The 2009 Forester engine generates a steady stream of severe failure complaints. The most common pattern is internal engine wear causing loud metallic knocking or grinding, loss of acceleration, and complete engine seizure—often with no warning lights beforehand. Owners report this happening between 3,100 and 92,000 miles, with a cluster of failures in the first 20,000–50,000 miles.
Head gasket failure is another widespread issue, typically showing up after 54,000 miles but sometimes earlier, with owners losing all coolant and experiencing stalling at highway speed. Oil supply pipe leaks and antifreeze seepage are documented, along with burning smells and smoke from the engine bay.
A smaller group reports recurring Check Engine lights that require multiple dealership visits and part replacements—spark plugs (wrong type installed), catalytic converters, O2 sensors—sometimes cycling back within days.
Two owners report complete engine fires on the highway. One owner complains of greasy windshield film tied to HVAC operation, accompanied by respiratory symptoms. Sudden unintended acceleration appears in at least one case, causing a collision.
Subaru issued a Stop Sale in April 2008 for 2008–2009 turbocharged Foresters citing internal wear, but many owners report their VINs fall within the affected range while being denied warranty support. Multiple TSBs (WVF-16, 02-103-07, 02-97-05) reference lubrication system defects in turbo engines, yet Subaru has refused to acknowledge these defects or provide assistance for repeat failures.
Failure modes owners describe
Internal engine wear and knocking
Loud metallic knocking, grinding, or banging noise from the engine, often followed by loss of power, sluggish acceleration, and complete engine failure. Owners report noise getting progressively louder before engine seizure.
When: 3,100 miles to 92,000 miles; several cases in first 20,000–50,000 miles
Symptoms owners cite: Loud multi-tone metallic banging from engine bay; Engine sounds louder from cabin; Grinding or knocking noise that worsens over time; Loss of acceleration power or sluggish performance; Engine dies and will not restart; Check Engine light illuminates (sometimes after noise starts); All warning lights flicker on (Check Engine, Traction Control, Cruise Control, AWD indicator)
Codes mentioned: Check Engine Light, Traction Control Light, Cruise Control Light
Repairs/costs cited: Complete engine replacement required in most cases; some owners report turbo replacement at 50,000 miles with turbo failure again at 100,000 miles. Internal wear on failed units confirmed by Subaru.
Recalls/TSBs owners mention: Subaru issued a Stop Sale order in April 2008 for 2008/2009 Impreza, Forester, and Legacy vehicles with 2.5L turbo engine produced from 01/08/08 onward, citing internal wear issues. Some owners report their VINs fell within the Stop Sale range but Subaru claimed they were not affected. TSBs cited: WVF-16, 02-103-07, 02-97-05 (lubrication delivery defects). Subaru has refused to acknowledge defect or assist with repeat failures.
Head gasket failure
Cylinder head or head gasket failure causing internal coolant and oil leaks, loss of engine power, stalling, and overheating. Multiple owners report sudden failure with no prior warning.
When: 54,000 miles to 125,000 miles; some early failures reported
Symptoms owners cite: Loss of acceleration or sluggish response; Check Engine light illuminates; Traction Control light illuminates; Engine stalls while driving; Coolant depletion with no visible external leak; Oil dripping onto exhaust heat shields; White smoke from exhaust on cold start; No warning lights before failure in some cases
Codes mentioned: Check Engine Light, Traction Control Light
Repairs/costs cited: Head gasket replacement costs reported at approximately $2,000. Some owners report radiator replacement prior to gasket failure. One owner consumed full coolant reservoirs daily with no visible external leaks.
Recalls/TSBs owners mention: Recall 08V460000 (Engine and Engine Cooling) issued; owners report some VINs were excluded from coverage. No other manufacturer-initiated support documented in narratives.
Check Engine light and drivability issues
Recurring Check Engine light, sometimes flashing, often accompanied by loss of acceleration, inability to accelerate uphill, and need for repeated repairs. Multiple diagnostic attempts often required before resolution, or failure to diagnose.
When: Within 9 days to several weeks after previous repair
Symptoms owners cite: Check Engine light comes on and stays on, or flashes; Cruise Control light flashing or stays on; Vehicle Dynamics Control light or Traction Control light illuminated; AWD indicator light illuminated; Unable to accelerate or sluggish acceleration; No response or delayed response from accelerator; Feeling of driving in 'mud' or heavy resistance
Codes mentioned: Check Engine Light, Catalytic converter fault (mentioned by dealers but often misdiagnosed), O2 sensor fault (Oxygen sensor)
Repairs/costs cited: Owners report multiple visits to dealership for same issue. Repairs included wrong spark plugs installed initially (later replaced with platinum-tip correct plugs), faulty catalytic converter replacement, O2 sensor replacement (both sensors checked in one case), exhaust manifold leak repair, and heater box replacement. One owner needed spark plug replacement and air filter; another required multiple repairs over one month with four visits to dealership.
Recalls/TSBs owners mention: Dealership mentioned checking fuel grade quality. One dealership left work order open in case issue recurred. No broader recall or TSB mentioned for this specific symptom set.
Oil and coolant leaks from engine
Leaking oil supply pipes, blown head gaskets, and antifreeze leaks causing oil dripping onto hot exhaust components and potential fire hazard. Cylinder head-side oil supply pipe leaking identified.
When: Variable; at least one case at routine maintenance; one at 54,000 miles
Symptoms owners cite: Oil dripping from engine onto exhaust heat shields; Burning smell from engine oil on exhaust; Smoke coming from engine compartment; Large puddle of oil on garage floor; Antifreeze leaking; Engine overheating
Repairs/costs cited: Cylinder head-side oil supply pipe replacement mentioned; head gasket repair approximately $2,000. Fire hazard noted if not repaired promptly.
Recalls/TSBs owners mention: Recall 08V460000 mentioned; one owner reported notified of recall and VIN later determined not covered.
Offensive fumes and greasy windshield film (off-gassing and HVAC contamination)
Greasy, oily film accumulating on all interior glass and surfaces, visible especially at night and in freezing temperatures. Film cannot be wiped off with household cleaners and requires industrial cleaning. Associated with defrost and heater operation. Owner reports chemical-type symptoms after exposure.
When: Began end of December; occurred with defrost and heater operation
Symptoms owners cite: Greasy film on windshield that expands to all glass and interior materials; Film visible at night and in freezing temperatures; Cannot be cleaned with normal household cleaners; Breathing issues and cough when running defrost or heater; Shortness of breath and lung tightness; Nose and sinus congestion; Uncontrollable coughing on long drives with windows closed; Persistent respiratory symptoms (owner sought care at National Jewish Hospital)
Repairs/costs cited: Dealership washed windshield and glass multiple times (first four visits); waxed windows to reduce visibility of film; replaced heater box; found and repaired two leaking A/C valves. Film continued to accumulate and respiratory symptoms persisted despite repairs.
Recalls/TSBs owners mention: Dealership blamed vinyl off-gassing initially. No mention of broader campaign or warranty adjustment for this symptom.
Turbo failure (2.5L turbo engine)
Complete turbo failure requiring replacement, with recurrence of turbo failure at subsequent mileage. Design flaws in lubrication delivery system cited by owner referencing multiple TSBs.
When: At 50,000 miles (first failure); again at 100,000 miles (second failure)
Symptoms owners cite: Engine noise and performance loss; Turbo malfunction
Repairs/costs cited: Turbo replacement cost approximately $3,500. Owner reports turbo replaced by dealership at 50,000 miles; failed again 50,000 miles later at 100,000 miles total.
Recalls/TSBs owners mention: Subaru refused to acknowledge TSB defects (WVF-16, 02-103-07, 02-97-05) related to lubrication delivery system. SOA stated they would not assist with repairs of same failure on repeat occurrence. Class action lawsuit mentioned by owner.
Engine fire
Engine fire and vehicle engulfment while on highway. Two separate incidents reported with fire and smoke from engine and cabin.
When: After approximately 3.5 hours of highway driving (one case)
Symptoms owners cite: Check Engine light illuminates; Check Oil light illuminates; Fire and smoke coming from engine; Smoke filling cabin; Vehicle engulfed in flames within minutes
Codes mentioned: Check Engine Light, Check Oil Light
Repairs/costs cited: Vehicle destroyed in fire; no repair attempted.
Sudden unintended acceleration
Vehicle suddenly accelerates when brakes are applied or while parking, causing loss of driver control and collision with building. Occurred twice in same vehicle.
When: While applying brakes on city street (35–40 mph); again during parking maneuver
Symptoms owners cite: Vehicle accelerates suddenly when brakes applied; Loss of driver control; Clunking sound from engine area; Check Engine light and Traction Control light may illuminate
Codes mentioned: Check Engine Light, Traction Control Light
Repairs/costs cited: Dealership performed diagnostic tests but could not identify failure. Vehicle not repaired in one case. Owner refused to drive vehicle without diagnosis.
Catastrophic engine seizure without warning
Complete, sudden engine seizure at highway speed with no prior indicator lights or symptoms. Engine stops running entirely and never restarts.
When: 45,000 miles; 9,610 miles
Symptoms owners cite: Unusual noise from engine compartment (heard at pull-over point; may not have warning while driving); Loud metallic grinding and banging from engine; Engine barely stays running at low RPMs; Engine power decreases; Burning smell; Check Engine light comes on just before complete stop
Codes mentioned: Check Engine Light
Repairs/costs cited: Complete engine replacement required. One owner reports no diagnostic warning at all; another heard noise within last 20 miles before complete failure.
Recalls/TSBs owners mention: Subaru blamed one owner's failure on driver (alleged misuse) despite owner maintaining proper maintenance. Subaru disregarded owner's mention of other complaints and refused to fix vehicle or accept it as a Subaru issue.
Synthesized from 28 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.