2003 Subaru Forester Engine Problems

Which parts fail

• Engine
  9
• Exhaust system
  2

Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).

Mileage when the problem started

• Under 25k
  415%
• 25k–50k
  14%
• 50k–75k
  622%
• 75k–100k
  519%
• 100k–150k
  933%
• 150k+
  27%

Owner reports

Selected complaints filed with NHTSA by 2003 Subaru Forester owners, lightly cleaned up (personal details are redacted by NHTSA).

Frontal impact while striking a deer at this speed should have deployed both air bags. The air bag light sometimes would remain on, but mostly it was off. From what I have found through other complaints is that this year vehicle is known for this issue, but a recall has not been issued. Is it going to take a death to force Subaru to correct this issue? The other issue found while repairing the vehicle is that both head gaskets are seeping coolant, the drivers side is seeping more just like the recall describes on 1999-2002 models. Even though this a 2003 it was purchased in the fall of 2002, Subaru failed to contact me and advise me to add the $1.44 coolant additive to save the head gaskets. How is a consumer supposed to know these little details? Now the vehicle has too many miles for them to care, sticking me with the estimated $2000 repair.

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.

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. …

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. …

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. …

My 2003 Subaru Forester - purchased new - currently has 55,000 miles on it. It was last serviced 3 months ago. At that time, nothing was mentioned about coolant problems or leaks. Last week, on the turnpike, the RPM needle started swinging wildly and I lost power. I managed to get to the shoulder of the turnpike and shut down and by that time smoke was pouring out from the engine. The problem diagnosed is that the coolant had leaked at the head gaskets - a problem that I am now learning Subaru has known about for some time. I have to replace the engine at a cost of at least $2600. I was never contacted by Subaru or the dealership to inform me that this May be a problem although I consistently have received notifications about repurchasing an extended warranty. Obviously, a 2003 vehicle with 55,000 miles on it has not been driven excessively. …

2003 Forester has extremely strong aromas of fuel when starting & driving in cold weather. Fuel vapors are very dangerous, here are side effects of inhalation: inhaling gasoline fumes brings concentrated hydrocarbons into your lungs and bloodstream. Some of the ingredients in gasoline are extremely toxic and are mutagens. Liver damage and permanent brain damage are possibilities. The side effects caused by the inhalation of gasoline can range from central nervous system (cns) depression, which can include: eye and throat irritation, mild or pronounced dizziness, headache, lack of appetite, drowsiness and in-coordination. In more serious circumstances, it can cause unconsciousness, pulmonary edema, and death. Subaru should issue a recall and address the issue, because they installed a defective product!

Upon starting and running the vehicle in temperatures below freezing (32 degrees f), the fuel lines near the intake manifold in the engine bay leak gasoline, transmitting an unburnt fuel smell to the cabin via the HVAC system and blower fan. These fumes are toxic and therefore hazardous to motorist and passenger health. Also, fuel dripping near a hot intake manifold is a fire hazard. The lines appear corroded in spots and the fuel leak is visible and apparent. There is no recall for this issue. However, based upon the inspection, the apparent fuel leak in such close proximity to the hot engine is a major hazard for the motorist of the Forester and other motorists on the road - this issue should be resolved and Subaru should announce a recall on all (2003) Forester models.

I purchased a new Subaru Forester xs in July 2003 and had it serviced regularly at now defunct Subaru dealerships. While I was driving one day, the car suddenly overheated. The foreign and domestic auto service mechanic I was able to reach showed me that the engine was leaking coolant in 3 places, requiring a costly repair of the head gasket. I learned from him that this head gasket failure was a common problem with subarus. I had the car under warranty with Subaru for 60,000 miles. At no time was I notified by the dealer from whom I purchased the car or by any Subaru service center, that special coolant was required to mitigate this defect. I had the car repaired at a cost of over $2,000.

Noticed anti-freeze odor after vehicle had been run and turned off. Did not see any leaks. Problem continued several weeks before noticing several leak spots on garage floor, so made appointment with mechanic who knew immediately it was a head gasket problem. We purchased the car new in October, 2002 and have maintained it according to the maintenance schedules. The vehicle had 52,000 miles on it when we spent $1300 to repair a problem that Subaru of America knew about and has known about for some time. We never received any notice or recall of any kind relating to this problem. Subaru of America should make some sort of restitution to its customers for this manufacturers defect.

Engine complaints in other Forester years