Fuel Hoses Lines/piping And Fittings problems of the 2004 Subaru Forester

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. . Read more...

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.

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.

Immediately upon starting the engine a strong smell of gasoline filled the entire passenger cabin. Cold weather temperature was well below freezing. Has happened previously, and is corrected by tightening the fuel line connections.

2004 Subaru Forester xs when temperatures drop the fuel line shrinks around the fitting and raw gas leaks at a rate of 1 drop per 3-5 seconds directly onto the exhaust manifold. We first noticed the pool of gas on the exhaust manifold on a 20° f day. The raw gas fumes that filled the cabin were so strong we got severe headaches and had to turn off the heater and drive home with the windows down. I am pregnant & became extremely nauseated. Upon exit the smell of fuel was extremely strong on the passenger side near the front wheel well. When the car is running & the hood is open you can see the gas dripping where the fuel line is clamped to a fitting and collecting on the manifold. I called the dealership first thing in the morning. They told me it was a common problem and when the weather warms up the line will expand and it will be fine. The problem is, it's an abnormally cold winter with temps in the single digits & we can't wait until spring to drive our car with out fears of blowing up. We can't even park it in the garage when not driven due to the strong fumes. When asked if there was a recall I was also told that there is only one for the wrx for this issue, which happens to use the exact same parts. How have other models with the same fuel line, clamps and fittings, & posing the exact same risk not been recalled? this is not lack of maintenance, age, or neglect. This is a design flaw that poses serious risk. It just so happens this is the first winter cold enough to unmask the problem. Please google search 2004 Forester gas leak and you will see, this is unfortunately common. It occurs in multiple models, over multiple years, all using the same shrinking fuel line. Please don't wait until this fire risk takes a life before it is investigated.

Upon starting car in cold weather (approx. 25 degrees f or colder), there is a strong fuel smell. Cannot turn heat on as fuel smell fills cabin and makes passengers nauseous. Headaches have also occurred. When vehicle is parked in garage after driving in cold weather, fumes accumulate in garbage and leak into house as well. Apparently fuel lines shrink in cold and leak fuel directly onto engine. This is both health and fire hazard.

After coming home and parking my car in the garage my wife came in from the garage and said it smelled like gas. I found the source to be my 2004 Subaru. I drove it the dealer the next morning and they said that the fuel lines due to the cold, as it was below 20 degree's, pulled away from the fuel rail so raw gas was pooling on the manifold. They kept it for a week saying it was not safe to drive, and replaced all the fuel lines and clamps for $850. They said it was one of the worst leaks they have seen. I have now read numerous complaints on this issue and noticed the 2003 wrx, same engine, was recalled for this safety issue. I guess I am lucky as it could have caught me, my house or who knows what on fire if it has sparked.

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/cn the fuel lines, clamps and upper intake gaskets were replaced. The fuel lines were cracked. Updated 04/01/14.

Strong raw fuel smell in cabin of car during cold start/cold weather. It appears that the fuel lines shrink in cold weather and pull away from the metal fuel lines causing vapor leak as well as fuel leaks. The problem is that the fuel lines are located under the intake manifold and are impossible to tighten unless the manifold is removed. This is a huge safety hazard.

Gas lines leak on 2004 Subaru Forester xt when ambient temperatures fall below 30 degrees fahrenheit. Significant amounts of fuel leak into the engine area, and strong fumes enter the passenger area. Nhtsa has already issued a TSB on the Subaru wxt regarding the same problem. Concerned about fire hazard and inhalation of gasoline vapors. Very strong odor. Could not continue to drive.

Fuel odor noted in passenger compartment starting 4/9/11, (137218 mi) 55 degree ambient temperature, vehicle running for 10+ minutes and up to temperature. At stop light when odor began. Children in the vehicle became nauseated and began retching. Windows down to vent passenger compartment. Odor identified in passenger compartment and engine bay only, no raw fuel odor in exhaust or surrounding the vehicle. 4/11/11, 52 degrees, 137463 mi 4/13/11, tightened accessible fuel line clamps in engine bay 4/27/11, 40 degrees, 138113 mi 4/28/11, 53 degrees, 138215 mi 4/30/11, isolated leak to area immediately below manifold, near air filter on left side (passenger side) of engine; able to visualize fuel leaking onto engine at rate of 5 drops/10 seconds. 5/1/11 45 degrees, 138511 mi concerns over safety of exposed fuel in engine bay (explosion hazard), as well as effect of fumes on adults/children (toxicity), and non-compliance with epa standards. To contact Subaru of America to discuss options for repair/replacement of affected parts.

In very cold temperatures (below freezing), the fuel line under the intake on the passenger side will occassionally leak at the connection between the rubber hose and steel line. It will drip fuel onto the engine block until it warms up. The smell of gasoline can be detected inside the vehicle and around the engine area. The fuel drips at a rate of about 1 drip per 1-3 seconds until the hose warms up and seals against the steel line. The dealer could not duplicate the problem, but they offered to tighten the fuel line fittings. The intake manifold had to be lifted and the cost was about $150, but they couldn't guarantee a fix. It will have to be rechecked in colder weather. This 2004 Forester xt has 70,000 miles on it.

1. Noticed strong gas odor after driving car. Upon inspection, noticed gas pooled on engine top, passenger side, under intake manifold. 2. Appears that fuel line is leaking. Unable to ascertain exactly where, because leak is behind intake manifold. Occurs during very cold weather. 3. Repairs forthcoming.

Raw fuel smell in cabin during cold start. Took to mechanic and he sees fuel leaking from the fuel line under passenger intake manifold. To resolve issue he will have to pull the intake, replace fuel lines and use better clamps. The clamps and hose used by Subaru is faulty as I see a ton of complaints online about the same issue. They even did a recall on the wrx which has the same motor as the Forester.

I own and daily drive a 2004 Forester xt. It has recently developed what I consider to be a severe safety related issue. Last night, after driving approximately 30 minutes, there was an overwhelming smell of raw fuel in the cabin. This situation happened again this morning while sitting in traffic, at a red light. The smell of gasoline was so strong, I felt light headed and had to roll down the windows when the temperature outside was 24 fahrenheit. I found that Subaru of America (soa) issued a recall for the same problem on wrx models which produced this symptom. Upon inspection of my engine, I can both see and smell raw fuel seeping from one or more of the fuel lines. I continued my research and found that there are many reports of this issue covering many year models of the Forester and the legacy models. Due to the volatility of gasoline and the inherent dangers to humans in vapor form, I feel this is a critical safety issue. I have read many reports and noticed the apparent large population of affected vehicles. This is very disconcerting. I am contacting soa to report this problem and to request they cover the failure under goodwill.

The contact owns a 2004 Subaru Forester. The contact stated that as the temperature started to drop he noticed fluid leaking from the engine. He inspected the vehicle and realized that the hard fuel line was loose. The manufacturer was contacted and offered no assistance. The vehicle had not been repaired. The failure mileage was approximately 104,000.

In cold weather (below 0â°f) vehicle leaks fuel in the engine compartment. Vehicle was parked outside starting at 6:30 am, with an outdoor air temperature of approximately -11â°f after a 6 mile drive. When vehicle was restarted at 11:30am, with an outdoor air temperature of approximately 3â°f, fuel smell was noticed within one mile. Fuel leak is from high pressure hose on passenger side of vehicle, just forward and below the manifold. Car was towed to shop and shop replaced high pressure fuel hose and clamps. Photos of exact location of leak, components replaced, repair bill and national weather service temperature data available in pdf format.

Gas lines leak on 2004 Subaru Forester xt when ambient temperatures fall below 20 degrees fahrenheit. Significant amounts of fuel leak into the engine area, and strong fumes enter the passenger area. Nhtsa has already issued a TSB on the Subaru wxt regarding the same problem. Concerned about fire hazard and inhalation of gasoline vapors.