2003 Subaru Forester engine problems

Filed Feb 8, 2021 · Engine · 133,000 miles · MN

The head gasket failed in a manner which caused engine oil to leak onto the hot exhaust manifold. A strong burning odor is present after the engine warms up completely.

Filed Feb 8, 2021 · Engine, Fuel system · 133,000 miles · MN

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.

Filed Jun 5, 2015 · Engine · 90,000 miles · MN

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.

Filed Feb 22, 2015 · Engine, Fuel system · PA

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.

Filed Dec 30, 2014 · Engine, Fuel system · 240,000 miles · IL

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.

Filed Sep 30, 2014 · Engine · 111,969 miles · VA

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.

Filed May 11, 2014 · Engine · 138,000 miles · MI

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.

Filed Jan 30, 2014 · Engine, Fuel system · 81,100 miles · NJ

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.

Filed Jan 25, 2014 · Engine, Fuel system · 138,000 miles · OH

While driving vehicle in extremely cold weather notice strong fuel smell coming in car.

Filed Jan 9, 2014 · Engine, Fuel system · 77,116 miles · IL

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.