Bag models.
AFFECTED VEHICLES
OWNER NOTIFICATION
SOA will contact owners of affected vehicles by telephone when repair parts become available at dealers. A notification letter will also be sent on or around June 14, 2004. A copy the Owner notification letter is shown in this bulletin.
DEALER PROGRAM RESPONSIBILITY
Dealers are to promptly service all vehicles subject to this recall at no charge to the vehicle owner reguardless 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.
VEHICLES IN DEALER INVENTORY
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 recall is taken into dealer new or used inventory, or is in the dealership for service, necessary steps should be taken to ensure the recall correction has been made before selling or releasing the vehicle.
New or used vehicles listed in a recall/campaign that are in dealer stock must be:
^ Immediately identified
^ Tagged or otherwise marked to prevent their delivery or use prior to inspection and/or repair
^ Repaired in accordance with the repair procedures outlined in this Product Campaign Bulletin
Any Authorized Subaru Dealer failing to perform the applicable service procedures defined in this bulletin to correct all affected vehicles in their inventory (new, used, demo) prior to the vehicle being placed in service may be subject to civil penalties of up to $5,000 per violation (i.e., for each vehicle), as provided in 49 USC �30165(a) of the Safety Act, and will also be in breach of the Subaru Dealer Agreement.
PARTS INFORMATION
REPAIR PROCEDURES
Tools & Equipment Needed:
1. Clip Tool
2. 1/4" Drive 10 mm Socket
3. 1/4" Drive Ratchet
4. 1/4" Drive 6" Extension
5. # 2 Phillips Screw Driver
6. Small Mini Screwdriver and/or Plastic Trim Stick
7. Air/Battery Gun or Ratchet
8. Torque Wrench (capable of 5.5 ft.lb spec or 66 in.lb)
9. 10 mm Open End Wrench
10. Vacuum Cleaner
11. Protective Covers for Seat, Door Pad, and Instrument Panel
12. Disposable Gloves
NOTE:
Before beginning, ensure your clothing and hands are free from dirt and grease. Find a clear and clean area to lay removed trim parts to avoid dirt getting on these parts.
The reverse side of the Headliner Trim Panel has a pressed fiberglass layer. The residue from this layer may cause irritations to the skin and may leave dust inside the interior of the vehicle. Please wear protective gloves to keep fiberglass away from skin and to keep trim clean. Remove gloves after retrofit is complete and thoroughly vacuum the entire interior of the vehicle.
Disassembly
Use extreme care when removing, positioning and storing trim parts to avoid damaging them. Be careful to keep all interior parts clean.
Pay close attention to the original position of all trim panels and weather strips to maintain fit & finish.
1. Open hood and all doors. Lower all windows.
2. Record radio stations.
3. Disconnect "Negative" Battery Cable from Battery Terminal.
^ Be careful not to touch Battery Cable to metal objects.
^ Be careful of Battery Terminal grease.
4. Remove the A-Pillar upper trim covers. Start by pushing the metal tab with a flat blade screwdriver or similar tool to release the top portion. Next, gently pull on the trim to disengage the lower clip.
Note:
If the metal clip is damaged during removal, the A-Pillar trim must be replaced.
5. Remove the Sun Visors by carefully removing the covers and the mounting screws. If equipped with vanity mirror lights, disconnect the wiring connector. Remove the Sun Visor Hooks by pressing the (A) on both sides, using a flat tip screwdriver and pulling the hook towards you.
6. Remove the Map Light Lens, Map Light Screws, and disconnect all wiring connectors. If equipped, disconnect wiring connector for Sun Roof.
7. If equipped, remove the Sun Roof Garnish.
8. Remove front & rear Assist Grips by carefully removing the covers and screws. Pull the left side of assist grip toward you, and rotate the right side of it counterclockwise to remove.
9. Remove B-Pillar lower trim covers (it will stay attached to the Seat Belt) and position it safely out of the way to avoid damaging it or other interior parts.
10. Remove B-Pillar upper trim by carefully removing the cap on the upper portion of the pillar trim. Remove the bolt.
11. Remove center interior Room Light Lens, Room Light, and disconnect wiring connector.
12. Remove C-Pillar upper trim and trim cover.
(1) Carefully pull on trim cover to gain access to the metal clip. Slide a mini screwdriver under metal tab and push upward to disengaged clip. Carefully remove trim cover.
^ Removal of this trim can be accomplished without removal of the rear seat, however removal is easier with the rear seat removed.
^ If you leave the rear seat installed, to ease removal of upper C-Pillar trim bolts, remove rear seatback Headrests LH/RH and lay aside.
(2) Carefully remove the cap on the upper portion of the C-Pillar trim. Remove the 4 Bolts to remove the trim.
13. Disconnect the antenna lead at the connector located by the driver's side C-Pillar.
14. Reconnect "Negative" Battery cable. (Power Seat equipped vehicles only).
15. Position Front Seats and Seat Back to a position that can provide some support to the Headliner when it is lowered in later steps.
16. Unclip the 3 clips holding the rear of the Headliner near the rear window.
17. Slide Front of Headliner to the passenger side slightly to release the clip in the front of the Headliner. Gently lower the Headliner while releasing any wires from the retaining clips on the Headliner.
18. Disconnect the "Negative" Battery cable from the Battery Terminal.
IMPORTANT:
Make sure battery is disconnected for at least 30 seconds before moving to next step.
19. Disconnect Side Curtain Air Bag electrical connections (located at the rear end of the Side Curtain Air Bag Assembly).
How to disconnect:
(1) Push the lock arm (A).
(2) With the lock arm (A) pushed in, move the slide lock (B) in the direction of arrow.
(3) With the slide lock moved, release the lock arm (back to its original position), and disconnect the connector.
CAUTION:
When pulling the side lock or disconnecting the connector; be sure to hold onto the connector and not the wire.
20. Remove both Side Curtain Air Bags - (9 bolts each side - Sunroof Model); (8 bolts each side - Non Sunroof Model). Remove the bolts (A) and clip (B), and then remove the Side Curtain Air Bag module.
Important:
^ Start with the front end of the Side Curtain Air Bag and move towards the rear.
^ Be careful not to disturb the routing of the Sun Roof Drain tubes (if equipped).
^ Be careful when removing bolts, that the metal brackets which are part of the Side Curtain Air Bag Assembly do not damage seat covers or other interior trim parts as they fall to a lower position. You might want to tape or secure a rag to the end brackets for protection.
^ Be careful not to mix the Side Curtain Air Bag bolts with other trim part bolts. Use the same bolts for reinstalling the new Side Curtain Air Bag.
Side Curtain Air Bag Installation
NOTE:
Retain the packaging that the new Side Curtain Air Bag was shipped in. It will be required for returning the removed parts.
21. Install Side Curtain Air Bag.
^ Start with the rear bolts and move forward.
^ Torque Side Curtain Air Bag Bolts to 5.5 ft.lb.
^ Connect Side Curtain Air Bag electrical connectors.
How to connect:
Holding the connector, push it in carefully until a connecting sound is heard.
CAUTION:
Be sure to insert the connector in until it is locked. Then pull on it gently to make sure that it is locked.
Assembly
Assembly can be accomplished by reversing the order of the disassembly (with the exception of the "Negative" Battery Cable steps, as noted).
22. Vacuum Interior of Vehicle.
^ Remove gloves before re-entering vehicle to remove all fiberglass residue on Seats, Carpet and Interior Trim, including Instrument Panel.
23. Check operation of interior lighting: Center Room Lamp, Map Lights, and Sun Visor Vanity Lights. Check Sun Roof operation if equipped.
24. Verify Air Bag System operation by turning key on and confirming Air Bag System Warning Lamp goes out after 6 seconds.
25. Reset Radio stations and clock. Verify radio reception.
RECALL CAMPAIGN IDENTIFICATION LABEL
Type or print the necessary information on a Recall Campaign identification label. The completed label should be attached to the vehicle's upper radiator support.
CLAIM REIMBURSEMENT AND ENTRY PROCEDURES
Credit for performing this recall campaign will be based on the submission of properly completed repair order information. Dealers may enter the applicable claim information through their Dealer Communications System.
Enter the applicable part number shown. Parts will be reimbursed at dealer cost plus applicable handling allowance.
Disclaimer