This Bulletin provides the diagnostic procedure for the STARLINK® Remote Engine Start (RES).
full bulletin at NHTSA ↗2005 Subaru Outback engine problems
severe 23 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
23
Recalls
0
Avg fix
$3,100
2fires
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This Service Information Bulletin provides the Service Manual Correction to the diagnostic procedure for DTC B2A16 (Immobilizer Key Collation Diagnosis).
full bulletin at NHTSA ↗This Bulletin announces the diagnostic procedures to be followed when diagnosing engine oil leakage on FA and FB type engines.
full bulletin at NHTSA ↗The purpose of this bulletin is to advise of SOA’s revised Catalytic Converter Recycling Program shipping procedure.
full bulletin at NHTSA ↗This bulletin contains additional information for recommended materials listed in the Service Manuals for individual models.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
2005 Outback owners report a cascade of engine and related system failures across the model's life. Head gasket failures dominate, striking as early as 19,000 miles and recurring even after repair—warped cylinder heads compound the problem and aren't always caught during initial fixes. Turbo failures are rampant, particularly in the turbocharged XT models, happening at 35,600 miles, 67,000 miles, 85,000 miles, and repeatedly in the same vehicles (one owner replaced the turbo four times). Metal shards and debris from failed banjo bolt filters scatter through the oil system and engine, destroying motors entirely.
Throttle control issues leave drivers stranded: the accelerator becomes unresponsive, engines stall or surge unpredictably, cruise control malfunctions, and the check engine light illuminates with fault code P2138. Some owners report the engine cannot build boost at high altitude. Cooling system problems manifest as persistent overheating even after radiator cap replacement and head gasket repair. A fuel return line shrinks in cold weather, leaking onto the engine block. Two fires of undetermined origin occurred in the 2005 XT. Repair costs cited include $1,800 for turbo replacement, $2,000–$3,000 for head gasket work, and thousands for engine replacement. Warranty coverage is inconsistently applied and sometimes denied despite extended service contracts purchased.
Same Subaru Outback engine reports on nearby years: 2006 · 2007 · 2008
Failure modes owners describe
Head gasket failure
Cylinder head gaskets fail, allowing oil to drip onto the hot exhaust manifold, producing visible foul-smelling smoke. Failures occur at low mileage (19,000 miles documented) and recur after repair. Dealerships sometimes miss warped cylinder heads during initial diagnosis, requiring a second repair.
When: 19,000 miles; recurrence after initial repair; another instance after 100,000 miles when extended warranty expired
Symptoms owners cite: Check engine light illuminated; Temperature gauge rising to red; Smoke pouring from engine compartment; Oil dripping onto hot exhaust system; Visible, foul-smelling smoke when driving
Codes mentioned: P2138
Repairs/costs cited: Head gasket replacement $2,000 cited; cylinder head planing required in one case due to warping; repeated repairs necessary
Recalls/TSBs owners mention: Subaru refused warranty coverage despite emissions warranty still active on one vehicle; another owner notes Subaru aware of similar failures in earlier models and previous class action settlement
Turbo failure with metal debris
Turbo chargers fail prematurely, often with internal gears breaking apart and scattering metal shards into the oil system and engine. Banjo bolt oil supply filter design is implicated in at least one case per Subaru Service Bulletin 02-103-07. Failures occur across the lifespan and sometimes recur in the same vehicle multiple times.
When: 35,600 miles; 67,000 miles; 85,000 miles; as early as less than one month after purchase (second-hand car); repeated failures in same vehicle at 2016, 3 months later, and January 2018
Symptoms owners cite: Check engine light illuminated; Whistling or whooshing sound from engine area; Loss of power while driving; Slow acceleration on inclines; Rattling noises from engine; Vehicle left stranded
Repairs/costs cited: Turbo replacement $1,800 cited; one owner replaced turbo four times; metal shards found in oil pan and oil filter; in one case, turbo support was stripped requiring engine replacement; complete engine replacement necessary in multiple cases
Recalls/TSBs owners mention: One owner purchased extended $1,975 service contract at 100,000 miles; Subaru denied the turbo failure claim pending service records; owner cites multiple reports on Subaru forums and suspects design defect
Timing belt tensioner failure
The timing belt tensioner slips, causing the timing belt to shatter. This occurred during a test drive at a Subaru dealership immediately after head gasket repair, suggesting potential cascade failure or inadequate inspection.
When: Discovered during test drive after head gasket repair; original breakdown at 19,000 miles
Symptoms owners cite: Engine breakdown during test drive; Timing belt shattered
Repairs/costs cited: Tensioner and timing belt replacement; required one week and a half for repair
Throttle/accelerator control malfunction
The throttle pedal becomes unresponsive or the engine surges unexpectedly. In some cases, the accelerator does not engage even when pressed to the floor and the vehicle will not move until the engine is shut off and the battery disconnected to reset the system. Other instances involve sudden uncontrolled acceleration while applying brakes. Check engine light and cruise control light often illuminate simultaneously.
When: Occurring intermittently over years; one case spans 2 years and worsens; another occurs at 150,000 miles with loss of power
Symptoms owners cite: Throttle pedal becomes non-responsive; Engine revs at high RPM without operator input (4–5 seconds); Sudden acceleration despite applying brakes; Engine idle cannot be controlled, ranging from idle to 3,000 RPM; Check engine light illuminated (P2138 code cited); Cruise control light flashing; Loss of throttle control at highway speeds; Engine stalls or nearly dies when accelerating from stop
Codes mentioned: P2138
Repairs/costs cited: Accelerator pedal assembly replacement; problem recurred after six months; dealership unable to diagnose in some cases; one case required fuel injector replacement tied to cruise control mechanism; another required battery disconnect and engine reset
Recalls/TSBs owners mention: Dealerships report inability to replicate and fix the problem; one owner mentions other Subaru owners experience the same issue but Subaru will not admit it is a safety problem
Engine overheating and cooling system failure
Engine overheats persistently. One owner experienced overheating during an entire cross-country drive even after head gasket and timing belt repairs. Radiator cap failure is implicated in at least one case; keeping RPMs elevated temporarily mitigates the problem.
When: Occurred throughout cross-country trip at 19,000 miles; persistent after head gasket repair
Symptoms owners cite: Temperature gauge rising to red; Check engine light illuminated; Smoke from engine compartment; Persistent overheating despite coolant and water additions
Repairs/costs cited: Radiator cap replacement; heads planed and new gaskets installed; problem persisted until RPM management strategy employed
Power loss at high altitude
Engine loses power and cannot build boost at high altitude (10,000–11,500 feet), causing the vehicle to become immobilized when minor obstructions (snow, incline) are encountered. RPM ceiling is approximately 2,000, near the torque converter stall speed. Dealerships could not replicate or diagnose the issue.
When: Two separate incidents at altitudes of 10,000–11,500 feet
Symptoms owners cite: Sudden loss of most engine power; Engine unable to go above 2,000 RPM despite full throttle; Wheels will not turn under any circumstance; Loss of traction control ability; Normal power returns once obstructions are cleared
Recalls/TSBs owners mention: Two dealerships unable to replicate the problem and unable to fix; owner filed verbal complaint with Subaru of America on July 27 and followed up July 29 with Subaru still trying to contact dealer
Fuel return line leak
The return fuel line on the driver's side on top of the engine shrinks in cold weather, allowing fuel to leak onto the engine block. The leak stops when the engine warms up but recurs with cold exposure.
When: Recurring problem; owner has repaired it at least twice, previous owner once before
Symptoms owners cite: Fuel smell in cabin when stationary; Fuel dripping on engine block; Leak disappears when engine warms
Repairs/costs cited: Fuel line repair required multiple times
Recalls/TSBs owners mention: Owner notes this problem has been reported in other Subaru models
Engine fire
Two separate reports of fires in 2005 Outback XT models. One fire began in the front right headlight cluster electrical system while the vehicle was parked; another fire began approximately 30 minutes after engine shutdown with unknown origin. Both fires occurred in public or private structures.
When: One at approximately 6:30 PM while parked; one approximately 30 minutes after engine shutdown
Symptoms owners cite: Vehicle catching fire; Fire alarm triggered (first case)
Recalls/TSBs owners mention: One owner states no response from Subaru; insurance dropped policy citing loss not covered; fire department found no arson or foul play in first case
Synthesized from 23 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had engine trouble with your 2005 Subaru Outback?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the engine problem on the 2005 Subaru Outback?
It's a meaningful issue. 23 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $3,100.
At what mileage does the engine typically fail?
Across the 20 complaints that reported odometer mileage, most engine failures cluster between 21,350 and 124,000 miles, with the median around 90,000. A quarter of owners report trouble before 21,350; a quarter make it past 124,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $3,100 for engine repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to engine?
No active recalls currently cover engine issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Subaru/Outback.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.