DTC P2404/Reprogramming Files (09-109-23)

Publication date: 2023-07-25
Reference number: 09-109-23

DTC P2404/REPROGRAMMING FILES

TECHNICAL SERVICE BULLETIN

Reference Number(s): 09-109-23, Date of Issue: July 25, 2023

SUBARU:

2016-19MY Legacy & Outback

APPLICABILITY

2016-19MY Legacy & Outback

INTRODUCTION

This bulletin announces diagnostic procedures along with availability of new Engine Control Module (ECM) reprogramming files to address DTC P2404 (Evap System Leak Detection Pump Sensor Circuit Range/Performance) detection. In rare cases, condensation can accumulate within the internal pump for the Evaporative Leak Check Module (ELCM) causing improper operation. The new logic incorporates a cleaning mode for the ELCM pump to provide added protection. If P2404 is found stored in the ECM memory, follow the procedures outlined below.

PAK FILE APPLICABILITY

Model	MY	Spec.	File Name	Old Part Number	Decryption Keyword	New CID #
Legacy & Outback	16	2.5L NA, MT	22765AJ13G.pak	22765AJ13A 22765AJ13B 22765AJ13C 22765AJ13D 22765AJ13E 22765AJ13F	81D16D74	EB4I360A
	16	2.5L NA, CVT	22765AJ14G.pak	22765AJ14A 22765AJ14B 22765AJ14C 22765AJ14D 22765AJ14E 22765AJ14F	9FBD8A92	EB4I360C
	16	2.5L NA, CVT	22765AJ15G.pak	22765AJ15A 22765AJ15B 22765AJ15C 22765AJ15D 22765AJ15E 22765AJ15F	3ADF94F5	EB4I360B
	16	3.6 L NA, CVT	22765AJ17F.pak	22765AJ17A 22765AJ17B 22765AJ17C 22765AJ17D 22765AJ17E	0601B6A4	DB4I360D
Legacy & Outback	17	2.5L NA, CVT	22765AK49H.pak	22765AK49A 22765AK49B 22765AK49C 22765AK49D 22765AK49E 22765AK49F 22765AK49G	6217255B	EB4I560A
	17	2.5L NA, CVT	82201AK48H.pak 22765AK48H.pak	22765AK48A 22765AK48B 22765AK48C 22765AK48D 22765AK48E 22765AK48F 22765AK48G	5F49B685	EB4I560C
	17	2.5L NA, CVT	22765AK50H.pak	22765AK50A 22765AK50B 22765AK50C 22765AK50D 22765AK50E 22765AK50F 22765AK50G	DAEEA764	EB4I560B
	17	3.6 L NA, CVT	22765AK31G.pak	22765AK31A 22765AK31B 22765AK31C 22765AK31D 22765AK31E 22765AK31F	82CDECD6	DB4I560D
	18	2.5L NA, CVT	82201AK85E.pak 22765AK89E.pak	22765AK85A 22765AK85B 22765AK85C 22765AK85D	DF9B30D7	EB4T800C
	18	3.6 L NA, CVT	22765AK89E.pak	22765AK89A 22765AK89B 22765AK89C 22765AK89D	E319774E	DB4T800D
	19	2.5L NA, CVT	22765AN06D.pak	22765AN06A 22765AN06B 22765AN06C	12D316B6	EB4VA00C
	19	3.6 L NA, CVT	82201AN11E.pak 22765AN11E.pak	22765AN11A 22765AN11B 22765AN11C	FB343B30	DB4VA00D

Service Procedure Flowchart

SERVICE PROCEDURE/INFORMATION

STEP 1: Using Subaru Select Monitor (SSM), check for diagnostic trouble codes P2404. Confirm P2404 is stored and proceed to the next step.

STEP 2: Are any of the diagnostic trouble codes listed below also stored withing the ECM?

P2419 - Evap System Switching Valve Control Circuit Low
P2420 - Evap System Switching Valve Control Circuit High
P2401 - Evap System Leak Detection Pump Control Circuit Low
P2402 - Evap System Leak Detection Pump Control Circuit High
P24BA - Evap System Leak Detection Pump Pressure Sensor Circuit Low
P24BB - Evap System Leak Detection Pump Pressure Sensor Circuit High
P24B9 - Evap System Leak Detection Pump Pressure Sensor Circuit Range/Performance

NO - Proceed to STEP 3.

YES - Perform diagnosis following the applicable Service Manual. Once repaired, perform the reprograming procedure outlined in STEP 11.

STEP 3: 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. CAREFULLY disconnect the ground terminal from the battery sensor.

STEP 4: Remove the left rear wheel and mud guard. Refer to STIS: Body & Electrical/WIRING SYSTEM > EXTERIOR/INTERIOR TRIM > Mud Guard

STEP 5: CAREFULLY disconnect the ELCM drain tube. Inspect for signs of water or oil.

Have signs of water or oil been detected withing the ELCM drain tube?

YES - Clean and dry the drain tube using a non-alcohol base cleaner. Proceed to STEP 6.

NO - Proceed to STEP 6.

STEP 6: Connect the vehicle to a recommended power supply. See APPENDIX A for addition information regarding power supply. Using SSM, perform the Evaporative System Leak Test. Collect and save all data.

Once the evaporative system leak test is complete, check the DTCs and examine the vacuum value results. Record the value shown in the row labeled MID: $3C, TID: $C4, and Scaling ID: $FE. This value should be lower than -0.26 PSI.

Is DTC P2404 stored within the ECM?

NO - Proceed to STEP 7.

YES - Proceed to STEP 8.

STEP 7: Was the vacuum value result observed in STEP 6 found to be lower than -0.26 PSI?

YES - Proceed to STEP 11.

NO - Proceed to STEP 8.

STEP 8: Using SSM, perform the ELCM Pump Active Test for a period of 35 minutes or more. See APPENDIX A for addition information regarding power supply.

Once the ELCM Pump Active Test has been performed for a period of 35 minutes or more, repeat the Evaporative System Leak Test outlined in STEP 6. Check the DTCs and the vacuum value results.

Is DTC P2404 stored within the ECM?

NO - Proceed to STEP 9.

YES - Proceed to STEP 10.

STEP 9: Was the vacuum value result observed during the second Evaporative System Leak Test found to be lower than -0.26 PSI?

YES - Proceed to STEP 11.

NO - Proceed to STEP 10.

STEP 10: Replace the Evaporate Leak Check Module and repeat the Evaporative System Leak Test outlined in STEP 6. Check the DTCs and the vacuum value results.

Is DTC P2404 stored within the ECM?

NO - Proceed to STEP 11.

YES - Contact Subaru Techline with ability to provide SSM data and the testing results attained using this bulletin.

STEP 11: Reprogram the ECM following the normal FlashWrite procedure. See APPENDIX A for addition information regarding power supply.

WARRANTY/CLAIM INFORMATION

For vehicles within the Basic New Car Limited, an applicable Emission Warranty period or covered by an active Subaru Added Security Classic or Gold plan, this repair may be submitted using thefollowing claim information:

Labor Description	Labor Operation #	Labor Time	Fail Code
ECM REPROGRAMMING & DRAIN TUBE CLEAN/EVAP TESTING	A455-223	1.0H	UPG-48
LEAK CHECK MODULE R&R AND ECM REPROGRAMMING	A455-244	1.9H	UPG-48

IMPORTANT: Always note the original Calibration Identification number (CID) the vehicle came in with on the repair order before reprogramming and, make sure to list the NEW CID for any newly-installed programming (as confirmed from the actual control module AFTER installation). The NEW CID MUST also be noted on the repair order as this information is required for entry in the claim specific data field during claim submission.

NOTE: The PAK file listings provided in this bulletin are the latest available at the time of publishing. Updates are often released thereafter without revision to the original bulletin. For this reason, it is critical to always have the latest version of Select Monitor software installed on your system. You can confirm if a later version is available by entering the CID listed in this bulletin into FlashWrite. If a newer CID is shown as available in FlashWrite, reprogram using that file.

IMPORTANT REMINDERS:

SOA strongly discourages the printing and/or local storage of service information as previously released information and electronic publications may be updated at any time.
Always check for any open recalls or campaigns anytime a vehicle is in for servicing.
Always refer to STIS for the latest service information before performing any repairs.

APPENDIX A

Subaru of America, Inc. (SOA) highly recommends utilizing either the Subaru Midtronics DCA8000 Dynamic Diagnostic Charging System or the Subaru Midtronics GR8-1100 Diagnostic Battery Charger to the vehicle in the Power Supply Mode feature anytime a vehicle control module is being reprogrammed. Once the Midtronics charger is connected to the vehicle, if the battery is fully charged, it will take less than three (3) minutes to boot-up the charger, select the Power Supply Mode, and have the battery voltage stabilized and ready for reprogramming.

NOTE:

For instructions on using the Power Supply Mode, reference the applicable User Manual for the Midtronics DCA-8000 Dynamic Diagnostic Charging System and the Midtronics GR8-1100 Diagnostic Battery Charger on STIS.
Confirm all electrical loads such as lights, audio, HVAC, seat heaters, and rear defroster are all switched OFF before setting up the charger for Power Supply Mode.
Select the correct battery type (Enhanced Flooded, Flooded, Gel, AGM or AGM Spiral).
Input the CCA which matches the vehicle's battery.
NOTE: OE and replacement batteries have different CCA ratings. Always confirm the battery's CCA rating before proceeding.
If using a DCA-8000 Dynamic Diagnostic Charging System, set the power supply voltage to 13.5 Volts.
DO NOT connect the DST-i or DST-010 until the Power Supply mode function has completed its battery test mode and the Charging Voltage has dropped to and shows a steady 13.5 Volts on the display.
Once Power Supply Mode reaches a steady 13.5 Volts, connect the DST-i or DST-010 to the OBD connector and proceed with initiating the normal FlashWrite reprogramming process.
Amperage will fluctuate based upon the vehicle's demand for power.
NOTE: If the voltage rises beyond 14 Volts while programming is in process, the procedure will abort. This can indicate a need to test or charge the vehicle battery before any further attempt at programming is made.
ALWAYS set the power supply voltage to 13.5 Volts when using Power Supply Mode. NEVER turn the ignition switch on when charging at voltages 15 Volts or higher.

REMINDER: If the DCA-8000 or GR8-1100 indicates the vehicle's battery must be charged, charge the battery fully before proceeding to reprogram the vehicle while using the Power Supply Mode.

NOTE: Control module failures resulting from battery discharge during reprogramming are not a matter for warranty. Should any DTCs reset after the reprogramming update is performed, diagnose per the procedure outlined in the applicable Service Manual.

VERY IMPORTANT:

This information is applicable to the Subaru Midtronics DCA-8000 Dynamic Diagnostic Charging System and the Subaru Midtronics GR8-1100 Diagnostic Battery Charger ONLY . It does not apply to any other brand/type of "generic" battery charger whatsoever. ONLY the DCA-8000 and the GR8-1100 and their Power Supply Mode feature have been tested and approved by SOA.