2003 Subaru Outback Fuel System Problems

WHEN DRIVING THE CAR DOWN THE ROAD A STRONG ODOR OF RAW GASOLINE WAS SMELT IN THE CABIN OF THE CAR, I PULLED OVER AND POPPED THE HOOD OPEN AND FOUND GAS SPRAYING OUT OF THE RUBBER FUEL LINE ON THE PASSENGER SIDE OF THE ENGINE COMING FROM IN BETWEEN THE RUBBER HOSE AND THE METAL LINE FEEDING THE FUEL INJECTORS AS IF THE HOSE CLAMP WAS LOSE. IT WAS -5 F OUTSIDE WHEN THIS OCCURRED, THE CAR WAS PARKED TILL IT WARMED UP TO WORK ON IT, 30 F HERE IN MINNESOTA AND THE FUEL LEAK HAD DISAPPEARED. I CHECKED THE TIGHTNESS OF THE HOSE CLAMP AND IN WAS TIGHT. THE RUBBER HOSE AND METAL TUBE ALSO SHOWED NO SIGN OF DETERIORATION. THE PASSENGER SIDE OF THE ENGINE COMPARTMENT WAS SOAKED IN GASOLINE WHEN THE LEAK OCCURRED. THE HAS 80,000 MILE ON IT.

A METAL CAP INSIDE THE FUEL PUMP ASSEMBLY HAS SHEARED AT THE PLACE WHERE ITS SCREWS ONTO THE FUEL PUMP BODY. THIS CAUSED A DROP IN FUEL PRESSURE, WHICH STOPPED THE ENGINE COMPLETELY. *TR

SUBARU OUTBACK, 2003, 4-CYLINDER WITH 90,000 MILES S/N: [XXX] SIGNIFICANT ACCELERATION FROM VERY SLOW SPEED; TURNING OFF THE ENGINE WAS THE ONLY METHOD OF STOPPING THE CAR. DROVE THROUGH GARAGE WALL; OCCURENCE OVER SIX MONTHS; ABOUT ONE-TIME PER MONTH. PROGRESSIVELY GOT WORSE UNTIL THE CAR WENT THROUGH THE GARAGE WALL. PER DEALER: "SIGNIFICANT CARBON BUILD-UP IN THROTTLE HOUSING & IDLE CONTROL VALVE. CARBON BUILD-UP CAUSED BY REFORMULATED GASOLINE." REPIAR ACTION: CLEAN THROTTLE HOUSING & REPLACE IDLE CONTROL VALVE = $ 750.00 AT MAY 11, 2010. NO SERVICE BULLETINS OR HISTORY, PER DEALER. MY COMMENT: "POTENTIAL DISTEROUS SAFETY ISSUES: NOT ONLY PROPERTY DAMAGE, BUT SIGNIFICANT PERSONAL INJURY COULD BE CAUSED IF THIS HAPPENS IN PARKING LOTS, CROSSWALKS, DRIVEWAYS, ETC." [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

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. SUBARU'S 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. *TR