2004 SUBARU IMPREZA Fuel/propulsion System Problems

There is a recall for fuel lines for MY2002-2003 Imprezas and the issue was resolved or a fix was implemented on late MY2004 vehicles. Unfortunately this means early MY2004 vehicles are still impacted by the issue with no recall in place. During cold weather or during cold engine startup fuel lines are prone to leaking onto cylinder head. Raw fuel can be observed dripping, and can be smelled in the engine bay and inside of the vehicle. This poses a fire risk during vehicle operation and the MY2002-2003 recall should be extended to MY2004 vehicles built prior to August 2003.

Rubber fuel lines under the intake manifold leak fuel when the temperature falls below 40 degrees F. The smell permeates the cabin and fuel can be seen wetting nearby surfaces under the intake. An inspection can be performed. This represents a fire safety hazard that could occur while the vehicle is in motion, jeopardizing all surrounding traffic. The problem is widely noted on Subaru internet forums, but only a recall for 2002-2003 models has been reported. My car is a very early 2004, so it shares traits of the 2003 engines. There are no warning lamps or notifications, only the smell of raw gas when the car starts and is in motion in winter temperatures. This has happened repeatedly since the issue first occurred, so I avoid driving this vehicle if at all possible.

THERE IS A STRONG FUEL/GASOLINE SMELL COMING THRU THE AIR VENTS FROM THE ENGINE WHEN THE TEMPERATURE GOES UNDER 30-25 DEGREES FARENHEIT. I'VE CHECKED UNDER THE HOOD AND THERE IS TWO FUEL HOSES THAT START LEAKING WHEN IT GETS COLD OUTSIDE. THIS HAS BEEN HAPPENING EVERY WINTER SINCE I GOT MY CAR BACK IN 2016. I HAD THE CLAMPS ON THE HOSES RETIGHTENED BY A SUBARU DEALERSHIP BUT THAT DIDN'T SOLVE THE PROBLEM. I'M WRITING THIS COMPLAINT BECAUSE THERE IS AN OPEN RECALL FOR THIS ISSUE ON THE 2002 AND 2003 WRX, BUT NOT ON THE LATER MODELS. THERE'S MANY PEOPLE ON THE INTERNET WITH THE SAME ISSUE AND IT SEEMS TO BE HAPPENING TO OTHER YEARS OF WRX AND EVEN OTHER MODELS OF SUBARU. IT'S REALLY STRESSFUL AND ANNOYING HAVING THE STRONG SMELL OF FUEL COMING IN TO YOUR CAR. ALSO IT'S A FIRE HAZARD HAVING GASOLINE POOLING UP ON THE ENGINE BLOCK. THIS ISSUE HAS BEEN KNOWN TO SUBARU OF AMERICA BUT THEY ONLY TOOK CARE OF THE 2002 AND 2003 WRX MODELS. I'M HOPING THIS CAN SOMEHOW HELP OTHER SUBARU OWNERS GET THIS PROBLEM FIXED AS IT CAN BE SOMETHING THAT COULD END UP GETTING WORST.

I ARRIVED AT A GAS STATION WHERE I FILLED UP MY SUBARU IMPREZA RS 2.5L WITH 87 UNLEADED MID GRADE FUEL AND FROM THAT POINT ON STILL TILL TODAY MY VEHICLE HAS HAS THE CHECK ENGINE LIGHT ON, WHEN THE AIR CONDITIONER IS TURNED ON AND I'M GOING 55 MPH OR HIGHER GASOLINE CAN BE SMELLED WITHIN THE VEHICLE. WHEN REFUELING THE GAS PUMP CONTINOUSLY STOPS AS IF THE FUEL CHAMBER IS FULL. AFTER REFUELING THE VEHICLE FAILS TO TURN OVER OR STAGGERS WEAKLY TO START.

Mileage: 198,000

TL* THE CONTACT OWNS A 2004 SUBARU IMPREZA. THE CONTACT STATED THAT THE CHECK ENGINE INDICATOR ILLUMINATED. ALSO, WHEN THE CONTACT FILLED UP THE FUEL TANK, THERE WAS A STRONG ODOR INSIDE THE VEHICLE. THE CONTACT ALSO LOCATED FUEL INSIDE THE VEHICLE ON THE REAR DRIVER'S SIDE. THE VEHICLE WAS TAKEN TO PAUL MILLER SUBARU (3469 US-46, PARSIPANNY, NJ) WHERE IT WAS DIAGNOSED THAT FUEL WAS LEAKING FROM ALL THE FUEL LINES UNDER THE VEHICLE. THE MANUFACTURER WAS NOT CONTACTED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 110,000.

Mileage: 110,000

DRIVER SIDE FUEL LINE THAT IS CONNECTED TO THE FUEL RAIL UNDERNEATH THE TURBO INLET HOSE LEAKS GAS. THE SMELL IS VERY NOTICEABLE AND I'M PRETTY SURE IT'S DANGEROUS SINCE IT COULD CAUSE AN ENGINE FIRE.

Mileage: 79,000

DURING COLD WEATHER A STRONG SMELL OF FUEL CAN BE DETECTED COMING FROM THE ENGINE BAY WHILE BOTH MOVING AND STATIONARY. THIS PROBLEM ONLY OCCURS DURING COLDER WEATHER.

Mileage: 151,598

DURING THE PAST 8+ WINTERS, THERE IS A STRONG FUEL SMELL. I'VE CALLED SUBARU OF AMERICA AND THEY SAID THAT ONLY THE TWO PREVIOUS MODELS WERE RECALLED FOR THIS PROBLEM. ACCORDING TO MY RESARCH, IT SOUNDS LIKE THIS PROBLEM PERSISTS WITH MANY SUBARU MODELS. I'VE BEEN ABLE TO CLOSE THE AIR VENTS TO KEEP THE SMELL OUT IN PREVIOUS YEARS. TODAY, WHITE SMOKE STARTED TO COME OUT OF MY HOOD WHILE DRIVING AND STATIONARY. THE TEMPERATURE IS IN THE SINGLE NEGATIVE DIGITS.I BELIEVE THERE IS NOW ENOUGH FUEL LEAKAGE ONTO THE MANIFOLD THAT IT IS STARTING THE SMOKE.

Mileage: 215,000

IT RECENTLY BEEN COLD IN COLORADO AND NOW I HAVE THIS RAW FUEL SMELL IN CABIN DURING COLD WEATHER. FUEL LINE LEAKING COMING FROM THE RUBBER HOSE CONNECTOR LOCATED UNDER THE INTAKE MANIFOLD, BETWEEN TWO DIRECT FEED LINE TO THE INJECTOR.

UNDER COLD CONDITIONS (40F OR LESS) THE RUBBER FUEL RAILS WILL CONTRACT UNDER THE INTAKE MANIFOLD AND WILL SLOWLY LEAK GASOLINE CAUSING AN OVERWHELMING SMELL AND POSSIBILITY FOR A FIRE. THIS HAPPENS WHEN THE CAR IS BOTH STATIONARY AND UNDER MOTION. THIS PROBLEM WAS ACKNOWLEDGED IN THE YEAR 2009 FOR THE 2002-2003 YEAR MODELS FOR THE SUBARU IMPREZA WRX AND A RECALL WAS ENACTED. HOWEVER, THIS RECALL DID NOT INCLUDE THE 2004-2005 MODELS EVEN THOUGH THE SAME ENGINE WITH THE SAME FUEL RAILS WERE USED. THIS PROBLEM HAS BEEN CONSISTENT AND PREDICTABLE FOR THE 3 WINTERS THAT I HAVE OWNED THE CAR. I HAVE ALSO HEARD FROM OTHERS WITH THE SAME YEAR CAR THAT THEY ARE HAVING SIMILAR PROBLEMS. THE PICTURES I INCLUDED SHOW THE SCREW THAT CLAMPS THE RUBBER HOSES. THE GAS LEAKS AT THIS CONNECTING POINT BUT IT WAS HARD TO GET A PICTURE OF THE ACTUAL HOSES. I HAVE CONTACTED SUBARU OF AMERICA AND THEY DIRECTED ME TO BRING THIS UP WITH NHTSA. THANK YOU!

Mileage: 140,000

IN TEMPATURES LESS THAN FREEZING, A STRONG ODOR OF GASOLINE IS NOTICED WITHIN THE CABIN. FUEL LINES ARE NOT CRACKED IN ANY WAY, CLAMPS HAVE BEEN TIGHTENED, ALL MEASURES TAKEN UP TO REPLACING ALL FUEL LINES, WHICH IS NOT NEEDED. THIS IS A KNOWN ISSUES WITH PRIOR MODELS AS WELL.

PLEASE NOTE THAT RECALLS HAVE BEEN DONE FOR THE EXACT SAME PROBLEM ON THE 2002 & 2003 SUBARU IMPREZA MODELS, BUT NOT THE 2004. WHEN THE VEHICLE IS PARKED OR BEING DRIVEN IN COLDER TEMPERATURES (BELOW 45 DEGREES), THE FUEL HOSE CONSTRICTS CAUSING FUEL TO SPILL OUT ONTO THE INTAKE MANIFOLD & THE ENGINE TO HEAVILY SMOKE. DURING WARMER TEMPERATURES, THE VEHICLE DOES NOT SMOKE BUT THERE IS STILL A STRONG SMELL OF GASOLINE IN THE PASSENGER COMPARTMENT. THE FUEL HOSES ARE INTACT WITH NO CRACKS OR BREAKS OF ANY KIND. I HAVE FOUND HUNDREDS OF OTHER 2004 MODEL CONSUMER'S WITH THE SAME ISSUE. I HAVE ATTACHED A COPY OF ONE OF THE FORUM'S FOR YOUR REFERENCE. I HAVE CALLED SUBARU OF AMERICA REGARDING THIS, BUT HAVE BEEN TOLD MY CLAIM IS NOT VALID BECAUSE THE VEHICLE HASN'T HAD THIS PROBLEM BEFORE. I EXPLAINED THAT THE VEHICLE HADN'T LIVED IN COLDER TEMPERATURES UNTIL WE BOUGHT IT. STILL NO HELP. THIS HAS THE POTENTIAL TO CAUSE AN ENGINE FIRE AND POSES A HUGE SAFETY RISK. PLEASE HELP!

Mileage: 144,000

STRONG FUEL SMELL WHEN TEMPERATURES ARE BELOW FREEZING THAT DOES NOT DISIPATE. 2002-2003 MODELS HAVE BEEN RECALLED FOR SAME DESIGN FLAW IN FUEL LINE. SINCE I OWN A 2004, REPAIR MAY COST UPWARDS OF $400 DUE TO EXTENSIVE LABOR INVOLVED. FOUND MANY OTHERS WITH SAME ISSUE WHEN RESEARCHING SITUATION ONLINE. I AM CONCERNED ABOUT POTENTIAL FIRE HAZARD.

Mileage: 120,000

IN COLD WEATHER <30 DEGREES F, GASOLINE LEAKS FROM THE FUEL LINES UNDER THE INTAKE MANIFOLD. THE LEAK APPEARS TO BE COMING FROM WHERE THE RUBBER FUEL LINE IS CONNECTED TO THE METAL FUEL LINE ON UNDER THE PASSENGER SIDE OF THE INTAKE MANIFOLD. LOOKS TO BE A LOOSE HOSE CLAMP. THERE IS NO ACCESS TO THIS LINE TO FACILITATE TIGHTENING.

Mileage: 70,000

RAW FUEL SMELL WHEN STARTING OUR 2004 SUBARU WRX IN SUB FREEZING WEATHER. THE FUEL FUMES FILL THE CABIN AND CREATE A FIRE HAZARD UNDER THE HOOD.

Mileage: 44,604

MY 2004 IMPREZA WRX STI LEAKS GASOLINE OUT OF A FUEL LINE UNDER THE INTAKE MANIFOLD EVERY TIME THE TEMPERATURE DROPS BELOW ABOUT 30 F. THE RUBBER HOSE CONNECTING THE METAL FUEL LINES ISN'T LONG ENOUGH AND AT THAT TEMPERATURE THE SHRINKAGE IS ENOUGH TO MAKE IT VISIBLY DRIP GASOLINE WHILE THE CAR IS RUNNING. THE HOSE LOCATION REQUIRES REMOVING THE INTAKE MANIFOLD TO GAIN ACCESS TO FIX THE PROBLEM. I'VE RESEARCHED THIS ISSUE AND THERE ARE MANY, MANY SUBARU OWNERS WITH THE SAME PROBLEM. SUBARU DID A RECALL FOR 2000-2002 VEHICLES, BUT THIS PROBLEM AFFECTS MANY OTHER YEARS OF IMPREZA WITH THE EXACT SAME FUEL RAIL SETUP. *TR

Mileage: 95,000

THERE IS A VERY STRONG SMELL OF UNBURNED FUEL IN THE CABIN ON COLD DAYS (BELOW 10F). THE FUEL SMELL DISSIPATES WHEN THE CAR WARMS-UP. THE SMELL HAS CAUSED PASSENGERS IN THE CAR TO BECOME SICK AND IS A SERIOUS DISTRACTION TO DRIVING. WHEN I CONTACTED TWO DIFFERENT SUBARU DEALERS, THEY ACTED LIKE IT WAS THE FIRST TIME THEY HAD HEARD OF THIS ISSUE AND BOTH WANTED TO TAKE THE ENGINE APART. HOWEVER, A QUICK SEARCH ON THE INTERNET REVEALS THIS IS A PREVALENT ISSUE FOR THE SUBARU IMPREZA IN COLD WEATHER. *TR

Mileage: 65,000

WHILE UNDER FREEZING TEMPERATURES OUTSIDE CAR SMELLS STRONGLY OF FUEL WHILE RUNNING. SOMETIMES IT TAKES HALF AN HOUR OR MORE TO JUST WHAT I CONSIDER BREATHABLE AIR IN THE CABIN. IT WAS -20 DEGREES OUTSIDE SO OPENING WINDOWS IS NOT AN OPTION AND DRIVING IN GAS FUMES IS NOT SAFE. *TR

Mileage: 148,000

THERE IS A STRONG GASOLINE ODOR WHEN STARTING THE CAR UP IN COLD WEATHER. THE ODOR OF GASOLINE FILLS THE PASSENGER COMPARTMENT. IT ONLY HAPPENS WHEN IT'S COLD OUTSIDE. WE JUST PURCHASED THE CAR USED IN JULY. *TR

Mileage: 52,000

AS WITH THE PREVIOUS YEARS OF THIS VEHICLE, I AM EXPERIENCING THE FUEL LEAK UNDER MY INTAKE MANIFOLD FROM THE RUBBER FUEL LINES IN COLD WEATHER. I HAVE NOT EXPERIENCED FIRE BUT THE DANGER IS PRESENT AS THE LEAK IS NEAR THE TURBO INLET AND EXHAUST. THE 2002-03 IMPREZAS HAVE BEEN RECALLED. *TR

Mileage: 135,000

IN COLD TEMPERATURES, MOST OFTEN DURING COLD STARTS, THE VEHICLE'S CABIN FILLS WITH THE SMELL OF GASOLINE. USUALLY TAKES ABOUT 15 TO 30 MINUTES FOR ODOR TO GO AWAY. DURING THAT TIME AT STOP SIGNS, STOP LIGHTS, ETC THE SMELL OF GASOLINE PERSISTS. *TR

Mileage: 141,000

UPON COLD STARTING THE CAR THERE IS A PROMINENT RAW FUEL SMELL. IT ONLY SEEMS TO HAPPEN WHEN TEMPERATURES OUTSIDE ARE SUB-FREEZING. THE LOWER THE TEMPERATURE THE WORSE THE FUEL SMELL BECOMES. AFTER THE CAR HAS WARMED UP THE FUEL SMELL GOES AWAY. IT IS VERY SIMILAR TO THE PROBLEM SUBARU HAD WITH IT'S 02-03 IMPREZAS, WHICH THEY ISSUED A RECALL FOR THE FUEL LINES, WHICH WERE TOO SHORT AND IN THE COLD WOULD SHRINK FURTHER CAUSING A LEAK UNTIL THE CAR WARMED UP. I AM SUBMITTING THIS COMPLAINT BECAUSE SUBARU OF AMERICA DENIES THE ISSUE EXISTS AND IS CHARGING AROUND $400 AT THE DEALERSHIP TO SWAP OUT THE FUEL LINES. *TR

Mileage: 91,000

TL* THE CONTACT OWNS A 2004 SUBARU IMPREZA. THE CONTACT STATED THAT THEY SMELLED FUEL COMING FROM THE VENTS INSIDE THE CABIN OF THE VEHICLE. THE CONTACT LOOKED UNDER THE HOOD AND FOUND THAT THE CLAMP GOING TO THE HIGH PRESSURE FUEL RAIL FOR THE INJECTORS WAS LOOSE AND LEAKING FUEL. THE CONTACT TIGHTENED THE CLAMP AND PLANNED TO TAKE THE VEHICLE TO THE DEALER. THE FAILURE AND THE CURRENT MILEAGES WERE 95,068.

Mileage: 95,068

UPON STARTING THE CAR DURING THE COLDER WINTER MONTHS, A RAW FUEL SMELL WILL BEGIN TO FILL THE CABIN IF THE HVAC SYSTEM IS TURNED ON TO VENT FRESH AIR. THIS SMELL IS STRONG ENOUGH TO CAUSE LIGHTHEADEDNESS AND THE SENSATION OF NAUSEA. UPON FURTHER INVESTIGATION, THE PASSENGER SIDE FUEL LINE IS LEAKING FUEL UNDERNEATH THE INTAKE MANIFOLD, TO THE EXTENT THAT YOU CAN VISIBLY SEE A PUDDLE OF FUEL BOILING ON TOP OF THE ENGINE BLOCK. THIS HAPPENS BECAUSE THERE ARE TWO HARD METAL FUEL LINES RUNNING TO THE FUEL INJECTORS CONNECTED BY A SMALL PIECE OF RUBBER HOSE WITH CLAMPS. HOWEVER THIS HOSE FROM THE FACTORY IS CUT TOO SHORT, SO WHEN THE TEMPERATURE IS COLD ENOUGH THE RUBBER LOOSES ITS ELASTIC PROPERTIES AND AS THE METAL LINES VIBRATE / MOVE WITH THE MOTOR, IT LEAKS FUEL OUT OF THE RUBBER HOSE. THIS PROBLEM HAS BEEN ADDRESSED BY SUBARU IN THE TSB #09-36-03. THEY OFFER TO REPLACE THE RUBBER HOSE AND HARD METAL FUEL LINE FOR MODEL YEARS 2002 AND 2003 IMPREZA WRX'S FREE OF CHARGE. HAVING BEEN AN OWNER OF A 2002 IMPREZA WRX BEFORE PURCHASING MY 2004 IMPREZA WRX, I HAD THIS SERVICE PERFORMED AT MY LOCAL SUBARU DEALERSHIP. I AM DISGUSTED TO FIND OUT THAT THIS COVERAGE DOES NOT APPLY TO THE MODEL YEAR 2004 IMPREZA WRX, WHEN IT FEATURES AN IDENTICAL MOTOR AND DRIVETRAIN TO THE PREVIOUS YEARS (2002, 2003.) THIS MEANS THAT THE FUELING SYSTEM IS IDENTICAL AS WELL, AND THAT THE PREVIOUSLY ACKNOWLEDGED RAW FUEL LEAK IS HAPPENING IN MY CAR AS WELL. THE FACT THAT THE 2004 IMPREZA WRX HAS THE SAME MOTOR. AND SAME FUEL SYSTEM, AND SUBARU OF AMERICA WILL OPENLY DENY COVERAGE TO HAVE THE PARTS REPLACED IS TRULY DISGUSTING IN ITSELF. RAW FUEL LEAKING ON TOP OF A HOT ENGINE BLOCK, AROUND SOURCES OF IGNITION IS THE MOST EXTREME OF SAFETY HAZARDS, AND NOW I OWN A VEHICLE IN WHICH I CANNOT TRANSPORT MY WIFE AND CHILD. I AM TRULY DISAPPOINTED IN SUBARU FOR TURNING A COLD SHOULDER TO THIS. *TR

Mileage: 105,000