2002 Subaru WRX recalls and problems

THE DESIGN OF THE FUEL LINE (METAL RAIL/RUBBER HOSE INTERFACE) IS SUSCEPTIBLE TO FUEL ODOR AND/OR SEEPAGE IN EXTREME COLD TEMPERATURE CONDITIONS.OWNERS MOST OFTEN NOTICED FUEL ODOR IN THE OCCUPANT COMPARTMENT AREA DURING INITIAL COLD ENGINE START-UP.ONCE THE ENGINE IS WARMED, THE ODOR/SEEPAGE ISSUE DISSIPATES.FROM SUBARU'S DATA, ODI NOTES THAT THE INCIDENT RATES ARE HIGHER IN STATES WITH COLDER TEMPERATURES.THERE WAS ONE ALLEGATION OF A FIRE INCIDENT IN WHICH THE OWNER HAD REPORTED THAT HE NOTICED FUEL ODOR A FEW DAYS EARLIER, BUT ODI COULD NOT CONFIRM THE ORIGIN OF THE FIRE. TO ADDRESS THIS ISSUE, SUBARU WILL REPLACE THE FUEL LINE WITH A LONGER RUBBER HOSE SEGMENT VERSION/DESIGN ON 5,724 MY 2002-2003 VEHICLES BUILT THROUGH SEPTEMBER 12, 2002 IN 16 STATES (AK, CO, IA, ID, ME, MI, MN, MT, ND, NE, NH, NY, SD, VT, WI & WY).IN ADDITION, SUBARU WILL EXTEND THE WARRANTY COVERAGE TO 12 YEARS/UNLIMITED MILEAGE ON VEHICLES IN THE REMAINING 34 STATES.THIS ENGINEERING ANALYSIS IS CLOSED (SEE RECALL CAMPAIGN 09V-468)

COMPLAINANTS REPORT FUEL LEAKAGE MOST FREQUENTLY IN WINTER DURING INITIAL COLD ENGINE STARTUP.OWNERS WILL EITHER NOTICE A FUEL ODOR INSIDE THE OCCUPANT COMPARTMENT OR FUEL ODOR/LEAKAGE AT THE FUEL LINES ON THE RIGHT SIDE ATOP THE ENGINE. ONCE THE ENGINE HAS WARMED, THE ODOR/LEAKAGE MAY CEASE.SUBARU REVISED THE FUEL PIPE/HOSE DESIGN FOR MODEL YEAR (MY) 2003-04 WRX VEHICLES PRODUCED AFTER AUGUST 2003.SUBARU ALSO INTRODUCED A MY 2004 IMPREZA STI VEHICLE WITH A DIFFERENT ENGINE AND FUEL PIPE/HOSE LAYOUT.OUT OF THE TOTAL OF 994 COMPLAINTS, 944 CONCERN MY 2002-03 WRX VEHICLES BUILT THROUGH AUGUST 2003.SUBARU ALSO REPORTS ONE FIRE ON A MY 2002 WRX VEHICLE THAT OCCURRED IN FEBRUARY 2006.IN MARCH 2009, ODI INSPECTED AND VIDEO TAPED A MY 2002 WRX VEHICLE WITH A FUEL LEAK DURING COLD ENGINE START UP.THE VIDEO WAS PROVIDED TO SUBARU AND IS IN THE INVESTIGATION FILE. THIS INVESTIGATION IS BEING UPGRADED TO AN ENGINEERING ANALYSIS (EA09-011) TO FURTHER STUDY THIS ISSUE.

SUBARU REPORTS THAT THE FUEL ODOR IS CAUSED BY FUEL SEEPAGE DURING COLD START OF THE ENGINE UNDER EXTREMELY COLD TEMPERATURES. THE LEAK OCCURS IN A FUEL LINE IN THE ENGINE COMPARTMENT.IT REPORTS THAT THE FAILURE IS DUE TO THE MISALIGNED ANGLE BETWEEN TWO FUEL DELIVERY LINES WHICH RESULTED IN SUCH FUEL SEEPAGE DURING THE FIRST FEW SECONDS OF COLD ENGINE START DURING THESE COLD TEMPERATURES.SUBARU REPORTS THAT THE TWO FUEL LINES ARE CONNECTED WITH A HOSE THAT BECOMES TOO STIFF IN VERY COLD TEMPERATURES TO CONFORM TO THE MISALIGNMENT. SUBARU HAS ISSUED A TECHNICAL SERVICE BULLETIN (SUBARU SERVICE BULLETIN NUMBER 09-36-03) TO REPLACE THE FUEL LINES WITH NEW LINES THAT ARE PROPERLY ALIGNED AND THAT HAVE A LONGER CONNECTING HOSE.ODI PHONE CALLS TO MANY OF THE COMPLAINANTS CONFIRM THAT FUEL ODOR IS NOTICABLE DURING VERY COLD TEMPERATURES AND COLD START BUT GOES AWAY AS THE ENGINE WARMS UP, AND THE ODOR IS NOT PRESENT IN WARMER TEMPERATURES. A FEW OWNERS REPORT THAT ATTEMPTS TO ELIMINATE THE LEAKAGE BY TIGHTENING THE CONNECTING HOSE CLAMPS IS NOT EFFECTIVE IN ELIMINATING THE FUEL ODOR.A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL MONITOR THIS ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

DURING THE EA, ODI AND VRTC PERFORMED THE FOLLOWING ACTIVITIES:1.CONDUCTED A MAIL SURVEY OF 246 SUBJECT VEHICLE OWNERS TODETERMINE THE ROADWAY SURFACE THAT CAUSED OWNERS' CONCERN;2.INTERVIEWED COMPLAINING OWNERS;3.CONDUCTED FIELD INSPECTIONS OF SEVEN (7) COMPLAINT VEHICLES;4.INSTRUMENTED TESTING AT VRTC OF COMPLAINT AND PEER VEHICLES;5.REVIEWED SUBARU'S RESPONSE TO OUR INFORMATION REQUEST;6.MET WITH SUBARU FOR TECHNICAL REVIEW OF TESTINGAS A RESULT OF THE WORK CONDUCTED BY VRTC AND ODI DURING THIS INVESTIGAITON, A CONSISTENT OR CHRONIC PATTERN OF POOR BRAKE PERFORMANCE HAS NOT BEEN IDENTIFIED.VRTC CONDUCTED OVER 11,500 BRAKE TESTS.THEY DID NOT OBSERVE ANY LONG-DURATION, LOW DECELERATION EVENTS (SOME OWNERS REPORTED DELAYS OF 4 TO 10 SECONDS) IN THE TEST VEHICLES.SEE ODI'S CLOSING REPORT AND VRTC'S TEST REPORT FOR FULL DETAILS

SUBARU'S SUPPLEMENTAL RESPONSE OF SEPTEMBER 29, 2003, IDENTIFIED THAT THE 2002, 2003 SUBARU WRX MODELS AREEQUIPPED WITH THE BOSCH 5.3 ABS SYSTEM, AND IDENTIFIED THAT OTHER MODEL SUBARU VEHICLES ARE ALSO EQUIPPED WITH THE BOSCH 5.3 ABS SYSTEM, BUT HAVE DIFFERENT CALIBRATIONS THAN THE WRX MODEL VEHICLES.SUBARU IDENTIFIED THAT CHANGES WERE MADE IN THE ABS ECU TO ADDRESS A CALIBRATION LOGIC ISSUE WHEN DRIVING THE VEHICLE WITH THE SPARE TIRE MOUNTED.SUBARU REPORTED THAT BOTH THE ABS HYDRAULIC UNIT AND THE ABS ECU WERE MODIFIED, AND GAVE VIN NUMBERS TO IDENTIFY THE IMPLEMENTATION OF THE MODIFIED UNITS IN PRODUCTION. TESTING IS UNDERWAY TO GAIN AN UNDERSTANDING OF THE WRX VEHICLE PERFORMANCE DURING AN ABS ACTIVATION.FUTHER, ANALYSIS OFTHE DIFFERENCES IN VEHICLE PERFORMANCE RESULTING FROM ABS SOFTWARE CHANGES WILL BE EXAMINED.