NHTSA Complaint #10865217 — 2005 SUBARU BAJA

IT IS A COMMONLY KNOWN PROBLEM WITH SUBARUS OF THIS ERA THAT THE HIGH PRESSURE RUBBER FUEL LINES UNDERNEATH THE INTAKE MANIFOLD WILL BEGIN TO LOSE THEIR ELASTICITY AS THEY AGE AND LEAK PROFUSELY WHEN THE TEMPERATURE DROPS BELOW 30 DEGREES FAHRENHEIT. MECHANICS KNOW THIS AND IT IS DISCUSSED EXTENSIVELY ON THE SUBARU FORUMS. THIS HAPPENED TO MY 2005 SUBARU BAJA WHEN I WAS TRAVELING IN THE MOUNTAINS. WHEN I STARTED THE VEHICLE IN THE MORNING, FUEL WOULD BEGIN PUDDLING ON THE TOP OF THE ENGINE. IT WAS VERY NOTICEABLE DUE TO THE FUEL VAPORS PRODUCED. AS THE ENGINE WARMED THE RUBBER WOULD SWELL AND STOP THE LEAK AFTER A GOOD 30 MINUTES OR LONGER DEPENDING ON THE OUTSIDE TEMPERATURE. I HAD TO TRAVEL WITH A FIRE EXTINGUISHER AT THE READY AND COULD NOT KEEP ANY VENTS OPEN IN THE CABIN. IT WAS EXTREMELY DANGEROUS AND COULD NOT BE REMEDIED UNTIL I WAS BACK FROM MY TRIP. SUBARU ISSUED A RECALL A FEW YEARS AGO FOR A SMALL PART NEAR THE FUEL PUMP AND TANK BECAUSE IT HAD THE POTENTIAL TO LEAK, BUT THEY HAVEN'T ADDRESSED THIS FAR MORE PERVASIVE ISSUE AT ALL. THE REMEDY REQUIRES A DIFFICULT AND COSTLY REMOVAL OF THE INTAKE MANIFOLD AND THE REPLACEMENT OF ALL THE RUBBER LINES THAT RUN BETWEEN THE HARD PIPES ON THE HIGH PRESSURE FUEL CIRCUIT. I SUSPECT THIS IS WHY THEY ARE NOT ISSUING A RECALL. IT IS A VERY REAL PROBLEM AND NEEDS TO BE ADDRESSED IMMEDIATELY.