2004 Subaru Forester Fuel system Problems

leaking fuel lines under turbo in engine compartment when in cold weather

NHTSA ID

11580020

Incident

Mar 28, 2024

THERE IS A FUEL LEAK ON THE LOW AND HIGH PRESSURE FUEL RUBBER HOSES, AND THEY CAUSE FUEL ODOR TO ENTER THE CB VIA CLIMATE CONTROL. IT IS A VERY STRONG ODOR, THAT REQUIRES ME TO EITHER DRIVE WITH THE WINDOWS DOWN OR WAIT FOR THE CAR TO CLEAR OUT THE FUEL ODOR OUT OF THE CABIN. MOSTLY OCCURS DURING COLD WEATHER DAYS. ONCE ENGINE WARMS UP, ODOR FADES AWAY. MANY PEOPLE WITH SIMILAR CARS SAY IS A COMMON ISSUE WITH SUBARUS.

NHTSA ID

11406648

Incident

Nov 5, 2020

Mileage

140,200 mi

NEOPREEN HOSE TO THE RIGHT SIDE FUEL RAIL STARTED LEAKING. THIS HOSE IS NEAR THE TOP OF THE ENGINE AND THE LEAK CAUSED FUEL TO RUN ALL OVER ENGINE, WHICH WAS THEN DRAWN INTO THE CABIN VIA THE CLIMATE CONTROL SYSTEM. THIS OCCURRED WHILE DRIVING, AND RAW FUEL WAS DRIPPING FROM THE HIGH PRESSURE HOSE ONCE STOPPED.

NHTSA ID

11391059

Incident

Jan 29, 2021

Mileage

97,000 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

TL* THE CONTACT OWNS A 2004 SUBARU FORESTER. THE CONTACT STATED THAT AT START UP, THERE WAS AN ABNORMAL FUEL ODOR INSIDE OF THE VEHICLE. AFTER EXITING THE VEHICLE, THE CONTACT BECAME AWARE OF A FUEL LEAK UNDER THE FRONT OF THE VEHICLE. SCHLOSSMANN SUBARU CITY OF MILWAUKEE LOCATED AT 4640 S 27TH ST, MILWAUKEE, WI 53221, (414) 459-3677 WAS CONTACTED BY PHONE AND INFORMED OF THE FAILURE. THE VEHICLE WAS NOT TAKEN TO BE DIAGNOSED NOR REPAIRED. THE MANUFACTURER WAS INFORMED OF FAILURE. THE FAILURE MILEAGE WAS 101,000.

NHTSA ID

11298419

Incident

Nov 10, 2019

Mileage

101,000 mi

HAVE GAS SMELL WHICH I CANNOT FIND THAT IS ONGOING. I DID HAVE A GAS LINE REPAIR ON A GAS PRESSURE LINE THAT BURST THAT WAS LOCATED BEHIND THE REAR SEAT BUT STILL HAVE AN ONGOING GAS SMELL WHEN I FILL THE GAS TANK. I SEE MANY COMPLAINT REGARDING GAS SMELL FOR THIS YEAR VEHICLE SO I AM ALSO POSTING. I DO NOT SEE A RECALL REGARDING GAS SMELL BUT WITH ALL THE COPLAINTS THERE SHOULD BE ONE. ITS UNKNOWN AS TO WHAT IS THE PROBLEM.

NHTSA ID

11206030

Incident

Dec 20, 2017

Mileage

130,650 mi

THE RUBBER INJECTOR LINES RUNNING BELOW THE INTAKE MANIFOLD ON THE TURBOCHARGED (XT) MODEL, INCLUDING MY VEHICLE, ARE WELL KNOWN TO DEVELOP A DANGEROUS LEAK. EITHER THE RUBBER DRIES OUT OR THE FACTORY CLAMPS LOOSEN UP OVER TIME, LEAKING GASOLINE ONTO THE ENGINE BLOCK. THIS IS A VERY DANGEROUS DESIGN FLAW THAT HAS BEEN RECOGNIZED AS AN ISSUE ON THE IMPREZA BUT YOU FORGOT ABOUT FOERESTER OWNERS, SUBARU! SHAME ON YOU.

NHTSA ID

11161910

Incident

Dec 1, 2017

Mileage

125,000 mi

DURING COLD WEATHER, WHILE AT A STOP AND IN MOTION, THERE IS A STRONG FUEL SMELL INSIDE THE CABIN. THE SOURCE WAS DETERMINED TO BE THE FUELS LINES AND SPECIFICALLY THE FITTINGS ON THE LINES. DURING COLD WEATHER, EITHER THE FITTINGS OR THE HOSES CONTRACT, CAUSING FUEL TO LEAK IN THE ENGINE BAY, NEAR THE HOT HEADERS AND HOT TURBO.

NHTSA ID

11157009

Incident

Jan 6, 2017

Mileage

65,000 mi

TL* THE CONTACT OWNS A 2004 SUBARU FORESTER. WHILE ATTEMPTING TO START THE VEHICLE IN COLD WEATHER, THE CONTACT NOTICED AN ABNORMAL FUEL ODOR UNDER THE FRONT PASSENGER SIDE OF THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE DEALER AND THE MANUFACTURER WERE NOT CONTACTED. THE APPROXIMATE FAILURE MILEAGE WAS 160,000.

NHTSA ID

11151274

Incident

Nov 12, 2018

Mileage

160,000 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. THE CONTACT NOTICED AN ODOR OF FUEL AND A LEAK COMING FROM THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE FUEL LINES NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE VEHICLE HAD NOT BEEN DIAGNOSED BY A DEALER. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 123,000.

NHTSA ID

11091135

Incident

Mar 1, 2016

Mileage

123,000 mi

MY FORESTER HAS BEGUN TO SMELL LIKE GAS WHEN IT IS TURNED ON WHILE IT IS COLD OUTSIDE. A FUEL LINE IS LEAKING ON THE RIGHT SIDE FUEL RAIL. THE FUEL IS LEAKING RIGHT NEXT TO THE EXHAUST MANIFOLD AND THE TURBO (SEE, REALLY HOT PARTS, SEE ALSO, DANGEROUS). THIS IS A WELL KNOWN ISSUE WITH THE CAR AND IS A SERIOUS SAFETY HAZARD. I DO NOT BELIEVE IT IS RIGHT TO REQUIRE OWNERS TO PAY HUNDREDS TO THOUSANDS OF DOLLARS TO KEEP THEIR CARS FROM BURSTING IN TO FLAMES. PLEASE SEE ALL THE OTHER COMPLAINTS ON THIS SAME ISSUE AND DO SOMETHING TO PROTECT AND REIMBURSE THE OWNERS OF THE VEHICLES FOR THIS SAFETY ISSUE. THANK YOU.

NHTSA ID

11080085

Incident

Mar 17, 2018

Mileage

145,000 mi

LEAKING FUEL LINE UNDER MANIFOLD, FUEL SMELL VERY STRONG AND LEAKS INTO ENGINE BAY.

NHTSA ID

11071717

Incident

Sep 23, 2017

GOT UP TO AND STARTED MY CAR TO GET IT WARMED UP SINCE IT WAS 8 F OUTSIDE. 20 MINUTES LATER WHEN I GOT INTO THE CAR THERE WAS A STRONG SMELL OF GAS. UPON INSPECTION OF THE ENGINE COMPARTMENT I FOUND THAT THERE WAS A FUEL LINE ON THE DRIVERS SIDE DRIPPING GASOLINE ONTO THE ENGINE BLOCK, WHERE IT WAS POOLING. WHILE SEARCHING ONLINE FOR INFO ON THIS, I FOUND THAT THIS IS A COMMON ISSUE WITH EARLY 2000'S SUBARUS, EVEN TO THE EXTENT THAT THEY RECALLED THE WRX MODELS FOR THIS EXACT REASON, BUT MADE NO MENTION OF THEIR OTHER MODELS.

NHTSA ID

11058587

Incident

Jan 3, 2018

Mileage

201,000 mi

GAS SMELL COLD WEATHER CAR IDOLING

NHTSA ID

11057668

Incident

Dec 25, 2017

Mileage

160,000 mi

JUST LIKE 60 OR SO OTHER 03-05 FORESTER XT OWNERS, I'M EXPERIENCING THE FUEL LEAK FROM THE RUBBER FUEL LINE WHERE IT CLAMPS ON TO THE METAL LINE TO THE FRONT DRIVERS SIDE INJECTOR. JUST LIKE EVERYONE ELSE, THE ISSUE ONLY OCCURRED WHEN TEMPERATURES DROPPED BELOW ABOUT 20F - UNCOINCIDENTALLY, IN MY OPINION, THIS WAS THE FIRST NEW ENGLAND WINTER THIS CAR HAD EVER SEEN. SUBARU HAS ISSUED A RECALL FOR WRX WITH THE SAME EXACT ISSUE INVOLVING THE SAME EXACT HARDWARE. GET ON IT SUBARU, THIS IS COMPLETELY UNACCEPTABLE AND AN EXTREMELY DANGEROUS DESIGN FLAW. YOU'VE ALREADY FESSED UP TO THE ISSUE WITH OTHER VEHICLES USING THE EJ255 NOW DON'T FORGET ABOUT US FOZZY OWNERS.

NHTSA ID

11054095

Incident

Dec 11, 2017

Mileage

125,000 mi

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

CAR HAS A STRONG GAS ODOR IN THE CAB WHEN TEMPERATURE DROPS TO 20 DEGREES AND BELOW. OCCURING ON COLD START AND CONTINUING IN MOTION ON LOCAL AND HIGHWAY DRIVING. AFTER A FEW UNSUCCESSFUL FIXES BY AUTHORIZED SUBARU SERVICE PROBLEM STILL EXISTS FOR THREE YEARS SOA NEEDS TO RECOGNISE THIS GAS LEAK FOR THIS MODEL AND YEAR AS A RECALL AND PERMINENT FIX PLEASE HELP

NHTSA ID

11025492

Incident

Dec 15, 2015

Mileage

60,000 mi

THERE IS A RAW GAS SMELL INSIDE THE CAR WHEN PARKED, OR STOPPED WHILE THE CAR IS RUNNING IN COLD WEATHER.

NHTSA ID

10966013

Incident

Mar 15, 2017

Mileage

126,000 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

THERE IS A TERRIBLE GAS SMELL DURING COLD WEATHER FROM SOME LEAK IN THE FUEL LINE. OTHER SUBARU MODELS HAVE BEEN RECALLED FOR THIS SAME PROBLEM, BUT NOT THE FORESTER. THE SMELL IS SO BAD THAT IT HAS GIVEN ME HEADACHES AND NAUSEA. THE SMELL IS PARTICULARLY AWFUL WHEN THE HEAT IS TURNED ON, WHICH IS PROBLEMATIC SINCE ONE WANTS THE HEAT ON WHEN IT'S THAT COLD OUT. SMELL PERSISTS AROUND THE CAR EVEN WHEN IT ISN'T RUNNING AND IS SO BAD I CAN'T PARK IT INSIDE MY ATTACHED GARAGE BECAUSE IT COMES INTO THE HOUSE. SUBARU REALLY NEEDS TO ADDRESS THIS. I HAVE MENTIONED IT TO MY MECHANIC SEVERAL TIMES AND THEY HAVE TRIED TO CORRECT IT BY TIGHTENING FUEL LINE CONNECTIONS, WHICH HAS NOT SOLVED THE ISSUE. THEY TOLD ME ABOUT THE OTHER MODELS BEING RECALLED, AND WHEN I RESEARCHED IT MYSELF I DISCOVERED THAT THERE ARE HUNDREDS (AT LEAST) OF SUBARU FORESTER OWNERS WHO HAVE COMPLAINED ABOUT THE SAME PROBLEM. THIS IS A HEALTH HAZARD. I DON'T THINK ANYONE SHOULD BE BREATHING THESE CONCENTRATED FUMES. SUBARU NEEDS TO DO A RECALL AND REPLACE THESE FAULTY LINES. THIS PROBLEM HAS BEEN ONGOING FOR AT LEAST THE PAST 2 YEARS/WINTERS. MY MOST RECENT VISIT TO THE MECHANIC (TO ADDRESS THE FUEL SMELL AGAIN) WAS DECEMBER 23, 2016.

NHTSA ID

10937987

Incident

Dec 23, 2016

CAR LEAKS FUEL PROFUSELY FROM FUEL LINE NEAR ENGINE BLOCK WHEN RUNNING DURING COLD WEATHER TEMPERATURES BELOW 20 DEGREES FAHRENHEIT.

NHTSA ID

10936225

Incident

Dec 19, 2016

IN VERY COLD WEATHER, THERE IS A STRONG GASOLINE SMELL INSIDE THE CAR THAT REMAINS AS THE CAR WARMS UP. THIS ONLY OCCURS WHEN TEMPERATURES ARE WELL BELOW FREEZING.

NHTSA ID

10936221

Incident

Dec 16, 2016

Mileage

90,000 mi

FORESTERS HAVE A COMMON PROBLEM OF A VERY COMMON PROBLEM OF THE FUEL LINE LEAKING. THE COLD CAUSES SHRINK TO THE FUEL LINES CAUSING A LEAK INTO THE ENGINE AND FUEL VAPORS TO ENTER THE CABIN. THIS ISSUE OCCURS WHETHER IT'S STATIONARY OR IN MOTION AS WELL AS ALL OTHER CONCEIVABLE STATES THAT THE VEHICLE CAN BE IN. A RECALL WAS ISSUED FOR THE WRX, THE SAME SHOULD OCCUR WITH THE FORESTER. THIS ISSUE OCCURS EVERY WINTER WHEN THE TEMP DROPS BELOW 20 DEGREES.

NHTSA ID

10935600

Incident

Dec 14, 2016

Mileage

146,000 mi

STRONG FUEL ODOR HAS BEEN ENTERING THE CABIN DURING STARTUP ON COLD MORNINGS. THIS IS CAUSED BY A FUEL LINE LEAKING ONTO THE ENGINE. THE LEAK CAN BE SEEN BUT IS INACCESSIBLE WITHOUT REMOVING THE INTAKE MANIFOLD. ONCE THE VEHICLE HEATS UP AND THE LINE EXPANDS THE LEAK STOPS. I AM VERY CONCERNED ABOUT THE POTENTIAL FOR A VEHICLE FIRE AND THE DANGER OF INHALING GASOLINE FLAMES. *TR

NHTSA ID

10933813

Incident

Dec 7, 2016

Mileage

143,000 mi