1999 Subaru Outback Fuel system Problems

“My 1999 Subaru Outback wagon issued a cel with a 440 code. In finding the source of the problem, I discovered that the gas fill pipe below the gas cap has rotted out and has developed, holes leading to raw gas spillage and failure of the emissions system. The design of the cover around the outside of this pipe caused the accumulation of dirt and debris over the years that has rusted the pipe from the outside in. This is a poor design that allows the dirt to collect here. There is nothing in the manual that indicates any cleaning of this area is required to prevent this from occurring.”

“Fuel filler tube corrosion causes leak of fuel and fuel vapor. Check engine light illuminates code p0440 (evap emissions malfunction). Fuel filler tube and valve assembly parts cost is $200. Labor $275. Common problem on subarus that should be investigated and recalled due to fuel vapor leakage poses an environmental safety hazard.”

“Vehicle has been experiencing hesitation after accelerating from a stopped position, this problem has been occurring every day and the dealer can find no remedy for it, the mechanics say it is a fuel problem and have had the consumer use high octane gas, the fuel filter was plugged and the dealer found the fuel was contaminated, all the work that has been completed on this vehicle has not remedied the hesitation problem.”

“There are several issues going on with my 1999 Subaru legacy Outback vehicle: 1) the check engine light goes on when the fuel gauge drops down to empty although the gas tank was just filled with gas. 2) the fuel gauge does not read correct. After the gas tank is full, the gauge fluctuates back and forth (sometimes the gauge reads near empty, sometimes the gauge reads 3/4 of the tank full) when operating the vehicle. 3) the car did not pass the california smog test. 4) the RPM gauge does not stay constant while driving at an even speed. …”