2004 Subaru Outback Fuel System Problems
5 owner-reported fuel system complaints from NHTSA data
Data sourced from NHTSA public database. For informational purposes only. Always consult a qualified mechanic.
Fuel System Recalls (2)
FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
Airtex Products LP (Airtex) is recalling certain model E8598M, E8518M, E8600M, E8596M, and E8597M fuel pumps manufactured July 26, 2013, and July 29, 2013 and used as aftermarket replacements on Subaru Baja's, Outback's and Legacy's. The affected fuel pumps were sold or installed into the aftermarket applications on or after July 26, 2013, and may may leak fuel from the base of a fuel line connection when the gas tank is full.
Fix: Airtex will notify owners, and will replace the fuel pump, free of charge. Recall is expected to begin on January 2, 2014. Customers may contact Airtex at 1-800-880-3056. The recall is expected to begin during January 2014. This recall is being conducted by Airtex, not by Subaru.
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP
CERTAIN PASSENGER OR SPORT UTILITY VEHICLES MAY HAVE A LOOSE OR OUT OF POSITION FUEL FILLER HOSE CLAMP.
Fix: DEALERS WILL INSPECT AND TIGHTEN THE CLAMP ON THE FUEL FILLER HOSE. OWNER NOTIFICATION BEGAN AUGUST 27, 2003. OWNERS SHOULD CONTACT SUBARU AT 1-800-782-2783.
Owner Complaints (5)
2004 SUBARU OUTBACK: STRONG FUEL ODOR INSIDE VEHICLE WHEN COLD OUT. RESEARCH SHOWS THIS IS A COMMON ISSUE WITH OUTBACK AND IMPREZA WRX. SUBARU RECALLED THE WRX, WHY NOT THE OUTBACKS! THIS DEFECT POSES AN EXTREME RISK FOR FIRE AND A RECALL IS NEEDED. *TR
FUEL LEAK WHEN TEMPERATURE DROPPED TO SUDDEN COLD BETWEEN 0 AND 10F. SO BAD THAT YOU CANNOT DRIVE THE CAR AS THE HEATER DRAWS IN THE FUMES (AND AT 4F YOU NEED TO USE THE HEATER). UNSAFE TO DRIVE DUE TO POSSIBLE FIRE IN ENGINE. CAR IS NOW IN THE SHOP - APPARENTLY THIS IS VERY COMMON WITH SUBARU, WHICH IS WHY I AM FILING A COMPLAINT. IF SUBARU KNOWS OF THIS, IT'S TIME FOR THEM TO TAKE ACTION. OR WILL IT TAKE AN ENGINE FIRE AND POSSIBLE DEATH FOR SOMETHING TO BE DONE? I CERTAINLY HOPE NOT! *TR
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. *TR
2004 SUBARU OUTBACK: STRONG FUEL ODOR INSIDE VEHICLE THAT, ACCORDING TO SUBARU DEALER, IS CAUSED BY LEAKAGE OF FUEL UNDER THE HOOD. THE DEALER REP. FURTHER EXPLAINED THE LEAK IS CAUSED BY EXPANSION/CONTRACTION OF TUBING DURING COLD WEATHER. THEY ALSO STATED THIS IS A COMMON OCCURRENCE (IT HAS OCCURRED TWICE IN MY VEHICLE) AND ON THE DAY I HAD MY VEHICLE REPAIRED (DECEMBER 2009) THEY HAD ALREADY SEEN ABOUT 6 VEHICLES FOR THE SAME PROBLEM. THIS SITUATION POSES AND EXTREME RISK OF FIRE AND A HEALTH HAZARD FOR OCCUPANTS OF THE VEHICLE. A RECALL IS NEEDED, NOW. *TR
GAS (FUEL) SMELL (FUMES) IN CABIN WHEN STARTING CAR IN COLD WEATHER. KNOWN PROBLEM: HTTP://TOWNHALL-TALK.EDMUNDS.COM/DIRECT/VIEW/.F117C3E HTTP://FORUMS.NASIOC.COM/FORUMS/SHOWTHREAD.PHP?T=131755&PAGE=47. *TR