2003 Subaru Impreza

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with consistently high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly, ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016, four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016, four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The PE is now closed/upgraded to an Engineering Evaluation (EA15-001) to include all manufacturersand vehicles known to be affected at this time.ODI's EA investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The recalls related to this PE are: 14V343, 14V344, 14V348, 14V351, 14V353, 14V655, 14V700, 14V701, 14V752, 14V763, 14V770, 14V773, 14V787, 14V802 and 14V817.The number of vehicles affected are an estimate since some vehicles may have both the driver and passenger side inflators recalled. The five ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

On September 6, 2011, Fuji Heavy Industries USA, Inc, on behalf of Subaru of America, Inc notified the Office of Defects Investigation (ODI) it would be conducting a safety recall of certain model year (MY) 2002 through 2007 Subaru Impreza, MY 2003 through 2008 Subaru Forester, and MY 2005 through 2006 Saab 9-2X vehicles originally sold or currently registered in one the salt belt states including the District of Columbia (DC). For the purpose of this investigation, salt belt states include Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and DC.ODI's analysis of consumer complaint data identified 11 reports alleging failure of either the right or left lower control arm due to excessive corrosion. All of these complaints were associated with vehicles currently registered or originally sold in a salt belt state. Through a similar analysis of complaint and warranty data submitted to ODI by Subaru, ODI identified 18 consumer complaints and 6 warranty claims associated with failure of the left or right front lower control arm due to excessive corrosion. All of these consumer complaints associated with vehicles either currently registered of originally sold in a salt belt state.Accordingly, this investigation is closed.

THE DESIGN OF THE FUEL LINE (METAL RAIL/RUBBER HOSE INTERFACE) IS SUSCEPTIBLE TO FUEL ODOR AND/OR SEEPAGE IN EXTREME COLD TEMPERATURE CONDITIONS.OWNERS MOST OFTEN NOTICED FUEL ODOR IN THE OCCUPANT COMPARTMENT AREA DURING INITIAL COLD ENGINE START-UP.ONCE THE ENGINE IS WARMED, THE ODOR/SEEPAGE ISSUE DISSIPATES.FROM SUBARU'S DATA, ODI NOTES THAT THE INCIDENT RATES ARE HIGHER IN STATES WITH COLDER TEMPERATURES.THERE WAS ONE ALLEGATION OF A FIRE INCIDENT IN WHICH THE OWNER HAD REPORTED THAT HE NOTICED FUEL ODOR A FEW DAYS EARLIER, BUT ODI COULD NOT CONFIRM THE ORIGIN OF THE FIRE. TO ADDRESS THIS ISSUE, SUBARU WILL REPLACE THE FUEL LINE WITH A LONGER RUBBER HOSE SEGMENT VERSION/DESIGN ON 5,724 MY 2002-2003 VEHICLES BUILT THROUGH SEPTEMBER 12, 2002 IN 16 STATES (AK, CO, IA, ID, ME, MI, MN, MT, ND, NE, NH, NY, SD, VT, WI & WY).IN ADDITION, SUBARU WILL EXTEND THE WARRANTY COVERAGE TO 12 YEARS/UNLIMITED MILEAGE ON VEHICLES IN THE REMAINING 34 STATES.THIS ENGINEERING ANALYSIS IS CLOSED (SEE RECALL CAMPAIGN 09V-468)

COMPLAINANTS REPORT FUEL LEAKAGE MOST FREQUENTLY IN WINTER DURING INITIAL COLD ENGINE STARTUP.OWNERS WILL EITHER NOTICE A FUEL ODOR INSIDE THE OCCUPANT COMPARTMENT OR FUEL ODOR/LEAKAGE AT THE FUEL LINES ON THE RIGHT SIDE ATOP THE ENGINE. ONCE THE ENGINE HAS WARMED, THE ODOR/LEAKAGE MAY CEASE.SUBARU REVISED THE FUEL PIPE/HOSE DESIGN FOR MODEL YEAR (MY) 2003-04 WRX VEHICLES PRODUCED AFTER AUGUST 2003.SUBARU ALSO INTRODUCED A MY 2004 IMPREZA STI VEHICLE WITH A DIFFERENT ENGINE AND FUEL PIPE/HOSE LAYOUT.OUT OF THE TOTAL OF 994 COMPLAINTS, 944 CONCERN MY 2002-03 WRX VEHICLES BUILT THROUGH AUGUST 2003.SUBARU ALSO REPORTS ONE FIRE ON A MY 2002 WRX VEHICLE THAT OCCURRED IN FEBRUARY 2006.IN MARCH 2009, ODI INSPECTED AND VIDEO TAPED A MY 2002 WRX VEHICLE WITH A FUEL LEAK DURING COLD ENGINE START UP.THE VIDEO WAS PROVIDED TO SUBARU AND IS IN THE INVESTIGATION FILE. THIS INVESTIGATION IS BEING UPGRADED TO AN ENGINEERING ANALYSIS (EA09-011) TO FURTHER STUDY THIS ISSUE.

My 2003 Subaru Impreza WRX has a very strong fuel odor that is coming into the cabin when I start my car up on cold days. It's been unusually cold here in Washington state this winter with temperatures in Seattle dipping well below freezing. I see that there is a recall for this exact problem for my exact car (https://static.nhtsa.gov/odi/rcl/2009/RCONL-09V468-4248.pdf). But when I called the dealer (Michael's Bellevue Subaru), and then subsequently called Subaru (1-800-SUBARU3), they told me that they will not fix this issue, since this recall does not apply to my state (Washington). I think that's not right. It is the exact same problem of cold weather causing this fuel line to leak, and they should honor this recall.

NHTSA ID

11448826

Incident

Jan 1, 2022

I NOTICED FRESH SMELL OF GASOLINE EVERYTIME I START THE CAR. I LOOK AT THE FUEL LINE AND ITS SIPPING FUEL.

NHTSA ID

11405009

Incident

Mar 25, 2021

Mileage

130,000 mi

SUBARU OF AMERICA RECALL WVK-21 OCCURED WHILE DRIVING AT OPERATING TEMPERATURE, CAUSING SMOKE TO RISE FROM ENGINE BAY. SUBARU OF AMERICA REFUSED TO FIX THE ISSUE AS MY VIN DID NOT COME UP IN THEIR SYSTEM WITH THE RECALL.

NHTSA ID

11399684

Incident

Feb 23, 2021

Mileage

180,000 mi

ON THE NIGHT OF 12/6/2020 I WAS BACKING OUT OF A FRIENDS DRIVEWAY TO DRIVE HOME, WHEN I REACHED THE STREET, I HEARD A LOUD CLUNK AND A GRINDING NOISE. I GOT OUT OF MY CAR TO INVESTIGATE WHAT HAD JUST HAPPENED AND THE FRONT PORTION OF MY PASSENGER SIDE FRONT LOWER CONTROL ARM HAD COMPLETELY LOST ALL STRUCTURAL INTEGRITY. FORTUNATELY MY CAR WAS AT A LOW SPEED AND I DID NOT LOSE CONTROL (PICTURES ATTACHED). HAD THIS HAPPENED WHILE DRIVING DOWN THE HIGHWAY, THIS WOULD HAVE BEEN A CATASTROPHIC FAILURE AND I WOULD HAVE LOST CONTROL OF THE VEHICLE THE EVENTS ON 12/6/2020 INDICATES THE REMEDIATION STEPS PROPOSED BY SUBARU ARE NOT ACCEPTABLE AS THIS PART FAILED CATASTROPHICALLY AFTER THESE STEPS HAD BEEN PERFORMED. THE SAFETY RECALL REMEDIATION STEPS IN QUESTION ARE THAT OF: "TYPE: SAFETY | SAFETY RECALL: WVX34 | NHTSA CAMPAIGN: 11V464000" ACCORDING TO SUBARU'S WEBSITE FOR THIS VEHICLE, THE SAFETY RECALL WAS COMPLETED: HTTPS://WWW.SUBARU.COM/VEHICLE-RECALLS.HTML/VIN=[XXX] ACCORDING TO THE CARFAX REPORT, THE SAFETY RECALL WAS PERFORMED ON 2/7/2012 ONLY 5 MONTHS AFTER THE RECALL WAS ISSUED. (SCREENSHOT ATTACHED) THE NATURE OF THE FAILURE AND THE DESCRIPTION OF THE ORIGINAL SAFETY RECALL SHOW THAT THE TESTING STEPS AND REMEDIATION STEPS ARE NOT SUITABLE FOR A COMPLETED SAFETY RECALL AS THE PART DID END UP FAILING AFTER THE ADDITIONAL COATING OF ANTI-CORROSIVE HAD BEEN APPLIED TO THE LOWER CONTROL ARM OF MY VEHICLE. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

11382853

Incident

Dec 6, 2020

Mileage

205,000 mi

HEAD GASKET ISSUE. WEEPING OIL BETWEEN THE HEADS AND THE BLOCK. NO LONGER OWN VEHICLE.

NHTSA ID

11318563

Incident

Feb 9, 2020

Mileage

170,000 mi

TL* THE CONTACT OWNS A 2003 SUBARU IMPREZA. THE CONTACT SMELLED FUEL INSIDE AND OUTSIDE THE ENGINE BAY. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 09V468000 (FUEL SYSTEM, GASOLINE). KEARNY MESA SUBARU (4797 CONVOY ST, SAN DIEGO, CA 92111, (858) 278-7100) WAS CONTACTED AND STATED THAT THE VEHICLE WAS NOT INCLUDED IN A RECALL. THE VEHICLE WAS NOT TAKEN TO A DEALER OR INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING OR REPAIRS. THE MANUFACTURER WAS CONTACTED AND INFORMED THE CONTACT TO CALL NHTSA. THE FAILURE MILEAGE WAS APPROXIMATELY 159,800.

NHTSA ID

11181362

Incident

Feb 19, 2019

Mileage

159,800 mi

LOWER PASSENGER CONTROL ARM TORE OFF. AS A RESULT, LOSS CONTROL OF VEHICLE AT HIGH SPEED ON THE HIGHWAY.

NHTSA ID

11160641

Incident

Dec 2, 2018

Mileage

115,000 mi

FUEL LINE LEAKING GAS IN COLD WEATHER. I REALLY DON'T THINK IT'S SAFE TO DRIVE WITH QUITE A BIT OF GAS LEAKING ALL OVER THE RIGHT SIDE OF THE ENGINE THAT GETS VERY HOT AND COULD CAUSE A FIRE.

NHTSA ID

10930227

Incident

Dec 4, 2016

Mileage

148,000 mi

This announcement is requesting retailer staff to retain the EyeSight protective hood covers from Generation 4 EyeSight cameras.

This bulletin contains additional information for recommended materials listed in the Service Manuals for individual models.

This announcement provides information on the remanufactured CVT transmission program.

This Service Information Bulletin was developed to provide interim guidance for vehicles exhibiting DTC B2A20.

This bulletin announces the service manual correction regarding clutch master cylinder reservoir service procedures.

This bulletin contains additional information for recommended materials listed in the Service Manuals for individual models.