Subaru Head Gasket Replacement Cost

If you own a Subaru, chances are you’ve heard about the dreaded head gasket issue that has plagued many Subaru engines over the years.

A leaking or blown head gasket can wreak havoc on an engine, causing costly repairs or even a complete replacement of the engine.

In this guide, we’ll break down the average Subaru head gasket replacement cost and discuss what’s involved in the repair process.

Why Do Subarus Have Head Gasket Issues?

Certain Subaru boxer engines from the late 1990s through mid 2000s have a tendency to leak or blow head gaskets due to a combination of factors:

• Engine design: The flat or "boxer" design of the engine puts stress on the head gasket seals.
• Cylinder compression: Higher cylinder compression ratios and forced induction in some models increases pressure and heat on the gaskets.
• Coolant system: Overheating issues related to the coolant system design can cause gasket failure.
• Manufacturer defect: Some argue the materials and manufacturing process used for earlier Subaru head gaskets were defective and prone to premature failure.

The most commonly affected Subaru models include the 1998-2003 Forester, 1999-2001 Impreza 2.5RS, and 2001-2005 Outback. But head gasket issues have been reported across many "EJ" series engines from the period as well.

Signs Your Subaru Needs New Head Gaskets

If your Subaru is leaking or blowing head gaskets, you'll likely notice some of these common symptoms:

• Coolant leaks: Look for wet spots or puddles under the engine, especially near the front of the cylinder heads.
• Oil in coolant reservoir: Check for a milky mayonnaise-like substance in the overflow coolant bottle.
• White exhaust smoke: A blown head gasket allows coolant into the combustion chamber, producing telltale white plumes from the tailpipe on startup.
• Rough idling: As air and coolant enter the cylinders, it causes instability at idle and sometimes stalling.
• Low coolant level: Keep an eye on coolant levels which will often drop as it leaks past bad gaskets into the cylinders.
• Overheating: A blown head gasket prevents proper circulation and cooling of engine components.

If you notice any combination of these issues, it's highly likely your Subaru needs new head gaskets.

Average Subaru Head Gasket Replacement Cost

The labor hours and cost to replace Subaru head gaskets can vary depending on the make and model of the car. Here are some average price ranges to expect:

Labor Cost

• $900-1500: Basic gasket replacement on 4-cylinder "EJ" engines generally takes 12-18 hours of labor.
• $1200-2000: Turbo or 6-cylinder "EJ" engines may require more labor, up to 24 hours for certain models.
• $1500-2500: More complex jobs involving additional repairs can drive labor costs even higher.

Parts Cost

• $300-600: Basic head gasket set for a 4-cylinder engine.
• $400-800: Turbo or 6-cylinder engines use specialized gaskets that cost more.
• $500-1000: Additional parts like timing components may need replacement increasing total parts costs.

So in summary, expect to pay anywhere from $1200 up to $3500 or more for a basic Subaru head gasket replacement depending on the specific vehicle and any additional needed repairs.

What's Involved in the Repair Process?

Replacing Subaru head gaskets requires removing and disassembling several engine components. Here are the basic steps involved:

1. Drain engine coolant and oil.
2. Remove accessory drive components like belts, pulleys, and alternator.
3. Disconnect exhaust system from manifolds.
4. Remove engine wiring harness and vacuum lines.
5. Unbolt intake and exhaust manifolds from cylinder heads.
6. Take off valve cover and timing components from the heads.
7. Remove cylinder heads from the engine block.
8. Clean and inspect cylinder head and block surfaces.
9. Install new head gaskets and torque heads to spec.
10. Reinstall components in reverse order and refill fluids.
11. Test drive and inspect for leaks.

It's a lengthy process requiring specialized tools and expertise. Shops generally recommend rebuilding the heads to ensure a durable repair if they've been damaged by overheating.

Other Repairs To Consider

While replacing the head gaskets is the main focus, mechanics often discover additional issues needing attention during a head job. Some other common repairs include:

• Cylinder head resurfacing: Machining flat and smooth surfaces for proper sealing.
• Valve job: Grinding valves and replacing seals if worn from overheating.
• Timing components: Chains, belts, tensioners are worn out on high mileage engines.
• Water pump: Often fails from heat stress and should be swapped preemptively.
• Thermostat: Another part prone to overheating failure that's easy to change.
• Coolant system: Flush radiator, hoses if sludge has accumulated from leaks.

Tacking on these ancillary repairs usually adds a few hundred to a thousand dollars or more to the overall job cost. But it ensures long-term reliability of the entire cooling and valvetrain systems.

Extended Warranty Options

Considering the frequency and high cost of Subaru head gasket repairs, some owners opt for an extended warranty. A few options to research include:

• Subaru supplemental extended warranty: Covers head gaskets and related components up to 100k miles for a fee.
• Third party mechanical breakdown insurance: Covers major engine repairs for older higher mileage vehicles.
• Certified Pre-Owned warranty: Comes with remaining factory warranty plus an added bumper-to-bumper term.
• Independent extended warranty: Customized plans from third parties for specific vehicles and mileage plans.

An extended warranty gives peace of mind should the head gaskets fail outside the powertrain coverage window. Do the math to see if the upfront cost pays off versus potential future repairs.

When To Consider an Engine Replacement

On higher mileage Subarus or those with extreme neglection from failed head gaskets, a new or rebuilt engine swap may be more cost effective than a head job. Here are some signs it may be replacement time:

• Over 150k miles with unknown gasket history
• Severe damage from overheating like cracked cylinder heads
• Excessive oil and coolant consumption between leaks
• Sluggish performance from worn components
• Rust or deposits throughout the coolant system
• Estimated repair cost exceeds 60% of vehicle value

An engine replacement including installation generally runs $3500-$5500 depending on the model. But it solves problems indefinitely versus potentially recurring head gasket issues.

DIY Head Gasket Replacement

Ambitious do-it-yourself mechanics can save big money attempting their own Subaru head gasket job. However, it requires advanced mechanical skills and specialty tools. Considerations include:

• In-depth repair manual and videos for guidance
• Torque wrench, gasket matching tools and sealant
• Machining and resurfacing the cylinder heads if needed
• Proper safety precautions working with engine components
• Completing all repairs correctly

And testing thoroughly before driving. While DIY can save big on labor costs, mistakes could ruin an otherwise healthy engine. Consider borrowing professional tools and paying for machine shop work if needed. It's always an option to have the dealer or mechanic complete tricky steps too. With careful planning and guidance, motivated owners can certainly tackle a Subaru head gasket job themselves to cut repair costs significantly.

Minimizing Future Repairs

Once those leaky Subaru head gaskets are replaced, follow these maintenance tips to help prevent a repeat failure down the road:

• Change coolant every 30k miles per the maintenance schedule.
• Inspect cooling system parts like hoses, thermostat and water pump periodically.
• Monitor coolant levels and quickly address any leaks that develop.
• Avoid prolonged idling or driving in slow traffic when the engine is cold.
• Perform scheduled tune-ups and address any other developing engine issues promptly.

Regular fluid flushes help remove contaminants, proper driving habits reduce heat stress, and catch repairs prevent damage from cascading. With proper long-term care after the head job, you can maximize the lifespan of your Subaru's repaired engine block.

Final Thoughts

Replacing Subaru head gaskets is an expensive but necessary repair for many older models with the inherent design flaws. Budgeting $1500-$3500 depending on your specific vehicle and mechanic is a good starting point.

Tackling associated repairs concurrently is wise to avoid future issues. An extended warranty provides peace of mind should leaks reoccur.

With any luck, your Subie will deliver many more miles of enjoyable driving once this maintenance is addressed properly.