Headlight Water Intrusion/Design Changes (07-202-23)

HEADLIGHT WATER INTRUSION/DESIGN CHANGES

TECHNICAL SERVICE BULLETIN

APPLICABILITY

2019-21MY Forester

INTRODUCTION

This bulletin announces the design changes to the headlights. The new assemblies are fitted with an extended flange on the housing along with an increased amount of adhesive added to provide optimum sealing. These changes reduce the chance of moisture entering the headlights. The headlight(s) should be replaced if water intrusion is found.

PRODUCTION CHANGE INFORMATION

The production change information for Forester is TBD.

PART INFORMATION

REMINDER:  Always order the most up-to-date replacement parts based on the specific VIN being repaired.

Part Description	Part Number
LAMP ASSEMBLY-HEAD LEFT	84001SJ071
	84002SJ171
	84002SJ471
	84913SJ271
	84913SJ071
LAMP ASSEMBLY-HEAD RIGHT	84001SJ061
	84002SJ161
	84002SJ461
	84913SJ261
	84913SJ061

SERVICE PROCEDURE/INFORMATION

REMINDER:  Customer satisfaction and retention starts with performing quality repairs.

Determine water intrusion is present and not a fogging situation. TSB 07-59-07R provides information on headlamp fogging. Confirm the headlamp(s) water intrusion is not a result of outside influence, such as physical damage, modification, etc.

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.

The service procedures for headlight replacement remain unchanged. Always refer to the applicable Service Manual and review the full requirements of the repair being performed. The Service Manual procedures contain information critical to performing an effective repair the first time, every time. This includes but is not limited to important SAFETY precautions, proper inspection criteria, necessary special tools, required processes and related one-time-use parts needed for a complete and lasting repair.

Refer to STIS: Body & Electrical/WIRING SYSTEMS > LIGHTING SYSTEM > Headlight Assembly 

IMPORTANT NOTES:  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  .

WARRANTY/CLAIM INFORMATION

For vehicles within the Basic New Car Limited Warranty period, this repair may be submitted using the following claim information:

Labor Description	Labor Operation #	Labor Time	Fail Code
ONE FRONTCOMBINATION LAMP BODY/LENS R&R	A916-111	0.4	XBW29
BOTH FRONT COMBINATION LAMP BODIES/LENS R&R	A916-114	0.5

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.