2004 Subaru Forester Engine Problems

Bracket to the sway bar bushing fell off

NHTSA ID

11456686

Incident

Mar 14, 2022

TL* THE CONTACT OWNS A 2004 SUBARU FORESTER. THE CONTACT STATED THAT THERE WAS A LEAK IN THE HEAD GASKET. THE VEHICLE WAS TAKEN TO THE LOCAL DEALER HERB GORDON SUBARU (3161 AUTOMOBILE BLVD, SILVER SPRING, MD 20904, (866) 520-7894) WHERE IT WAS DIAGNOSED WITH THE HEAD COVER GASKET WITH NEEDING TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. UPON INVESTIGATION, THE CONTACT ASSOCIATED THE FAILURE WITH NHTSA CAMPAIGN NUMBER: 04V473000 (ENGINE AND ENGINE COOLING) HOWEVER, THE VIN WAS NOT INCLUDED. THE MANUFACTURER WAS INFORMED OF THE FAILURE. THE CONTACT WAS INFORMED THAT THE REPAIRS WERE NOT COVERED UNDER WARRANTY AND THE COSTS FOR THE REPAIR WOULD BE OUT OF POCKET. THE FAILURE MILEAGE WAS APPROXIMATELY 161,000.

NHTSA ID

11387683

Incident

Oct 16, 2020

Mileage

161,000 mi

CAR WAS SHIFTED FROM DRIVE INTO NEUTRAL FOR OPERATOR TO USE A PARKING LOT GATE MACHINE. THE ENGINE SURGED A LITTLE WHILE IN NEUTRAL BUT SETTLED BACK DOWN. WHEN PARKING GATE OPENED THE OPERATOR SHIFTED INTO DRIVE AND LIGHTLY PRESSED THE GAS PEDAL. THE ENGINE IMMEDIATELY SURGED TO FULL THROTTLE AND RAPIDLY ACCELERATED ACROSS THE DRIVEWAY FOR A FEW SECONDS BEFORE BEING STOPPED BY COLLISION WITH A GRANITE POST. OPERATOR COULD NOT BRAKE HARD ENOUGH TO STOP THE VEHICLE IN TIME. DRIVER INJURED IN CRASH.

NHTSA ID

11319673

Incident

Mar 28, 2020

Mileage

57,000 mi

ANYTIME THE TEMPERATURE DROPS BELOW 60 DEGREES FAHRENHEIT THERE'S A STRONG SMELL OF GASOLINE INSIDE THE CAB OF THE VEHICLE. WHEN LOOKING UNDER THE HOOD I CAN SEE IT DRIPPING OUT OF SOMETHING UNDERNEATH THE INTAKE MANIFOLD. SEVERE GAS LEAK. NAUSEOUS AND DANGEROUS FUMES.

NHTSA ID

11133427

Incident

Jan 10, 2015

TL* THE CONTACT OWNS A 2004 SUBARU FORESTER. WHETHER THE VEHICLE WAS PARKED OR BEING DRIVEN, A FUEL ODOR WAS DETECTED IN AND OUTSIDE THE VEHICLE. THE FUEL ODOR WAS MOST NOTICEABLE WHILE OPERATING THE HEATER. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TAKEN TO MID-HUDSON SUBARU (1715 U.S. 9, WAPPINGERS FALLS, NY 12590 (866) 678-2048) SEVERAL TIMES, BUT NO LEAKS OR FAILURES WERE DETECTED. THE CONTACT STATED THAT THE DEALER FINALLY DETECTED A FUEL ODOR AND DIAGNOSED THE FAILURE AS A MALFUNCTION WITH TUBING OR PIPING WITHIN THE ENGINE. THE PARTS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED DUE TO THE COST. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THAT THEY WOULD CONTACT THE LOCAL DEALER. THE FAILURE MILEAGE WAS APPROXIMATELY 120,000. *TT *TR

NHTSA ID

11048212

Incident

Nov 23, 2016

Mileage

120,000 mi

FUEL LEAK IN LINES ABOVE ENGINE BUT BELOW INTAKE DURING COLDER WEATHER. FUEL FUMES PULLED INTO VEHICLE BY HEATING SYSTEM.

NHTSA ID

10949258

Incident

Dec 13, 2016

Mileage

76,000 mi

TL* THE CONTACT OWNS A 2004 SUBARU FORESTER. WHEN THE VEHICLE WAS STARTED, A VERY STRONG FUEL ODOR EMERGED FROM THE ENGINE COMPARTMENT. THE FUEL TANK LEAKED FUEL ONTO THE MANIFOLD. THE FAILURE WAS DIAGNOSED BY AN INDEPENDENT MECHANIC AS A FUEL TANK LEAK. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 149,966.

NHTSA ID

10933713

Incident

Dec 7, 2016

Mileage

149,966 mi

TL* THE CONTACT OWNED A 2004 SUBARU FORESTER. WHILE DRIVING VARIOUS SPEEDS, THE RPMS BEGAN TO INCREASE AND THE VEHICLE OVERHEATED. THE VEHICLE WAS PULLED OVER TO THE SIDE OF THE ROAD AND CAUGHT FIRE FROM THE ENGINE COMPARTMENT. THE FIRE WAS EXTINGUISHED BY THE FIRE DEPARTMENT. THERE WERE NO INJURIES AND A POLICE REPORT WAS NOT FILED. THE VEHICLE WAS TOWED AND LATER DEEMED DESTROYED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 110,000.

NHTSA ID

10916164

Incident

Oct 11, 2016

Mileage

110,000 mi

TO WHOM IT MAY CONCERN, HELLO, I AM THE OWNER OF A 2004 FORESTER XT WHICH I LOVE. I'VE OWNED THE CAR FOR ALMOST A YEAR AND ITS BEEN NOTHING BUT RELIABLE UP TO THIS POINT. THE WEATHER OUTSIDE IS FRIGHTFUL, AND WITH THAT COMES A COMMON PROBLEM FOR MANY SUBARU OWNERS. DURING THE COLD SNAPS, SAY BELOW 20F, THERE IS STRONG FUEL SMELLS WHICH FILLS THE CABIN. IT ONLY HAPPENS DURING START-UP, AND LASTS ABOUT 15 MINS BEFORE THE CAR WARMS UP. FROM SEARCHING MANY FORUMS AND INTERNET THREADS IT SEEMS THIS PROBLEM HAS BEEN OCCURRING SINCE EARLY 2001. THERE WAS A RECALL NOTICE (WVK-21)FOR THE 2002 -2003 WRX'S WHICH HAD A SAME PROBLEM I AM EXPERIENCING NOW. UNFORTUNATELY A RECALL WAS NEVER ISSUED FOR LATER MODEL SUBARUS WHICH SUFFER THE SAME PROBLEM. THE PROBLEM IS FUEL LEAKING FROM 5 MAIN FUEL LINES GOING INTO THE INTAKE MANIFOLD. IT SEEMS THAT WHEN IT IS COLD OUTSIDE, THE LINES ARE SHRINKING AND IS ALLOWING FUEL TO SPEW OUT EVERYWHERE. JUST FROM SEARCHING FOR 3 DAYS I'VE SEEN 125 CASES OF THIS HAPPENING TO OTHER OWNERS. WILL YOU PLEASE PUT OUT A BULLETIN BEFORE SOMEONE DIES FROM THERE CAR EXPLODING BECAUSE OF EXTRA FUEL LEAKING OUT OF THE FUEL HOSES. PLEASE I BEG OF YOU, PLEASE ISSUE A RECALL!!! *TR

NHTSA ID

10671695

Incident

Jan 5, 2015

Mileage

130,000 mi

THE SMELL OF FUEL BECAME OBVIOUS AFTER A 10-15 MINUTE DRIVE. UPON EXAMINATION, THERE WAS FUEL DRIPPING FROM A FUEL LINE. THIS OCCURRED AFTER THE FIRST FREEZE OF THE YEAR, FITTING OTHER DESCRIPTIONS OF THIS ISSUE I FOUND FOR THIS MODEL. *TR

NHTSA ID

10654794

Incident

Nov 11, 2014

Mileage

96,000 mi

2004 SUBARU FORESTER XT HAD CATASTROPHIC ENGINE AND TURBO FAILURE WHILE DRIVING ON HIGHWAY. IT IS CLEAR THAT MY VEHICLE SUFFERED FROM SUBARU SERVICE CENTER NEGLIGENCE AND A DESIGN FLAW OF A BANJO BOLT THAT FILTERS OIL TO THE TURBO BUT EASILY GETS CLOGGED, SHUTTING OFF OIL TO THE TURBO, CAUSING OIL DEPRIVATION TO THE TURBO, BURNING OUT THE TURBO, AND CAUSING FRAGMENTS TO GET INTO THE ENGINE, BLOWING OUT THE ENGINE AS WELL. WHILE I WAS SPARED AN ACCIDENT AND INJURY, IT WAS A CLOSE CALL AS WHILE I WAS DRIVING I SUDDENLY HAD A FAILURE TO ACCELERATE, AND VERY NEARLY WAS PLOWED IN FROM BEHIND BY A LARGE TRACTOR TRAILER TRUCK. MY CAR NOW REQUIRES A COMPLETE REPLACEMENT OF ENGINE AND TURBO, COSTING IN EXCESS OF $7,000. I HAVE DECIDED TO SELL THE VEHICLE RATHER THAN BEARING THE HUGE EXPENSE REQUIRED TO REPAIR. THE ISSUE WITH THIS BANJO BOLT AND SUBARU TURBO / ENGINES OF THIS ERA ARE WELL DOCUMENTED ON THE INTERNET AUTOMOBILE FORUMS AND IN SOCIAL MEDIA. SUBARU SHOULD COMPENSATE OWNERS FOR DEVALUING THEIR CARS, AND SHOULD HAVE A RECALL BEFORE MORE DRIVERS ARE HARMED OR KILLED. *TR

NHTSA ID

10592747

Incident

Feb 12, 2014

Mileage

76,485 mi

I AM EXPERIENCING AN EXTREMELY STRONG SMELL OF GAS. THIS BEGAN WINTER OF 2013, WHICH I HAD REPAIRED AT MY EXPENSE OF $700+, THOUGH MY MECHANIC INFORMED ME SUBARU WAS RECALLING THIS AND REPAIRING FOR FREE ON OTHER MODELS. I AM ABSOLUTELY DISGUSTED THAT THIS PROBLEM IS RECURRING NOW WINTER OF 2014, IN A VEHICLE WHICH I DRIVE MY SMALL CHILDREN IN. THE GAS SMELL IS HORRIFIC, TOXIC, AND DANGEROUS. *TR

NHTSA ID

10564606

Incident

Jan 4, 2013

FUEL LINES CRACK IN COLD WEATHER (APPROX UNDER 25 AND UNDER). STRONG FUEL SMELL IN CABIN WAS ENOUGH TO MAKE PASSENGERS ILL, CAR WAS NOT DRIVABLE. FUEL WAS POOLING IN THE ENGINE BAY NEAR THE HOT TURBO AND EXHAUST SYSTEM. CONTACTED DEALERSHIP, SERVICE WRITER KNEW WHAT THE ISSUE WAS AS SOON AS I TOLD HIM MAKE, MODEL AND YEAR - SAID IT'S VERY COMMON. FOUND PAGES OF COMPLAINTS ON NHTSA SITE AND HUNDREDS IN FORUMS. SUBARU ISSUED A RECALL FOR THE SAME ISSUE ON THE 2003 GENERATION WRX VEHICLES, BUT NOT THE FORESTERS. THIS IS A MAJOR PROBLEMS. SUBARU'S ARE PURCHASED AS IDEAL SNOW VEHICLE, AND REPAIRS COST UPWARD OF $600. THIS IS A DIRECT SAFETY ISSUE. *TR

NHTSA ID

10563688

Incident

Feb 7, 2014

Mileage

126,000 mi

VERY STRONG FUEL SMELL IN THE CAR WITH HEATER ON SO STRONG HAVE TO ROLL WINDOW DOWN. HAPPENS 2 TO 3 TIMES A WEEK ON COLD DAYS. STRONGEST WHEN ITS A COLD START. *TR

NHTSA ID

10562421

Incident

Dec 30, 2013

Mileage

120,000 mi

IN VERY COLD WEATHER (LESS THAN 10 F) THE RUBBER GAS LINES LEAK VERY SIGNIFICANT AMOUNTS OF GAS ONTO THE ENGINE AND VERYNEAR THE HOT TURBOCHARGER. ANOTHER SUBARU JUST CAUGHT FIRE IN THE O'NEILL TUNNEL. HTTP://BOSTON.CBSLOCAL.COM/2014/01/27/CAR-FIRE-CAUSES-BACKUP-IN-ONEILL-TUNNEL/ *TR

NHTSA ID

10562177

Incident

Jan 15, 2014

Mileage

68,000 mi

IN COLD WEATHER (BELOW 20 DEGREES OR SO) THE FUEL LINES IN THE ENGINE COMPARTMENT COME LOOSE AND LEAK RAW GASOLINE ONTO THE HOT ENGINE. OBVIOUSLY THERE IS A GOOD CHANCE OF AN ENGINE FIRE WITH POSSIBLE LOSS OF LIFE. THIS HAS BEEN REPORTED IN SEVERAL FORUMS, THERE IS A TSB OUT ON THIS FOR THE WRX (SAME ENGINE, SAME PART NUMBERS), AND MOST DEALERS (IN COLD STATES) KNOW OF THIS PROBLEM. *TR

NHTSA ID

10562155

Incident

Jan 7, 2014

Mileage

130,000 mi

ON VERY COLD DAYS WHILE CAR IS WARMING UP, A STRONG SMELL OF FUEL IS COMING FROM UNDER THE INTAKE MANIFOLD. A CLOSER INSPECTION REVEALS A SMALL FUEL LEAK FROM THE FUEL SUPPLY LINES NEAR THE TURBO. A SUBARU IMPREZA ENTHUSIAST FORUM HAS A "RAW FUEL SMELL" LOG OF MORE THAN 131 PAGES AND 3,000 POSTS (HTTP://FORUMS.NASIOC.COM/FORUMS/SHOWTHREAD.PHP?T=131755). SUBARU ISSUED A TECHNICAL SERVICE BULLETIN (TSB) FOR CERTAIN SUBARU IMPREZAS, BUT THEY HAVE NOT INITIATED ANY TSBS FOR ANY OTHER CARS ALL USING THE SAME OR SIMILAR ENGINES. SEE TSB 01-170-09. AS LEAKING FUEL ONTO YOUR ENGINE IS A SAFETY HAZARD, I WOULD LIKE TO SEE SUBARU INITIATE SOME KIND OF TSB OR RECALL FOR ALL ENGINES EXPERIENCING THIS PROBLEM. I UNDERSTAND MANY SUBARU OWNERS HAVE COMPLAINED TO SUBARU AND NHTSA WITH NO RESULTS. *TR

NHTSA ID

10561865

Incident

Jan 28, 2014

Mileage

87,000 mi

FUEL AND EXHAUST LINE LEAKS IN COLD WEATHER. OVER THE INITIAL THREE DAY PERIOD - DAY ONE CHILDREN COMPLAINED OF HEADACHES, DAY TWO DRIVER EXPERIENCED SEVERE HEADACHE AND NAUSEA BUT DID NOT REALIZE IT WAS DUE TO FUEL LEAK. DAY THREE CABIN FILLED WITH OVERPOWERING FUMES COMING FROM HEATING VENT. HAD TO DRIVE WITH HEAT OFF AND ALL WINDOWS OPEN IN ORDER TO BRING CAR IN FOR SERVICE. HAVE HAD TO BRING CAR IN TWICE THIS MONTH TO REPAIR ALL OF THE LEAKS AND RENT A CAR IN ORDER TO GET TO WORK APPOINTMENTS. CERTIFIED SUBARU SPECIALIST REPORTED THAT HE HAS SEEN QUITE A FEW INCIDENCES OF SAME ISSUE RECENTLY DUE TO EXTREME COLD WEATHER. THIS IS A DANGEROUS SAFETY ISSUE AND IS NOT ACCEPTABLE. 2002-2003 IMPREZA RECALLED DEC 2009 FOR SAME ISSUE. *TR

NHTSA ID

10561352

Incident

Jan 7, 2014

Mileage

156,000 mi

TL* THE CONTACT OWNS A 2004 SUBARU FORESTER. THE CONTACT STATED WHEN THE TEMPERATURE DROPPED, FUEL FUMES WERE EMITTED IN AND AROUND THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR INSPECTION. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 117,000. THE INTAKE MANIFOLD WAS REPLACED. UPDATED 03/12/14 UPDATED 3/12/14*CN THE FUEL LINES, CLAMPS AND UPPER INTAKE GASKETS WERE REPLACED. THE FUEL LINES WERE CRACKED. UPDATED 04/01/14

NHTSA ID

10561131

Incident

Jan 2, 2013

Mileage

117,000 mi

STRONG SMELL OF GASOLINE UPON STARTING THE CAR IN VERY COLD WEATHER. INSIDE AND OUTSIDE THE VEHICLE. ONLY HAPPENS WHEN IT IS COLD OUTSIDE. REALLY GIVES ME A HEADACHE AND MAKES ME NERVOUS ABOUT IGNITING. *TR

NHTSA ID

10561032

Incident

Jan 1, 2013

Mileage

129,000 mi

DURING THE RECENT COLD SNAP HERE IN TENNESSEE I GOT A REPORT FROM A FRIEND THAT HIS 2004 FORESTER XT WAS LEAKING FUEL INTO HIS ENGINE BAY. I WENT OUT TO START MY CAR THE NEXT DAY AND MINE IS DOING THE SAME THING. THE FUEL IS SLOWLY LEAKING ONTO THE ENGINE BLOCK. THIS IS AN EXTREMELY DANGEROUS SITUATION. I DID SOME RESEARCHING AND IT SEEMS THAT ALMOST ALL FORESTER MODELS FROM 2002-2006 HAVE THIS EXACT SAME ISSUE! SOME HAVE BEEN RECALLED, BUT THE FORESTER XT HASN'T. THE ENGINES ARE THE SAME...I DON'T UNDERSTAND WHY THIS DANGEROUS PROBLEM HASN'T BEEN RESOLVED BY SUBARU. *TR

NHTSA ID

10559009

Incident

Jan 6, 2014

Mileage

87,000 mi

THERE HAS BEEN A CONTINUOUS OIL LEAK FROM MY 2004 SUBARU FORESTER XS. MY MECHANIC DIAGNOSED THE PROBLEM AS A LEAK IN THE MAIN SEAL BETWEEN THE TRANSMISSION AND THE ENGINE. THIS IS NOT NORMAL AND IT WILL COST ME $1,000 TO FIX BECAUSE THE TRANSMISSION WILL HAVE TO BE REMOVED. THERE ARE OTHER COMPLAINTS REGISTERED ABOUT SIMILAR OIL LEAKS IN THIS MODEL YEAR. SUBARU SHOULD INVESTIGATE. *TR

NHTSA ID

10495001

Incident

Mar 9, 2012

Mileage

119,000 mi

THERE WAS A VERY STRONG GASOLINE SMELL INSIDE THE CAR (2004 SUBARU FORESTER XS) THAT HAPPENED IN COLD WEATHER DURING JANUARY 2012. IT HAPPENED AGAIN JUST RECENTLY IN JANUARY 2013. IT WAS SO STRONG IT MADE THE DRIVER AND PASSENGER HAVE A HEADACHE AND BECOME NAUSEOUS. MANY OTHER OWNERS HAVE REPORTED THE VERY SAME THING AND HAVE NOT BEEN SUCCESSFUL IN GETTING SUBARU TO AT LEAST INVESTIGATE. SUBARU HAS ISSUED A RECALL FOR THE WRX MODEL, BUT NOT FOR THE FORESTER. THIS IS A HEALTH AND SAFETY RISK THAT SHOULD BE TAKEN CARE OF BY SUBARU. *TR

NHTSA ID

10494984

Incident

Jan 10, 2012

Mileage

118,148 mi

STRONG FUEL ODOR INSIDE CABIN DEVELOPED WHEN OPERATING ON COLD MORNINGS; FUEL ODOR TYPICALLY WENT AWAY WITHIN 15 MINUTES OF STARTING THE CAR. INSPECTION OF FUEL LINES, FILTER, ETC. REVEALED NO OBVIOUS LEAKS ABOVE THE INTAKE MANIFOLD. DEALER QUOTED APPROXIMATELY $800 TO REMOVE INTAKE MANIFOLD AND INSPECT. I HAVE HAD TWO INDEPENDENT SHOPS ATTEMPT TO FIX THIS ISSUE OVER THE PAST 3 YEARS WITH VARYING DEGREES OF SUCCESS; THE MOST RECENT (2011) REMOVED THE INTAKE MANIFOLD AND REPLACED ALL RUBBER FUEL LINES UNDER THE MANIFOLD, BUT THE PROBLEM HAS RECURRED THIS FALL AND WINTER AND AT INCREASINGLY WARM TEMPERATURES. NOW, THERE IS A VISIBLE AND OBVIOUS LEAK FROM A FUEL LINE JUST AS IT GOES UNDER THE MANIFOLD--INACCESSIBLE WITHOUT REMOVING THE MANIFOLD. CLEARLY, THE PROBLEM IS WITH THE DESIGN OF THE METAL FUEL RAIL TO RUBBER LINE INTERFACE, SINCE THIS IS A COMMON PROBLEM IN FORESTER XTS ACROSS SEVERAL MODEL YEARS. SUBARU OF AMERICA ISSUED A RECALL FOR THIS PROBLEM ON THE WRX, BUT SO FAR HAS NOT ACKNOWLEDGED THE PROBLEM FOR THE FORESTER OR FORESTER XT. THIS IS A COSTLY REPAIR AND A HUGE SAFETY ISSUE: THE LEAKING FUEL DRIPS DIRECTLY ONTO THE ENGINE CYLINDER HEADS AND IN SOME CASES (ON PASSENGER-SIDE FUEL LINE LEAKS) IS IN CLOSE PROXIMITY TO THE TURBOCHARGER--REPRESENTING A SIGNIFICANT RISK OF ENGINE FIRE. THE FUEL FUMES IN THE CABIN ARE ALSO A HEALTH AND SAFETY RISK WHICH SHOULD BE DEALT WITH BY SUBARU. *TR

NHTSA ID

10489347

Incident

Dec 1, 2010

Mileage

75,000 mi

THE ENGINE OVERHEATED AND SEIZED WHILE ON A FREEWAY WITHOUT A SINGLE WARNING LIGHT REGARDING HIGH TEMP OR CHECK ENGINE. NO COOLANT WAS VISIBLE IN THE RADIATOR DURING INSPECTION AFTER THE INCIDENT. SHOULDN'T A 21ST CENTURY DRIVER/OWNER BE NOTIFIED BY SOME INDICATOR THAT THEY ARE ON THE VERGE OF HEATING AN ENGINE TO THE POINT OF FAILURE? AND WHERE DID THE COOLANT GO? DOES THIS VEHICLE HAVE A HISTORY OF BAD THERMOSTATS I'M NOT AWARE OF? IT WOULD HAVE BEEN A LOT SAFER IF THERE WERE SOME WARNING LIGHT FOR HIGH TEMP SO WE CAN PULL OVER TO ALLOW THE CAR TO COOL DOWN IN ORDER TO PREVENT AN ACCIDENT AND SAVE THE ENGINE. *TR

NHTSA ID

10481571

Incident

Aug 30, 2012

Mileage

84,572 mi