2003 Subaru WRX

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.

SUBARU REPORTS THAT THE FUEL ODOR IS CAUSED BY FUEL SEEPAGE DURING COLD START OF THE ENGINE UNDER EXTREMELY COLD TEMPERATURES. THE LEAK OCCURS IN A FUEL LINE IN THE ENGINE COMPARTMENT.IT REPORTS THAT THE FAILURE IS DUE TO THE MISALIGNED ANGLE BETWEEN TWO FUEL DELIVERY LINES WHICH RESULTED IN SUCH FUEL SEEPAGE DURING THE FIRST FEW SECONDS OF COLD ENGINE START DURING THESE COLD TEMPERATURES.SUBARU REPORTS THAT THE TWO FUEL LINES ARE CONNECTED WITH A HOSE THAT BECOMES TOO STIFF IN VERY COLD TEMPERATURES TO CONFORM TO THE MISALIGNMENT. SUBARU HAS ISSUED A TECHNICAL SERVICE BULLETIN (SUBARU SERVICE BULLETIN NUMBER 09-36-03) TO REPLACE THE FUEL LINES WITH NEW LINES THAT ARE PROPERLY ALIGNED AND THAT HAVE A LONGER CONNECTING HOSE.ODI PHONE CALLS TO MANY OF THE COMPLAINANTS CONFIRM THAT FUEL ODOR IS NOTICABLE DURING VERY COLD TEMPERATURES AND COLD START BUT GOES AWAY AS THE ENGINE WARMS UP, AND THE ODOR IS NOT PRESENT IN WARMER TEMPERATURES. A FEW OWNERS REPORT THAT ATTEMPTS TO ELIMINATE THE LEAKAGE BY TIGHTENING THE CONNECTING HOSE CLAMPS IS NOT EFFECTIVE IN ELIMINATING THE FUEL ODOR.A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL MONITOR THIS ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

DURING THE EA, ODI AND VRTC PERFORMED THE FOLLOWING ACTIVITIES:1.CONDUCTED A MAIL SURVEY OF 246 SUBJECT VEHICLE OWNERS TODETERMINE THE ROADWAY SURFACE THAT CAUSED OWNERS' CONCERN;2.INTERVIEWED COMPLAINING OWNERS;3.CONDUCTED FIELD INSPECTIONS OF SEVEN (7) COMPLAINT VEHICLES;4.INSTRUMENTED TESTING AT VRTC OF COMPLAINT AND PEER VEHICLES;5.REVIEWED SUBARU'S RESPONSE TO OUR INFORMATION REQUEST;6.MET WITH SUBARU FOR TECHNICAL REVIEW OF TESTINGAS A RESULT OF THE WORK CONDUCTED BY VRTC AND ODI DURING THIS INVESTIGAITON, A CONSISTENT OR CHRONIC PATTERN OF POOR BRAKE PERFORMANCE HAS NOT BEEN IDENTIFIED.VRTC CONDUCTED OVER 11,500 BRAKE TESTS.THEY DID NOT OBSERVE ANY LONG-DURATION, LOW DECELERATION EVENTS (SOME OWNERS REPORTED DELAYS OF 4 TO 10 SECONDS) IN THE TEST VEHICLES.SEE ODI'S CLOSING REPORT AND VRTC'S TEST REPORT FOR FULL DETAILS

CAR WAS RECALLED IN APPROXIMATELY 2009 FOR A FUEL LEAK WHICH COULD CAUSE AND ENGINE FIRE. I KNOW BECAUSE I'VE OWNED THIS CAR I BOUGHT IT NEW IN 2003. THE PROBLEM HAS REOCCURRED. TO FIX IT, THE INTAKE MANIFOLD HAD TO BE REMOVED AND 3 SHORT FUEL LINES HAD TO BE REPLACED. WORK WAS DONE BY ALPINE AUTOMOTIVE IN LAKE ZURICH, ILLINOIS. I'VE REACHED OUT TO SUBARU WHO SAY THEY KNOW OF NO ISSUE. HOWEVER, I FOUND AN ARTICLE PUBLISHED IN 2009 IN US NEWS & WORLD REPORT, SAYING THAT THE WARRANTY FOR THIS ISSUE WAS BEING EXTENDED BY 12 YEARS , WHICH PUTS THE CAR STILL IN WARRANTY FOR THIS ISSUE.. *BF

NHTSA ID

11181970

Incident

Feb 1, 2019

FUEL LEAKING ONTO MY ENGINE BLOCK COULD RESULT IN MY CAR ENGULFING IN FLAMES, NO RECALL FOR IT ON MY CAR BUT I SEE IT EVERYWHERE AND IT'S A SUPER COMMON PROBLEM. THE CABIN OF THE CAR ALWAYS SMELLS LIKE GAS USUALLY IN THE COLD, BUT WHEN I SMELL THE ENGINE IT SMELLS BADLY OF RAW GASOLINE.

NHTSA ID

11063189

Incident

Jan 2, 2018

Mileage

100,000 mi

TL* THE CONTACT OWNS A 2003 SUBARU WRX. THE CONTACT NOTICED A STRONG FUEL ODOR INSIDE THE VEHICLE. THE VEHICLE WAS TAKEN TO BYERS AIRPORT SUBARU (LOCATED AT 401 N HAMILTON RD, COLUMBUS, OH 43213). THE DEALER WOULD NOT REPAIR THE VEHICLE PER NHTSA CAMPAIGN NUMBER: 09V468000 (FUEL SYSTEM, GASOLINE). THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND DEMANDED THE DEALER TO REPAIR THE VEHICLE; HOWEVER, THE VEHICLE WAS NOT REPAIRED. THE CONTACT WAS ADVISED THAT THE RECALL HAD EXPIRED AND HE WOULD HAVE TO PAY FOR THE REPAIR. THE FAILURE MILEAGE AND VIN WERE UNKNOWN. UPDATED 10/24/17*LJ UPDATED 10/25/2017*JS

NHTSA ID

11015766

Incident

Nov 9, 2015

Mileage

110,000 mi

WHEN IT GET COLD OUT, THE FUEL LINE STARTS LEAKING AND THERE IS THE SMELL OF GAS IN THE CAR. THERE HAS BEEN A LIMITED RECALL FOR THIS ISSUE DEPENDING ON WHERE THE VEHICLE WAS PURCHASED. I LIVE IN A STATE NOT INCLUDED IN THE RECALL AREA. THIS DOESN'T CHANGE THE FACT THAT IT IS A SERIOUS SAFETY ISSUE AND THE MANUFACTURER SHOULD CORRECT IT NO MATTER WHAT STATE I LIVE IN (ILLINOIS). THIS IS CLEARLY A MANUFACTURER'S DEFECT AND ASK THAT THEY FIX THIS ISSUE.

NHTSA ID

10788271

Incident

Oct 30, 2015

Mileage

105,000 mi

MY DREAM CAR DEMOLISHED IN SPLIT SECOND. COULD HAVE VERY EASILY DIED AS WELL AS MY PASSENGER. I LOOKED UP THE RECALLS WHEN I GOT THE CAR AND IT WAS NOT LISTED YET, THE STEEL FRONT CONTROL ARMS IN THE SNOW BELT STATES RUST OUT AND CAUSE THE VEHICLE TO LOOSE CONTROL AND OR CRASH. WELL IT DID BOTH TO ME AS WELL AS EXCELERATE MY CAR. I WAS ON A DATE THAT NIGHT FOR THE FIRST TIME IN A WHILE. AND ON OUR WAY HOME, WE WERE COMING AROUND A SLIGHT BEND, I WAS GOING PROBABLY 35-40 MPH AND RIGHT WHEN I TURNED THE STEERING WHEEL GOING AROUND THE BEND I HEARD A CRACK/THUD NOISE AND INSTANTLY I SWEAR ON MY DADS GRAVE THAT THE CAR ACCELERATED, IT WAS OBVIOUSLY OUT OF CONTROL, I COULD NOT STOP THE CAR IT KEPT GOING THE SAME WAY AS THE TURN, AND HIT AN EMBANKMENT ABOUT 3 1/2 FEET TALL THE FRONT DOOR OPENED SOMEHOW WHEN I HIT. IT BENT THE COMPLETE DOOR UP AND LOOKED LIKE A LAMBORGHINI DOOR. LUCKILY WE HAD ARE SEAT BELTS ON! THE CAR THE PROCEEDED TO FLIP ON TO ITS ROOF. BACK, FRONT SIDE WINDOWS BLOWN OUT. BOTH UPSIDE DOWN IN AWE. MADE SURE SHE WAS OK. SHE WAS CUT UP ON HER ARM AND HAD SEATBELT MARKS. AS FOR ME I KNOW I HIT MY HEAD BAD BUT I DON'T EVEN REMEMBER, IT HAPPENED SO FAST AND UNPREDICTABLE! I HAD THAT CAR PAID OFF. LOVED IT SO MUCH BUT I'M VERY DISAPPOINTED I WAS NEVER AWARE OF THE RECALL. I LOOKED UP MY VIN THE DAY OR SO AFTER, AND IT SAID THE CONTROL ARMS WERE NEVER REPLACED. A MONTH OR SO LATER I CHECK AGAIN, AND IT SAYS THEY WERE FIXED.. NOW COME ON, THAT'S A LITTLE WEIRD AND CONVIENENT IF I SO HAPPENED TO SUE SUBARU. I ALSO HAD MY CAR AT A LOCAL SUBARU DEALER 3 MONTHS BEFORE FOR A OVERALL MAINTENANCE CHECK AND LOOK OVER... WHY DID THEY NOT KNOW, WHY DID THEY NOT EVEN SEE THE CORROSION. I WAS SO IN SHAMBLES AFTER THE WRECK, THAT WHEN THE INSURANCE GUY CAME TO LOOK AT MY CAR IT WAS TOTALED OBVIOUSLY. I TRIED POINTING OUT WHAT HAPPENED, HE REALLY COULD OF CARED LESS.

NHTSA ID

10725033

Incident

Sep 20, 2013

Mileage

153,000 mi

IN COLD WEATHER THE FUEL LINES LEAK ON THE 2003 SUBARU IMPREZA WRX! THERE WAS A LIMITED RECALL IN CERTAIN NORTHERN STATES, HOWEVER IT GETS COLD IN MANY STATES WHERE THERE WAS NO RECALL. THE CAR HAS BECOME DANGEROUS TO DRIVE B/C I CAN SMELL THE GAS WHICH MEANS THERE IS THE DANGER OF IGNITION. SUBARU KNOWS OF THIS ISSUE AND SHOULD ISSUE A RECALL FOR ALL CARS AFFECTED. *TR

NHTSA ID

10670820

Incident

Jan 7, 2015

Mileage

164,000 mi

ON THE MORNING OF FEB 3, 2014 I STARTED MY CAR AND IT SMELLED VERY STRONGLY OF RAW GAS. I TURNED OFF THE CAR AND HAD IT TOWED TO MY LOCAL REPAIR SHOP. THE TOW COST $84.70. I FOUND OUT LATER THAT MORNING THAT SUBARU ISSUED A RECALL BEGINNING DECEMBER 31, 2009 FOR 2002 AND 2003 SUBARU WRXS WHERE THE FUEL LINE LEAKS IN EXTREME COLD. UNFORTUNATELY, THE RECALL INCLUDED ONLY 16 STATES, AND OFFERED AN EXTENDED WARRANTY TO THE OTHER 34 STATES NOT NAMED IN THE RECALL (I RESIDE IN ONE OF THE 34 FOR THE "EXTENDED WARRANTY"). I PROMPTLY PHONED SUBARU OF AMERICA AND MY LOCAL DEALERSHIP, WEBSTER GROVES SUBARU ABOUT THE ISSUE. THE SERVICE DEPARTMENT EMPLOYEE, [XXX], ADVISED ME TO DRIVE MY VEHICLE OVER TO HAVE IT CHECKED OUT. CONSIDERING THIS IS TALKING ABOUT RAW GAS AND AT LEAST ONE FIRE HAS BEEN REPORTED IN RELATION TO THE RECALL, I DO NOT AGREE WITH THIS SUGGESTION. BOTH SUBARU OF AMERICA AND THE DEALERSHIP AFFIRMED THAT THE CAR WOULD HAVE TO BE TAKEN TO A DEALERSHIP TO SEE IF IT MIGHT BE CONSIDERED FOR THE RECALL. AFTER DIRECTLY TELLING [XXX] I WILL NOT DRIVE THE VEHICLE SINCE IT IS DANGEROUS (THE RECALL EVEN STATES THAT IT IS DANGEROUS!), SHE AGREED TO CALL HER DISTRICT MANAGER THEN RETURN MY CALL. THIS IS NOT THE WHOLE OF MY CONCERN. WE HAVE HAD COLDER WEATHER ALL OVER THE UNITED STATES THIS YEAR AND I AM VERY CONCERNED ABOUT THIS ISSUE. I WAS NOT NOTIFIED OF THE EXTENDED WARRANTY OR THE ISSUE BY SUBARU, AND I GATHER OTHER INDIVIDUALS WERE NOT AS WELL AND THEIR SAFETY COULD BE AT RISK. WHILE IT WOULD BE IDEAL FOR SUBARU TO PAY FOR THE NECESSARY REPAIRS TO MY VEHICLE, I ULTIMATELY HOPE THEY WILL NOTIFY ALL 2002 AND 2003 SUBARU WRX OWNERS OF THIS POTENTIAL HAZARD FOR THE SAFETY OF EVERYONE! THIS IS NOT JUST A SMALL OPTIONAL RECALL, BUT ONE THAT COULD CAUSE SERIOUS HARM TO DRIVERS, THEIR PASSENGERS AND FELLOW DRIVERS. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10562885

Incident

Feb 3, 2014

Mileage

127,000 mi

TL* THE CONTACT OWNS A 2003 SUBARU WRX. THE CONTACT STATED THE VEHICLE BEGAN LEAKING OIL FROM THE AVCS LINE AND WOULD LEAK ONTO THE MANIFOLD, CREATING A FIRE HAZARD. THE MANUFACTURER ADVISED THERE WERE NO RECALLS FOR THE FAILURE AND ANY REPAIRS WOULD BE THE CONTACT'S EXPENSE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE APPROXIMATELY 31,000.

NHTSA ID

10339906

Incident

Jun 19, 2010

Mileage

31,000 mi

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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.

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