Fuel Injection Rail Problems of Subaru Outback

2004 Subaru Outback, h6 (6-cylinder) with a faulty pulsation dumper/damper valve. Part of the fuel injection system, the valve assembly sits above the intake manifolds on both sides of the engine. The passenger side valve (metal construction) was literally weeping gasoline (strong smell inside cabin was the tip off). I removed the assembly and replaced the hoses first, but the valve was leaking through the top surface walls (not a seam). Awaiting replacement parts now. It appears that the foam cushioning material underneath the metal fuel rail protector was in direct contact with the valve over an extended period of time. Corrosion of the exterior valve wall is the most likely culprit. Subaru claims they've "never had to replace one" (3 dealers) and had no idea what the valve even does. Luckily, I observed and will have corrected the problem before a vehicle fire. This is an imminent threat for other h6 owners with this valve configuration. If corrosion of the valve is present at all, the valve should be replaced immediately. Subaru was uninterested in examining the issue or the parts involved. If the valve leaks more, the runner lines adjacent to it would quickly melt and the car would be destroyed.

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I own a 2003 Subaru Outback limited 2. 5l. During extremely cold weather (20 degrees f or lower,) the fuel lines leak where the rubber hose and clamp meet the metal pipe on the fuel rail for the intake manifold. This is a very dangerous condition since raw fuel is leaking onto the intake manifold and engine block. A source of ignition such as heat from the exhaust manifold or even a spark from static electricity could start a fire in the engine compartment. There is a technical service bulletin for the same problem, only for the Subaru impreza wrx. (TSB# 09-36-03). The Subaru Outback experiences the same leak even on the same short piece of hose on the passenger side of the engine. Subarus TSB on this involves replacing the hose and intake pipe since in very cold weather they get misaligned allowing fuel seepage to occur. The same problem occurs on the Outback, although there is no TSB for it and the dealers fix was tightening the hose clamps which did not resolve my problem. I am concerned for my safety and other drivers of Subaru Outbacks in cold weather since raw fuel dripping on a hot engine could easily ignite. This problem still occurs for me everyday when the temperature outside drops below 20 degrees f.

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There is frequently a strong smell of fuel within the vehicle compartment when the car is running, either standing still or otherwise being driven. There was a third party service bulletin issued (wxz-83-fuel hose explaining the problem which is that certain affected vehicles may have been produced with up to 3 improperly manufactured fuel hoses in the engine compartment. Over time and in cold weather the hoses could leak creating the potential for a fire in the engine compartment. I found out what the problem was on the internet. Subaru says there was a recall for this but that my vehicle was not one of the vehicles under the recall and that I would have to pay for any repairs - they said it could be the fuel rail assembly that is the problem. This does not seem fair or right. If its a defect (with serious safety implications) and my car was affected by the problem described (and who knows how many others), then the manufacturer should fix all cars with the problem at their expense.

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My 2001 Subaru Outback 4 cylinder engine developed a fuel leak approximately 1 month ago. The vehicle has approx. 51,000 miles on it. When I contacted the dealer, they indicated the fuel injector hoses leaking at the clamps was not unusual during cold weather on this type of vehicle. Estimated cost to diagnose the leaks & repair was approx $150- but they would let me know the exact cost once they have examined the vehicle.

In cold weather, my 2001 Subaru Outback has an extremely strong smell of gasoline. A quick search will reveal hundreds of complaints on the same issue. There has been a technical service bulletin issued by Subaru on this issue--NHTSA item # 616334, service bulletin # 010101. The TSB recommends an "inspection procedure for possible replacement of 3 fuel hoses". However, the Subaru dealer indicates the issue calls for a replacement of the entire fuel rail--costing more than $400. I cannot believe that neither the NHTSA nor Subaru have not categorized a systemic problem with leaking gasoline as a safety issue.

We strongly agree with the complaint filed 12/9/09 listed below. We also have a 2001 Subaru Outback and have had the Subaru dealership check out this problem several times. We have had fuel hoses replaced and clamps tightened and replaced many times and the problem remains. Obviously the problem is elsewhere in the fuel system. While every winter for at least the last 5-6 winter seasons our family smells and breathes in gasoline fumes and have to open windows to air out the cabin from the strong gasoline smell. We also refrain from using the heating system at times because the smell is much more noticeable when we run the heater. We have also found countless complaints online regarding this Subaru issue. Does a fire, damage, crash, injury or death have to occur before Subaru or the NHTSA will address this problem? component: fuel system, gasoline details: in cold weather, my 2001 Subaru Outback has an extremely strong smell of gasoline. A quick search will reveal hundreds of complaints on the same issue. There has been a technical service bulletin issued by Subaru on this issue--NHTSA item # 616334, service bulletin # 010101. The TSB recommends an "inspection procedure for possible replacement of 3 fuel hoses". However, the Subaru dealer indicates the issue calls for a replacement of the entire fuel rail--costing more than $400. I cannot believe that neither the NHTSA nor Subaru have not categorized a systemic problem with leaking gasoline as a safety issue. Occurrences: 1 injuries: 0 fail date: 12/07/2005 deaths: 0 date added to datbase: 12/9/2009.