2002 Subaru Outback Fuel System Problems

WHEN THE TEMPERATURE OUTSIDE GETS BELOW 35 DEGREES, MY CAR SMELLS VERY STRONGLY OF GAS INSIDE. I HAVE TO ROLL THE WINDOWS DOWN FOR VENTILATION. WHEN THE TEMPERATURE WARMS UP, THE SMELL GOES AWAY. IT IS WORSE WHEN I FIRST STARTED MY CAR IN THE MORNING. MECHANICS HAVEN'T BEEN ABLE TO FIGURE OUT THE PROBLEM BUT I JUST READ MANY COMPLAINTS ONLINE ABOUT THIS ISSUE. I WILL TAKE THEIR SUGGESTED FIXES TO MY MECHANIC.

TERRIBLE GAS SMELL. FUEL IS LEAKING BECAUSE IT IS COLD OUTSIDE.

WHEN TEMP. OUTSIDE GO BELOW 32 DEGREES, THE INSIDE OF MY CAR FILLS WITH RAW GAS SMELL, THIS HAPPENS EVERY WINTER. I LIVE IN WI. WHEN IT IS ABOVE FREEZING IT IS FINE AND ALL SUMMER IT IS FINE. I AM SO AFFRAID TO HAVE MY GRAND KIDS IN THE CAR. NOT SURE IF THE FUMES WILL EXPLODE.WHEN I AM DRIVING I DO NOT SMELL GAS. BUT IF I STOP AT A STOP SIGN OR LIGHT IT FILLS UP THE CAR. I HAVE TO ROLL DOWN MY WINDOWS TO GET FRESH AIR

UPPER FRONT FUEL LINE AND CONNECTION TO THROTTLE BODY? IS LEAKING RAW GAS AND FUEL IS POOLING ON TOP OF ENGINE JUST OUTWARD OF UPPER EXHAUST MANIFOLD AREA. *TR

SINCE THE RECENT TEMPERATURE DROP WHERE WE LIVE (MARYLAND, DC METRO REGION), WE'VE NOTICED A STRONG GASOLINE SMELL INSIDE THE CAR'S CABIN. THE SMELL IS STRONG ENOUGH THAT WE ARE UNCOMFORTABLE DRIVING LONG DISTANCES, FOR OUR OWN HEALTH AND THAT OF OUR CHILDREN. THE SMELL ONLY APPEARS WHEN THE CAR IS RUNNING (THOUGH IT DOESN'T SEEM TO DEPEND ON SPEED). WE'VE OWNED THE CAR SINCE MARCH 2010, AND THIS IS THE FIRST TIME WE'VE NOTICED THE ISSUE; IT'S ALSO THE COLDEST WEATHER WE'VE ENCOUNTERED SINCE PURCHASE. APPARENTLY THERE'S A FUEL-LINE-RELATED RECALL FOR IMPREZAS OF THIS VINTAGE, BUT NOT YET FOR OUTBACKS. *TR

THE SMELL OF RAW GAS PERMEATES THE PASSENGER CABIN WHEN THE CAR IS STARTED IN TEMPERATURES UNDER 10 DEGREES FAHRENHEIT. *TR

RUBBER FUEL LINKAGES CONTRACT IN LOW (BELOW 30F) TEMPERATURES, ALLOWING FUEL TO LEAK INTO THE ENGINE COMPARTMENT. THE LEAKING FUEL CREATES A VERY STRONG, AT TIMES INTOLERABLE, FUEL VAPOR SMELL IN THE CABIN. SOME LEAKS DRIP ONTO THE EXHAUST MANIFOLD AND ENGINE BLOCK SO ENGINE FIRE IS A POSSIBILITY. *TR

MY WIFE DROVE HER CAR, A 2002 SUBARU OUTBACK, ABOUT 5 MILES HOME FROM WORK, AND TOLD ME IN THE EVENING HER CAR REEKED OF GASOLINE WHEN SHE ARRIVED AT HOME. WHEN I CHECKED HER CAR THE GAS ODOR HAD DISSIPATED, BUT WHEN I STARTED IT AND BACKED IT OUT OF THE GARAGE THE GAS ODOR WAS VERY STRONG. I MOVED IT BACK INTO THE GARAGE AND SHUT IT OFF. I DISCOVERED ONLINE THAT THE ODOR WAS LIKELY DUE TO A FUEL HOSE LEAK ASSOCIATED WITH A COLD WEATHER START. THE TEMPERATURES HERE ARE COLD FOR MISSOURI, WITH HIGHS IN THE LOW 20'S. IT STILL IS COLD, ALBEIT AS A MINNESOTA BOY IT STILL SEEMS LIKE SPRING. AT ANY RATE, I FOUND A WEBSITE WITH USEFUL DIAGRAMS AND I LOCATED THE HOSE UNDER A BRACKET (OF COURSE), AND MANAGED TO UNCOVER THE HOSE AND TIGHTEN THE CLAMPS, WHICH WERE VERY LOOSE. AFTER RE-ASSEMBLY I DROVE THE CAR TO BURN OFF THE GAS REMAINING ON THE ENGINE AND I TESTED THE REPAIR WITH ANOTHER COLD WEATHER START LATER. I HAVE ORDERED A REPLACEMENT HOSE FROM THE SUBARU DEALERSHIP FOR 12 BUCKS. I UNDERSTAND THAT RECALLS AND SERVICE ADVISORIES HAVE OCCURRED AND ARE IN PLACE FOR OTHER SUBARU MODELS INCLUDING THE CLOSELY RELATED 2001 LEGACY. I WOULD LIKE TO ADD THE 2002 OUTBACK AND EVERY OTHER SUBARU THAT USES THE HOSE PART # 807707130. THE DISCUSSIONS ONLINE ABOUT THIS ISSUE REVEAL SOME PEOPLE ARE DRIVING WITH THEIR WINDOWS OPEN OR WITH CABIN AIR SET TO RECIRCULATE, OR WAITING UNTIL THE ENGINE WARMS UP ENOUGH FOR THERMAL EXPANSION TO SEAL THE LEAK. AS AN INDUSTRY CHEMIST I FIND THIS IGNORANCE ABOUT THE HAZARDS OF GASOLINE FIRES APPALLING. HOWEVER I THINK SUBARU'S PIECE-MEAL APPROACH TO ADDRESSING THEIR DEFECTIVE ENGINEERING IS FRIGHTENING. DON'T THEY CARE ABOUT THE SAFETY OF THEIR CUSTOMERS? MY WIFE TEACHES CHEMISTRY, A TYPICAL CUSTOMER, ACCORDING TO SUBARU ADS. SHE LOVES HER SUBARU. SUBARU DOES NOT LOVE HER. *TR

IN COLD WEATHER, MY 2002 SUBARU OUTBACK CABIN GETS FILLED WITH VERY STRONG RAW FUEL SMELL AS THE CAR WARMS UP WITH THE HEATER ON. IT HAS GOTTEN SO BAD, THAT MY DAUGHTER NEARLY THROWS UP EVERY MORNING ON OUR WAY TO SCHOOL IN COLD WEATHER. THIS IS AN ISSUE THAT MY LOCAL DEALER EXPLAINED AWAY HAS A TYPICAL SUBARU THING IN COLD WEATHER. THIS IS UNACCEPTABLE. THIS IS A HEALTH HAZARD AND SUBARU IS GETTING AWAY WITH IT. I HAVE BEEN USING THIS PARTICULAR CAR FOR THE LAST 10 YEARS, AND EVERY WINTER THE SMELL GETS WORSE AND WORSE. SUBARU NEEDS TO STEP UP, ACKNOWLEDGE THE PROBLEM AND FIX IT, OR FACE THE VERY REAL PROBLEM OF A MASSIVE LAWSUIT SOON. *TR

TL* THE CONTACT OWNS A 2002 SUBARU OUTBACK. THE CONTACT STATED THAT WHENEVER THE HEAT WAS ACTIVATED, THE CONTACT WOULD NOTICE A GASOLINE ODOR COMING THROUGH THE VENTS. THE VEHICLE WAS TAKEN TO THE DEALER ON FOUR OCCASIONS WHERE THE HEAD GASKETS WERE REPLACED EACH TIME. HOWEVER, ONE YEAR AFTER THE REPAIR THE CONTACT NOTICED THAT THE FAILURE RECURRED. THE VEHICLE HAD NOT BEEN RECENTLY DIAGNOSED. THE CURRENT AND FAILURE MILEAGES WERE 84,000.

THERE IS A DOCUMENTED PROBLEM WITH OLDER MODEL SUBARU OUTBACKS (EARLY 2000S) LEAKING GAS INTO THE ENGINE COMPARTMENT IN COLD WEATHER. DEALERS AND REPAIR SERVICES CANNOT FULLY RESOLVE THE ISSUE BECAUSE IT APPEARS TO BE A DESIGN FLAW WITH THE FUEL LINES AND CLAMPS. INTERNET FORUMS PROVIDE COUNTLESS CASES (HERE IS JUST ONE HTTP://ACTION.PUBLICBROADCASTING.NET/CARTALK/POSTS/LIST/1794410.PAGE). *TR

PROMINENT GAS SMELL INSIDE CABIN WHEN TEMPERATURE IS BELOW 32 DEGREES F. IT IS A KNOWN SAFETY ISSUE ON SUBARU'S BUT NOTHING IS BEING DONE BY SUBARU TO RECTIFY THIS POOR ENGINEERING SAFETY ISSUE ON THEIR BEHALF. I HAVE TALKED TO SUBARU OF AMERICA VIA EMAIL AND ON PHONE AND THEY SAY THAT THERE IS NO ISSUE WITH THIS CAR EVEN THOUGH THERE IS THOUSANDS OF PEOPLE THAT ARE EXPERIENCING THIS ISSUE. *TR

FUEL SMELL INSIDE AND OUTSIDE OF CABIN WHEN WEATHER IS COLD (20' OR BELOW). SHOP HAS EXAMINED THE VEHICLE AND CANNOT DETERMINE CAUSE. SEEN REFERENCES TO SIMILAR ISSUE WITH THE WRX MODEL AND FUEL LINES/CLAMP. *TR

OVER LAST FEW WINTERS, WHEN TEMPERATURES DROP TO FREEZING THERE HAS BEEN A BAD FUEL SMELL IN CABIN. ESPECIALLY WITH HEATER BLOWING, THOUGH IT STILL SMELLS INSIDE AND OUTSIDE THE CAR EVEN WITH THE HEAT OFF. ONCE THE WEATHER WARMS UP THERE IS NO NOTICEABLE SMELL. I HAVE TRIED TIGHTENING 5 CLAMPS AS SUGGESTED IN AN ONLINE HELP PAGE. NOT SURE IF THIS HELPED OR PROBLEM JUST WENT AWAY WITH THE COLD WEATHER. LOCAL SHOP COULDN'T SEE LEAK ON CURSORY CHECK WHILE THE ODOR AS AT IT'S WORSE. MAYBE ONLY VISIBLE IF IT'S FREEZING AND UP ON A LIFT. SUBARU DEALER SUGGESTED FUEL LINES NEED TO REPLACED AS NORMAL PROCESS AS CAR AGES. SUBARU SHOULD FIND SOLUTION TO THIS DANGEROUS PROBLEM THAT'S OBVIOUSLY COMMON TO THESE VEHICLES AND PUT OUT CLEAR INSTRUCTION ON DIAGNOSING AND FIXING THIS ISSUE. *TR

BOTH MY 2001 AND 2002 SUBARU OUTBACKS HAD A STRONG SMELL OF GASOLINE IN THE CABIN WHEN STARTING THE CARS. A CHECK UNDER THE HOOD SHOWED GASOLINE DRIPPING FROM SEVERAL OF THE RUBBER FUEL LINES WHERE THEY JOINED METAL FUEL LINES. THE FUEL WAS DRIPPING ONTO THE ENGINE AND RUNNING DOWN TO THE GROUND. UPON TIGHTENING THE FUEL LINE CLAMPS THE PROBLEM STOPPED. WHEN I USED GOOGLE TO CHECK ON THE PROBLEM THERE WAS SEVERAL 100,000 HITS WITH THE SAME PROBLEM. IT SEEMS TO BE RELATED TO LOW TEMPERATURE <+10F. *TR

MY 2002 SUBARU LEGACY OUTBACK WAGON, 2.5 LITER ENGINE, LEAKED FUEL FROM THE FUEL LINE. THIS WAS MOST PRONOUNCED ON A COLD DAY. THERE ARE MANY REPORTS OF THE SAME PROBLEMS. MY SUBARU DEALER TOLD ME THAT THIS PROBLEM IS COMMON. THOUGH WE SMELLED THE STRONG FUEL ODOR, FORTUNATELY, THERE WASN'T A FIRE. THE CAR IS NOW BEING REPAIRED AND WILL BE READY 01/21/09. THE ESTIMATED COST OF THE REPAIR IS $485. SUBARU KNOWS ABOUT THE PROBLEM AND REDESIGNED THE PART. THEY REFUSE TO COVER IT BECAUSE THEY SAY THE SERVICE BULLETIN NUMBER 09-36-03, ISSUED 04/01/03 ONLY APPLIES TO THE WRX, EVEN THOUGH THE OUTBACK HAS A SIMILAR SETUP. *TR

2002 SUBARU OUTBACK- DEC. 08'- EXPERIENCING VERY STRONG FUEL SMELL IN CABIN OF VEHICLE DURING COLD WEATHER. SAME SCENARIO UNFOLDED LAST YR. 07' WHEN IT GOT COLD. LAST YEAR DEALER CHARGED FOR INSPECT AND TIGHTENING OF CLAMPS ALONG FUEL LINES. THIS IS A KNOWN PROBLEM WITH THE SUBARU OUTBACKS..WHY NO RECALL?..WITH FUEL LINE LEAKS AS COMMON AS THEY ARE WITH THIS MODEL I AM SURPRISED THERE IS NO RECALL. IS THERE ANYTHING SUBARU IS OFFERING TO HELP OWNERS RECOVER MONIES BEING SPENT ON THIS FIX? *TR

TL*THE CONTACT OWNS A 2002 SUBARU OUTBACK. WHILE THE VEHICLE WAS IDLE SHE STATED THAT THERE WAS A STRONG FUEL SMELL IN THE VEHICLE. THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC WHO CLEANED THE EXHAUST SYSTEM. THE CONTACT STATED THAT THE FAILURE CONTINUED TO OCCUR. THE VEHICLE WAS TAKEN TO ANOTHER LOCAL MECHANIC WHO STATED THAT THE FAILURE WAS CAUSED BY A LOOSE LATCH IN THE HATCH BACK. THE MECHANIC REPAIRED THE LOOSE LATCH. THE FAILURE CONTINUED AFTER THE LATCH WAS REPAIRED. THE VEHICLE WAS TAKEN BACK TO THE MECHANIC AND HE WAS UNABLE TO DETERMINE WHAT CAUSED THE FAILURE TO OCCUR. THE VEHICLE WAS NOT REPAIRED. THE VEHICLE WAS PURCHASED USED IN 2007 WHO STATED THAT THE FAILURE HAD OCCURRED FOR TWO TO THREE YEARS. THE CONTACT STATED THAT THE FAILURE ONLY HAPPENED DURING COLD WEATHER CONDITIONS. THE FAILURE MILEAGE WAS 92,000. THE CURRENT MILEAGE WAS 108,000.

OVERWHELMING ODOR OF GASOLINE IN PASSENGER COMPARTMENT. *TR

FOR THE PAST 2 WINTERS, I HAVE EXPERIENCED A STRONG FUEL SMELL IN THE PASSENGER CABIN FOR THE FIRST 20 MINUTES OR SO OF RUNNING THE CAR IN TEMPERATURES BELOW 25 DEGREES, INCLUDING IDLING AT A TRAFFIC LIGHT. IT SEEMS TO BE GETTING PROGRESSIVELY WORSE. I BROUGHT IT TO MY PRIVATE MECHANIC LAST WEEK, AND HE WAS UNABLE TO PINPOINT THE SOURCE OF THE PROBLEM. IF YOU DO A GOOGLE SEARCH ON "SUBARU GAS SMELL" YOU WILL FIND 25,800 HITS OF PEOPLE REPORTING THE SAME PROBLEM WITH THEIR SUBARU'S, FOR A VARIETY OF MODELS/YEARS. BASED ON THOSE VOLUME OF COMPLAINTS, I'M VERY SURPRISED THAT THEIR HASN'T BEEN A RECALL? *TR