Bad fuel stink on cold mornings!

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PigSti

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Bad fuel stink on cold mornings!

Subaru Recall Campaign WVK-21

Dear Subaru Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Subaru of America, Inc. has decided that a defect which relates to motor vehicle safety exists in certain 2002 & 2003 model year Subaru WRX vehicles that are currently registered in the following states: Alaska, Colorado, Idaho, Iowa, Maine, Michigan, Minnesota, Montana, Nebraska, New Hampshire, New York, North Dakota, South Dakota, Vermont, Wisconsin and Wyoming.

DESCRIPTION OF THE SAFETY DEFECT
Subaru has determined that in extremely cold outside temperatures, fuel seepage can occur from a fuel delivery line.

DESCRIPTION OF THE SAFETY HAZARD
The affected fuel line is located under the engine intake manifold. Especially during engine start-up in cold temperatures, fuel may seep around the seals between the metal fuel line and the rubber hose. Fuel leakage, in the presence of an ignition source, could result in a fire.

REPAIRS
To correct this condition, Subaru will replace the fuel line and hose with a later production version that has a longer rubber hose segment.

WHAT YOU SHOULD DO
You should immediately contact your Subaru dealer for an appointment to have the fuel line replaced. Please tell the dealer if you have noticed any smell of gasoline in the past when starting up in cold weather.

HOW LONG WILL THE REPAIR TAKE?
The actual time to replace the fuel line is approximately 2 1/2 hours. This will typically make it necessary for you to leave your vehicle for a longer period of time on the day of your scheduled appointment to allow your dealer some flexibility in scheduling and completing the repair.
Click to expand...

Blue Fox, you have done this fix! Your thoughts?

Any help is greatly appreciated but this post is for me as I collect links and info for a one stop reference when I finally have to fix this myself!

Damn car is stinking of fuel on cold mornings. So the fuel rail rubber hose parts must be hardening up and the hose clamps are loosening. Been looking at some sites for tips but I'm sure Subaru released an updated fuel rail part set for the SG to correct it! Anyone know of it?

34oops.jpg


subaru_forester_fuel_lines_zps5e9b24cb.png


2004_Subaru_Forester_Intake_Manifold_Parts_Diagram_zpsa05b60f3.png


[ame="https://www.youtube.com/watch?v=uQb-iyiagT0"]2002 forester cold temp fuel leak - YouTube[/ame] [ame="https://www.youtube.com/watch?v=z3KkqKACuCc"]Wrx fuel leak - YouTube[/ame]

Sites visited:

Code: 
https://forums.nasioc.com/forums/showthread.php?t=131755
https://forums.nasioc.com/forums/showthread.php?t=1680046
https://forums.nasioc.com/forums/showthread.php?t=1893471
https://www.subaruforester.org/vbulletin/f88/soa-finally-admits-fuel-leak-problem-101998/
https://www.subaruforester.org/vbulletin/f87/smell-gas-cold-starts-41319/
https://www.subaruforester.org/vbulletin/f88/fixing-leaking-fuel-gas-line-86782/index2.html
https://www.scoobymods.com/fuel_smell_cold_weather-t2886.html?t=2886
https://www.scoobymods.com/subject_wvk_21_recall-t11931.html?t=11931
https://z32.wikispaces.com/Fuel+Hose+Clamps
https://www.clubwrx.net/forums/general-maintenance-troubleshooting-accidents/134350153-raw-fuel-smell.html
https://forums.nasioc.com/forums/showthread.php?t=131755
https://forums.nasioc.com/forums/showthread.php?t=1680046
https://forums.nasioc.com/forums/showthread.php?t=1893471
https://www.subaruforester.org/vbulletin/f88/soa-finally-admits-fuel-leak-problem-101998/
https://www.subaruforester.org/vbulletin/f87/smell-gas-cold-starts-41319/
https://www.subaruforester.org/vbulletin/f88/fixing-leaking-fuel-gas-line-86782/index2.html
https://www.scoobymods.com/fuel_smell_cold_weather-t2886.html?t=2886
https://www.scoobymods.com/subject_wvk_21_recall-t11931.html?t=11931
https://z32.wikispaces.com/Fuel+Hose+Clamps
https://www.clubwrx.net/forums/gene...oting-accidents/134350153-raw-fuel-smell.html


..continued
 
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Found it!

https://i42.photobucket.com/albums/e325/ikhan1999/subaru-fuel-smell-tsb.jpg

315zitk.jpg


Originally Posted by DS1 Motorsports
The issue is much simpler than it seems. 99% of these cars with the fuel leak / smell are simply loose clamps on the small rubber sections of hose that connect the metal pipes together. You tighten all the clamps and put a little green thread lock on them and the issue is solved. We've been fixing this issue since the 02's first experienced it and have not had one come back with the smell.
biggrin.gif


The $40 covers our time in getting to all the clamps and tightening them aka about a 1/2 hour of labor.

-Dylan @ Ds1
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Repair kit.

Each affected vehicle will require replacement of the engine fuel lines and
related hoses. “WVK-21 Repair Kit”, part number 10130AA000, is available for this repair. The kit contains the necessary fuel pipe set, hoses and intake manifold gaskets to complete this repair.
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Code: 
https://www.worldimpex.com/parts/subaru-wvk21-repair-kit_2603749.html
https://www.iwsti.com/forums/2-5-liter-litre-factory-motor/228170-fuel-smell-repair-kit-10130aa000.html
https://forums.nasioc.com/forums/showthread.php?t=2127350


https://www.worldimpex.com/parts/subaru-wvk21-repair-kit_2603749.html
https://www.iwsti.com/forums/2-5-li.../228170-fuel-smell-repair-kit-10130aa000.html
https://forums.nasioc.com/forums/showthread.php?t=2127350

:)
 
(1) Relieve fuel system pressure using the procedure from the appropriate model year repair manual under Engine section 22. Fuel. (MY 2002 page FU(DOHC TUBRO)-51, MY 2003 page FU(DOHC TUBRO)-54).

(2) Remove the intake manifold assembly as per repair manual Engine section 3. Intake manifold. (MY 2002 page FU(DOHC TUBRO)-15, MY 2003 page FU(DOHC TUBRO)-15).

Note:
The following photos show the updated fuel line and hose.


smell1.jpg

(3) Turn intake manifold on it side with the throttle body facing down on a clean work surface.

(4) Loosen the hose clamps at the ends of the steel line as shown below.


smell2.jpg

(5) To ease the removal of the steel line from the intake manifold, remove the 2 bolts holding the intake manifold wire harness protector.


smell3.jpg

(6) Remove the 3 line mounting bolts and then remove the line from the intake manifold.


smell4.jpg



(7) Install the new metal line using 3 new hoses from the kit and secure it to the manifold. The existing stainless steel clamps can be reused. Also re-install the wire harness protector bolts.

(8) After the new line and hoses have been installed, the intake manifold can be re-installed. Be sure to use the new intake manifold gaskets included in the campaign kit.
 
It's described in this bulletin related to the WVK-21 recall:
https://www-odi.nhtsa.dot.gov/acms/cs...9V468-1307.pdf

Code: 
https://www-odi.nhtsa.dot.gov/acms/cs/jaxrs/download/doc/ACM12948229/RCSB-09V468-1307.pdf

mmfv69.jpg


Description: WVK21 Repair Kit
Part Number: 10130AA000

Note that the bulletin above indicates that SOA will apply the WVK-21 fuel leak fix for free on any 2002-3 WRX with no questions asked (i.e. dealer doesn't need to duplicate the problem). However, that deal only lasts while the car has been "in-service" for less than 12 years. Deliveries of the 2002 WRX began on Mar 15, 2001, so time will run out on Mar 15, 2013 for some of the first-delivered 2002 WRX cars.
 
hmmmm...very interesting. Good find PigSti. I'm having the same issue on my '01 Outback. It's been doing it since I got it, but I haven't done anything about it since the smell stops pretty quick once it has warmed up a bit. This gives me a starting point, and now I'll look into it some.
 
Here it is the leak on a freezing morning, a fire hazard for sure!!

[ame="https://www.youtube.com/watch?v=BnQ4Lvwa43Q"]04 Subaru Forester gas leak - YouTube[/ame]

:furious:
 
That's a terrific find, Pigs.

Have you fixed yours yet?

& what model do you have?
 
Nope, not fixed. Could be the reason for the atrocious fuel economy or lack of it!. Same model as in the video..

Interested in getting the upgrade fuel rails if they are still available.
 
^ I'd bet that it has something to do with your poor economy, Pigs ... :iconwink: :(.

Considering that a car uses about a pencil line width of fuel per kilometre/mile/whatever ... It doesn't take much of a leak to make an impact on that!

My model (MY06) also has a fully pressurised fuel system, which is guaranteed to help any fuel to escape that can! Not sure if the series I SG also has this, but it almost certainly does.

Leaving aside the health risk, the risk to the health and well being of your wallet is substantial ... :poke: :rotfl: :(.

The fuel gauge in Roo2 is deadly accurate. When the needle exactly bisects the gauge marking, it is exactly a 12L increment. So Full = 60L; 3/4 = 48L; 1/2 = 36L; 1/4 = 24L and Empty = 12L left, and the fuel warning light comes on, and stays on.

This is quite unlike Roo1 ('93 Impreza), where the gauge was vaguely indicative only. As an aside, when I fixed the tacho in Roo1, the fuel gauge started working accurately ... :rolleyes: :shake: :shrug: :confused: :lol:.

The gauge in RonnyRoo (2009 MY10 SH) is marked in seven increments ... F, 6/7, 5/7, 4/7, 3/7, 2/7, 1/7 (= Empty). Not exactly intuitive ... :shrug:. Not even an integer divisor of the 60L tank - flaming weird, if you ask me!

Anyway, I have only very rarely got less than 400 kms before the needle hits "Empty" and the light comes on. i.e. exactly 12L left in the tank. This translates to around 500 kms on a full tank around town.
 
I'm tempted to just get these fuel rails done into one piece eliminating the stupid rubber sections completely!

https://www.google.com.au/search?hl....1ac.1.24.heirloom-hp..12.11.1887.W4TSu7hSMPc

If it's under the hood, it's a known issue with Subaru engines.

You can't fix it by tightening the fittings. The problem is under the intake manifold on one of the pipe/rubber hose junctions between the fuel rails. The pipe does not insert far enough into the rubber hose and when the hose shrinks from the cold, fuel leaks out.

Subaru issued a service bulletin on 4/1/03 regarding this issue (link (https://www.scoobymods.com/showpost.php?p=10035&postcount=1)). To fix it, you'll need parts #17544AA134 (new pipe) and #807707140 (new hose).

However, Subaru says the issue was fixed after engine #673467, so you shouldn't be having the issue with a 2005 model.
Click to expand...
To fix it, I'll need parts:
#17544AA134 (new pipe) and
#807707140 (new hose).


vnf4mg.jpg


Reference:

https://www.i-club.com/forums/engin...fuel-smell-cold-weather-2002-wrx-43929/page2/
 
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Gidday Pigs,

Engines shake, rattle and roll, but the fuel lines are rigidly attached to the body work ...

I suspect that the flexible hoses are there to eliminate fractures due to metal fatigue and flexing in use - so perhaps not such a good idea to get rid of them entirely :poke: :iconwink:.
 
carljwnc said:
hmmmm...very interesting. Good find PigSti. I'm having the same issue on my '01 Outback. It's been doing it since I got it, but I haven't done anything about it since the smell stops pretty quick once it has warmed up a bit. This gives me a starting point, and now I'll look into it some.
Click to expand...

Maddmatt
12-10-2009, 03:07 PM

Same here, also '01 Outback - when its very cold (less than 10 or so) the gas smell is very strong. While its that cold, with the engine running, open the hood. Then take a rag and start carefully cleaning the fuel lines - on mine it was pretty obvious which were leaking once I used the rag. Small adjustments to the fittings on either end of the suspect lines fixed the problems. Reappears every 2nd or 3rd year. Hope that helps.

https://www.expeditionportal.com/forum/archive/index.php/t-35632.html

:)
 
A fix without taking off the manifolds, If you can understand it...

https://www.i-club.com/forums/engin...old-weather-2002-wrx-43929/page6/#post3123635

Hi I'm new to this site, I have had the smell in my car, I also have called the dealer in Utah and they have sold me the replacement lines for this fix.

One thing that I wanted to tell people with the same problem, first I don't know if you have had it fixed or not, if you have not, I want to tell you don't have the dealer do it, it should only take you an afternoon to fix it( without removing the intake manifold.

What I did was remove the intercooler, the intake inlet hose, and the other fuel lines. there are two bolts that are attached to the intake man that are holding the fuel lines on.

Once you have disconnected the bolts there is a hose clamp you can see that is attached to the line underneath, you need a long screw driver for it. Then the others that are near where the inlet hose was.

As much as it sucks to do, I took the old fuel lines out by bending them in a half moon shape and they're no good anyway, also the on connection that's underneath the intake can be bent and folded to get out of the way.

The new lines will not go in all connected. I took and cut all three that are connected by a bridge fastener and made them individual lines, then just slid them in one by one and cable tied them together.

Then connected them in the place they belong, sounds dumb but, I did it in about 4 hours and also with out a dealers cost and with out removing the intake man.
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The only thing that fixed mine was to just take off the intake (not that difficult, but time consuming). and just get to it. I replaced the straight bits with high-pressure fuel injection line from the auto part store (about $8/foot, only needed a foot). You can reuse the fasteners if you like, I replaced mine with OEM ones. The curved pieces I would order from Subaru, much easier than trying to bend your own with the thick fuel injection line.
 
That's wild. I experienced this problem about a year ago on cold mornings after moving to Colorado. I wasn't aware of any recall, but after the 2nd time and doing some digging, i found just what the recall described. A rubber hose that was connected to an aluminum line with a wire gear clamp was seeping a little gas and saturating the rubber hose. I figured the clamp had loosened up, so i tightened it and wam bam, thank ya ma'am! Haven't had the problem since.
 
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