2003 Subaru Forester Engine Problems

WHEN AMBIENT AIR TEMPERATURE IS COLD (BELOW ABOUT 20-30 F), THE VEHICLE GIVES OFF A STRONG GASOLINE SMELL. THIS IS CAUSED BY THE FUEL RAIL CONTRACTING TO THE POINT THAT SOME FUEL IS SPRAYED ONTO THE ENGINE COMPARTMENT. OBVIOUSLY, THIS IS A FIRE RISK.

A RUBBER HOSE CONNECTING TWO METAL GAS LINES HAS STARTED TO LEAK. THIS IS DUE TO THE COLD WEATHER. SUBARU ISSUED A RECALL FOR THIS ON THE WRX MODELS OF THE SAME YEAR. THIS ENGINE IS THE SAME ENGINE AS IN THE WRX. IT IS THE 2.5 N/A. WHY ARE OUR MOTORS NOT BEING FIXED AS WELL? THIS IS A MAJOR FIRE HAZARD. IT IS NEAR THE IGNITION SYSTEM AND ABOVE THE EXHAUST PIPE. *JS

ON WINTER DAYS, WHERE TEMPERATURES ARE NOT UNUSUALLY LOW FOR A NORTHERN STATE, THE FUEL LINES ON THE FORESTER WILL SHRINK AND CONTRACT. THE RESULT IS THAT FUEL WILL LEAK OUT OF THE LINE RESULTING IN TWO THINGS, FUEL VAPORS IN THE CABIN AND FUEL PUDDLING ON THE ENGINE. FUEL PUDDLING ON THE ENGINE REPRESENTS ON OBVIOUS SAFETY HAZARD IN THE EVENT OF A FIRE. THE HEAVY FUEL VAPORS AND ODOR IN THE CABIN CAUSED ME TO BECOME NAUSEOUS AND LIGHT HEADED. IN ORDER TO DRIVE HOME SAFELY, THE WINDOWS HAD TO BE OPENED ALMOST COMPLETELY. LUCKILY THEY WERE NOT FROZEN UP, WHICH IS ALSO COMMON IN WINTER MONTHS. THERE HAVE ALSO BEEN SEVERAL DAYS WHERE WIND CHILL ALONE COULD RESULT IN FROST BITE IN ONLY A FEW MINUTES. I COULD NOT HAVE ROLLED DOWN MY WINDOWS SAFELY ON THOSE DAYS OR IN SIMILAR TEMPS BECAUSE OF THE ADDED VEHICLE SPEED. SOA IS AWARE THAT THIS IS A PROBLEM, BUT REFUSES TO CORRECT THE ISSUE OR ADMIT THAT IT APPLIES TO MOST OF ITS MODELS. THE PROBLEM EVEN CONTINUES ON LATER MODELS. THIS IS A WELL KNOWN ISSUE, SEE THIS THREAD THAT SPANS SEVERAL YEARS (CONTINUING TODAY): HTTP://WWW.SUBARUFORESTER.ORG/VBULLETIN/F87/SMELL-GAS-COLD-STARTS-41319/ THE LINES AND PROBLEM ARE ALMOST IDENTICAL TO THE IMPREZA ISSUE, WHICH RESULTED IN SUBARU SERVICE BULLETIN NUMBER 09-36-03. *TR

WE WERE DRIVING ON THE INTERSTATE TRAVELING ABOUT 70 MPH WHEN MY HUSBAND NOTICED THE BACK WINDOW HAD A GREASY FILM THAT THE WIPER ONLY MADE WORSE. WE PULLED OFF THE HIGHWAY TO A GAS STATION TO TAKE A LOOK AND NOTICED SMOKE BILLOWING FROM THE HOOD. AFTER WAITING A FEW MINUTES HE RAISED THE HOOD TO MORE SMOKE. HAVING JUST HAD AN OIL CHANGE TWO DAYS PRIOR, I RECALLED THAT THE SERVICE PERSON MENTIONED SLIGHT TRANSMISSION AND OIL LEAKS THAT WERE NOT MAJOR CONCERNS AND THE CAR WAS SAFE TO DRIVE AND COULD BE ADDRESSED LATER. TURNS OUT THERE WAS A HOLE IN THE PIPING DIRECTLY UNDERNEATH THE BATTERY, WHICH WAS CAUSED BY BATTERY ACID DRIPPING DIRECTLY ONTO THE METAL PIPING CAUSING THE AUTOMATIC TRANSMISSION FLUID TO LEAK OUT. AFTER REMOVING THE BOLTS FROM THE PLASTIC APRON UNDERNEATH THE CAR TO TAKE A BETTER LOOK, IT APPEARED TRANSMISSION FLUID HAD BEEN LEAKING FOR A WHILE. AFTER POURING SEVERAL QUARTS OF TRANSMISSION FLUID INTO THE CAR WE WERE ABLE TO SLOWLY DRIVE IT TO THE NEAREST SERVICE GARAGE (ABOUT 5 MILES), WHERE WE GOT A DIAGNOSTIC DONE. APPARENTLY THIS PROBLEM IS NOT A NEW ONE TO SUBARU AS A SERVICE BULLETIN WAS RELEASED FOR THIS PARTICULAR ISSUE (THOUGH THEY STATED IT COULD BE FROM CORROSION DUE TO ROAD SALT OR SALT WATER, NOT BATTERY ACID). A REPLACEMENT AT OIL COOLER PIPING KIT AND FOAM PACKING MUST BE INSTALLED TO PREVENT CORROSION DAMAGE. THE BATTERY PLACEMENT DIRECTLY OVER THE PIPING IS WHAT CONTRIBUTED TO THE HOLE IN THE PIPING, CAUSING A DANGEROUS SITUATION THAT COULD HAVE LED TO A FIRE UNDERNEATH THE CAR. APPARENTLY SUBARU HAS REDESIGNED THE LOCATION OF THE BATTERY IN RELATION TO THE AT FLUID PIPING IN THEIR LATER MODEL CARS SO IT WAS A CONCERNING ISSUE THAT WARRANTED THIS CHANGE. THE GARAGE MANAGER FELT IT SHOULD HAVE BEEN A RECALL ISSUE AS IT COULD HAVE LED TO THE VEHICLE CATCHING FIRE. *TR

WE PURCHASED THIS CAR NEW AND MAINTAINED IT ACCORDING TO THE MANUFACTURER'S MAINTENANCE SCHEDULE. HOWEVER, AROUND 75,000 MILES THE HEAD GASKETS STARTED LEAKING. AFTER EACH USE OF THE CAR, OIL WOULD LEAK ONTO THE EXHAUST MANIFOLD AND PRODUCE A BURNT OIL SMELL IN THE GARAGE; NOT GOOD. THE LEAK REMAINED LIMITED AND OUR SERVICE TECHNICIAN (AAA-APPROVED), ADVISED US TO NOT MAKE ANY REPAIRS RIGHT AWAY, BUT TO MONITOR THE LEAK. THE LEAKING BECAME PROGRESSIVELY WORSE AND AFFECTED BOTH THE LEFT AND RIGHT SIDE OF THE BOXER CYLINDER HEADS. AT 90,000 MILES, THE LEAKS REQUIRED A FULL HEAD GASKET REPAIR, NECESSITATING EXTRACTION OF THE ENTIRE ENGINE. WHILE THIS WORK WAS DONE, TIMING BELT, WATER PUMP AND OTHER UNRELATED MAINTENANCE ISSUES WERE PERFORMED. THE MAIN COMPLAINT WE HAVE IS WITH THE PREMATURE FAILURE OF THIS BOXER ENGINE'S HEAD GASKETS. SUBARU *KNOWS* THERE IS A PROBLEM AS IT RECOMMENDS AN COOLANT ADDITIVE FOR OLDER ENGINES IN AN ATTEMPT TO POSTPONE THE HEAD GASKET PROBLEMS. AND A QUICK GOOGLE SEARCH REVEALS THAT MANY THOUSANDS OF SUBARU OWNERS HAVE HAD HEAD GASKET PROBLEMS, YET SUBARU OF AMERICA (SOA) HAS NEVER ISSUED A RECALL. IF THE BOXER ENGINE DESIGN IS PRONE TO HEAD GASKET PROBLEMS, AS IT APPEARS TO BE IN SUBARUS, AND FAILURES HAPPEN WELL BEFORE 100,000 MILES, SUBARU SHOULD STAND BEHIND ITS DESIGN AND COMPENSATE OWNERS FOR THESE EXPENSIVE FAILURES. OUR REPAIR COST NEARLY $4,000, WITH NO GUARANTEE THAT IT WON'T HAPPEN AGAIN. WE BELIEVE SOA SHOULD ISSUE RECALL FOR A FAULTY ENGINE DESIGN, AND DEVELOP A HEAD GASKET THAT WILL STAND THE TEST OF TIME! SOA CONTINUES TO BUILD THIS SAME ENGINE INTO ITS CURRENT MODELS, AND THE PURCHASERS OF THESE VEHICLES WILL EACH DISCOVER THE HEAD GASKET PROBLEM, WHEN WARRANTIES HAVE EXPIRED AND REQUIRE EXPENSIVE REPAIRS. IF THESE PROBLEMS HAD LED TO CRASHES SOA BE FORCED TO ISSUE A RECALL.

VERY STRONG ODOR OF GASOLINE IN THE CABIN RIGHT AFTER STARTUP AND THROUGHOUT SHORT TRIPS, ESPECIALLY WITH HEATER ON. SEEMS TO HAPPEN MOST OFTEN WHEN OUTSIDE TEMPERATURES ARE NEAR OR BELOW THE FREEZING MARK. DID NOT EXPERIENCE BEFORE THIS WINTER, NOW OCCURS DAILY. PLEASE INVESTIGATE THIS PROBLEM BEFORE SOMEONE GETS HURT OR KILLED! IF SUBARU KNOWS THAT THERE IS A SAFETY PROBLEM WITH THE FUEL SYSTEM, OWNERS SHOULD NOT HAVE TO PAY FOR REPAIRS. *TR

UPON STARTING AND RUNNING THE VEHICLE IN TEMPERATURES BELOW FREEZING (32 DEGREES F), THE FUEL LINES NEAR THE INTAKE MANIFOLD IN THE ENGINE BAY LEAK GASOLINE, TRANSMITTING AN UNBURNT FUEL SMELL TO THE CABIN VIA THE HVAC SYSTEM AND BLOWER FAN. THESE FUMES ARE TOXIC AND THEREFORE HAZARDOUS TO MOTORIST AND PASSENGER HEALTH. ALSO, FUEL DRIPPING NEAR A HOT INTAKE MANIFOLD IS A FIRE HAZARD. THE LINES APPEAR CORRODED IN SPOTS AND THE FUEL LEAK IS VISIBLE AND APPARENT. THERE IS NO RECALL FOR THIS ISSUE. HOWEVER, BASED UPON THE INSPECTION, THE APPARENT FUEL LEAK IN SUCH CLOSE PROXIMITY TO THE HOT ENGINE IS A MAJOR HAZARD FOR THE MOTORIST OF THE FORESTER AND OTHER MOTORISTS ON THE ROAD - THIS ISSUE SHOULD BE RESOLVED AND SUBARU SHOULD ANNOUNCE A RECALL ON ALL (2003) FORESTER MODELS. *TR

AT COLD TEMPERATURES, FUEL LEAKING SOMEWHERE FROM VEHICLE, CAUSING STRONG ODOR INSIDE AND OUT OF CABIN. CONCERNED THAT THIS AMOUNT OF FUEL COULD BE HAZARDOUS TO BREATHE AND/OR CAUSE RISK FOR FIRE. NEED MORE PROACTIVE RESPONSE FROM SUBARU ON THIS MATTER, AT THIS POINT 26 OF 115 COMPLAINTS FOR THIS MAKE/MODEL/YEAR ARE FOR THIS ISSUE. *TR

STARTED AND DROVE VEHICLE APPROX. 1 MILE IN 20 DEGREE WEATHER WHEN I BEGAN TO SMELL AN EXTREMELY STRONG RAW GASOLINE ODOR. THE PASSENGER COMPARTMENT WAS INUNDATED WITH THE ODOR. I CHECKED FOR LEAKS BUT DID NOT SEE ANY(IT WAS AT NIGHT). I SLOWLY DROVE HOME WITH MY PASSENGER-SIDE WINDOWS OPEN. HAVEN'T DRIVEN THE VEHICLE SINCE.... *TR

AS I WAS DRIVING THE CHECK ENGINE LIGHT CAME ON FOR THE FIRST TIME - IT IS NOW ON CONTINUOUSLY DUE TO FUEL CAP. I PULLED OVER AT A SERVICE STATION ONLY TO REALIZE MY OIL WAS NEXT TO EMPTY. I PROMPTLY FILLED AND CONTINUED THE FINAL HALF HOUR TO MY DESTINATION. UPON ARRIVAL I INSPECTED THE ENGINE FROM UNDER THE HOOD & BELOW THE CAR. IT WAS AT THIS TIME I NOTICED BUILD UP AND FLUID AROUND BOTH HEAD GASKETS. INITIALLY THERE WAS OIL RESIDUE ONLY, NOW, 18 MONTHS LATER I HAVE COOLANT AND OIL LEAKAGE & CANNOT AFFORD TO SPEND THE $1800 I HAVE BEEN QUOTED TO REPLACE THE HEAD GASKETS. VERY DISAPPOINTED IN SUBARU FOR NOT HANDLING THIS IN A BETTER WAY. MY BROTHER HAS THE SAME CAR (YEAR MAKE & MODEL) AND HAS SIMILAR ISSUES AT FEWER MILES. MY PARENTS HAVE A 2008 OUTBACK AND HAD THEIR HEAD GASKETS FAIL AT 54,000 MILES. UNACCEPTABLE. I ENJOY EVERYTHING ABOUT MY SUBARU EXCEPT FOR THE EXCESSIVE AMOUNT IT WILL COST TO FIX SUCH A COMMON DESIGN FLAW. *TR

2003 SUBARU FORESTER ~114K MILES. DURING PASSING (~70 MPH)ENGINE HAS STALLED 2X IN PAST WEEK. AFTER COMING TO FULL STOP AND TURNING KEY IN IGNITION FULL "OFF", CAR RESTARTS WITH NO DIFFICULTY WILL TAKE TO DEALER THIS WEEK. HAD BATTER INSTALLED ~ 2 MONTHS AGO. *TR

FRONTAL IMPACT WHILE STRIKING A DEER AT THIS SPEED SHOULD HAVE DEPLOYED BOTH AIR BAGS. THE AIR BAG LIGHT SOMETIMES WOULD REMAIN ON, BUT MOSTLY IT WAS OFF. FROM WHAT I HAVE FOUND THROUGH OTHER COMPLAINTS IS THAT THIS YEAR VEHICLE IS KNOWN FOR THIS ISSUE, BUT A RECALL HAS NOT BEEN ISSUED. IS IT GOING TO TAKE A DEATH TO FORCE SUBARU TO CORRECT THIS ISSUE? THE OTHER ISSUE FOUND WHILE REPAIRING THE VEHICLE IS THAT BOTH HEAD GASKETS ARE SEEPING COOLANT, THE DRIVERS SIDE IS SEEPING MORE JUST LIKE THE RECALL DESCRIBES ON 1999-2002 MODELS. EVEN THOUGH THIS A 2003 IT WAS PURCHASED IN THE FALL OF 2002, SUBARU FAILED TO CONTACT ME AND ADVISE ME TO ADD THE $1.44 COOLANT ADDITIVE TO SAVE THE HEAD GASKETS. HOW IS A CONSUMER SUPPOSED TO KNOW THESE LITTLE DETAILS? NOW THE VEHICLE HAS TOO MANY MILES FOR THEM TO CARE, STICKING ME WITH THE ESTIMATED $2000 REPAIR.

MY 2003 SUBARU FORESTER - PURCHASED NEW - CURRENTLY HAS 55,000 MILES ON IT. IT WAS LAST SERVICED 3 MONTHS AGO. AT THAT TIME, NOTHING WAS MENTIONED ABOUT COOLANT PROBLEMS OR LEAKS. LAST WEEK, ON THE TURNPIKE, THE RPM NEEDLE STARTED SWINGING WILDLY AND I LOST POWER. I MANAGED TO GET TO THE SHOULDER OF THE TURNPIKE AND SHUT DOWN AND BY THAT TIME SMOKE WAS POURING OUT FROM THE ENGINE. THE PROBLEM DIAGNOSED IS THAT THE COOLANT HAD LEAKED AT THE HEAD GASKETS - A PROBLEM THAT I AM NOW LEARNING SUBARU HAS KNOWN ABOUT FOR SOME TIME. I HAVE TO REPLACE THE ENGINE AT A COST OF AT LEAST $2600. I WAS NEVER CONTACTED BY SUBARU OR THE DEALERSHIP TO INFORM ME THAT THIS MAY BE A PROBLEM ALTHOUGH I CONSISTENTLY HAVE RECEIVED NOTIFICATIONS ABOUT REPURCHASING AN EXTENDED WARRANTY. OBVIOUSLY, A 2003 VEHICLE WITH 55,000 MILES ON IT HAS NOT BEEN DRIVEN EXCESSIVELY. COMMENTS I HAVE HEARD ARE THAT "YOU'RE STILL BREAKING IN THE ENGINE". *TR

I PURCHASED A NEW SUBARU FORESTER XS IN JULY 2003 AND HAD IT SERVICED REGULARLY AT NOW DEFUNCT SUBARU DEALERSHIPS. WHILE I WAS DRIVING ONE DAY, THE CAR SUDDENLY OVERHEATED. THE FOREIGN AND DOMESTIC AUTO SERVICE MECHANIC I WAS ABLE TO REACH SHOWED ME THAT THE ENGINE WAS LEAKING COOLANT IN 3 PLACES, REQUIRING A COSTLY REPAIR OF THE HEAD GASKET. I LEARNED FROM HIM THAT THIS HEAD GASKET FAILURE WAS A COMMON PROBLEM WITH SUBARUS. I HAD THE CAR UNDER WARRANTY WITH SUBARU FOR 60,000 MILES. AT NO TIME WAS I NOTIFIED BY THE DEALER FROM WHOM I PURCHASED THE CAR OR BY ANY SUBARU SERVICE CENTER, THAT SPECIAL COOLANT WAS REQUIRED TO MITIGATE THIS DEFECT. I HAD THE CAR REPAIRED AT A COST OF OVER $2,000. *TR

I HAD REGULAR SERVICE DONE TO MY CAR AT CLAY SUBARU OF NORWOOD MASSACHUSETTS. THE REPRESENTATIVE STATED THAT THE MECHANIC NOTICED SOME OIL SEEPAGE FROM THE HEAD GASKET. THEY RECOMMENDED THAT I GET THE HEAD GASKETS REPLACED WITHIN A YEAR. SINCE THAT TIME I HAVE MONITORED THE OIL LEVEL AND HAVE HAD TO REPLACE ABOUT A QUART IN BETWEEN REGULAR OIL CHANGE INTERVALS. I AM CONCERNED BECAUSE I KNOW THIS REPRESENTS MAJOR ENGINE WORK. THEY QUOTED THAT IT WOULD COST ABOUT $2,000.00 TO REPLACE THE HEAD GASKETS. THE CAR ONLY HAD ABOUT 115,000 MILES ON IT. IT IS A 2003 SUBARU FORESTER THAT I PURCHASED NEW IN DEC 2002. *TR

NOTICED ANTI-FREEZE ODOR AFTER VEHICLE HAD BEEN RUN AND TURNED OFF. DID NOT SEE ANY LEAKS. PROBLEM CONTINUED SEVERAL WEEKS BEFORE NOTICING SEVERAL LEAK SPOTS ON GARAGE FLOOR, SO MADE APPOINTMENT WITH MECHANIC WHO KNEW IMMEDIATELY IT WAS A HEAD GASKET PROBLEM. WE PURCHASED THE CAR NEW IN OCTOBER, 2002 AND HAVE MAINTAINED IT ACCORDING TO THE MAINTENANCE SCHEDULES. THE VEHICLE HAD 52,000 MILES ON IT WHEN WE SPENT $1300 TO REPAIR A PROBLEM THAT SUBARU OF AMERICA KNEW ABOUT AND HAS KNOWN ABOUT FOR SOME TIME. WE NEVER RECEIVED ANY NOTICE OR RECALL OF ANY KIND RELATING TO THIS PROBLEM. SUBARU OF AMERICA SHOULD MAKE SOME SORT OF RESTITUTION TO ITS CUSTOMERS FOR THIS MANUFACTURERS DEFECT. *TR

2003 SUBARU FORESTER PROBLEMS WITH CYLINDER HEAD GASKET. CONSUMER STATES THERE ARE SEVERAL INTERNET COMPLAINTS ABOUT THIS DEFECT. SHE STATES THAT THE ESTIMATE COST FOR REPAIR IS ABOUT $1500.00 TO $1600.00 DOLLARS. *KB

EXHAUST/FUEL SMELL IN INTERIOR CAB DURING USE IN COLD WEATHER/ USE OF HEATER IN 2003 SUBARU FORESTER. *TR

STRONG FUEL SMELL INSIDE THE CABIN DURING COLD WEATHER. IT GETS SO BAD AT TIMES THAT IT CAUSES IRRITATION IN MY THROAT AND A BURNING SENSATION IN MY EYES. IT ALSO LEAVES A FOUL TASTE IN MY MOUTH THAT LASTS WELL AFTER I EXIT THE VEHICLE. *TR

LATCHES ON THE FORRESTER CANNOT BE OPENED UNLESS YOU HAVE A KEY FOB. THERE IS NO WAY TO ACCESS THE TAILGATE WITHOUT THE BATTERY OPERATED FOB. IF YOU HAVE A CHILD THAT GETS INTO THE CAR WITHOUT YOUR KNOWLEDGE, OR IF THERE IS AN ACCIDENT AND THE DOORS WILL NOT OPEN FROM THE SIDE. HOW WILL YOU GET OUT THE BACK--THERE IS NO WAY TO EVEN ACCESS WITH A KEY FROM THE OUTSIDE. IF YOU ARE IN AN ACCIDENT AND YOU LOOSE TRACK OF YOUR FOB TOO BAD, YOU CAN'T GET OUT FROM THE BACK. I MYSELF CARRY DOGS IN CRATES IN THE BACK OF THE FORRESTER. HAD I REALIZED THAT WHEN I HAVE CRATES, OR ANY OTHER LARGE ITEM IN BACK YOU DO NOT HAVE ACCESS TO THE BACK, I WOULD HAVE NEVER PURCHASED THE CAR. I BELIEVE THIS IS A SAFETY ISSUE. I CALLED THE DEALER AND ASKED HOW TO OPEN THE BACK OF THE CAR AND THEY SAID YOU HAVE TO REMOVE A PANEL. IF YOU ARE ON FIRE--YOU HAVE TO WAIT TO GET THE PANEL OFF TO GET THE DOOR OPEN, BUT IF YOU CAN'T GET TO THE BACK BECAUSE OF DOG CRATES, BABY CARRIAGES, CRIBS, PLAYPENS ETC. HOW WOULD YOU GET OUT. I WOULD LIKE TO GIVE A WRITTEN HARD COPY REPORT. 2. SUBARU KNOWS THERE IS A PROBLEM WITH THE HEADGASKET? MANIFOLD GASKET THAT THERE IS A DEFECT. WHEN IT GOES BAD, YOU MAKE THE FIX IT WILL NEVER HAPPEN AGAIN--WHY DOES THE OWNER HAVE TO FOOT THE BILL WHEN I WAS TOLD, BY THE MECHANIC, THAT IN FACT SUBARU KNOWS THIS AND IT IS ONLY A MATTER OF TIME BEFORE THE GASKET WILL GO, BUT ONCE YOU MAKE THE CORRECTION IT WILL NEVER HAPPEN AGAIN. *TR