The contact called on behalf of his mother who owns a 2016 Subaru Outback. The contact stated while driving at various speeds, there were abnormal knocking sounds coming from the engine. There was no warning light illuminated. Additionally, the contact stated that he was informed at a State Inspection that the vehicle was included in Subaru Campaign Numbers: WUJ95 and WTH68. The vehicle was taken…
2016 Subaru Outback engine problems
severe 32 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
32
Recalls
0
Avg fix
$3,100
3injuries
When does it fail?
Of the 32 engine complaints filed for the 2016 Subaru Outback, here's the actual mileage breakdown — failures cluster heaviest at 100,000-125,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Owners have filed 32 engine complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
No new NHTSA engine complaint has been filed on this vehicle in over 3 years — the issue may be aging out of the active population.
The failure pattern owners describe
Buyer takeaway: The 2016 Outback has a documented design defect in the exhaust pipe bellows that causes dangerous fumes to enter the cabin; many vehicles outside the limited recall window are affected but denied coverage. Additionally, chronic cam carrier oil leaks pose fire risk and expensive repairs, while unintended acceleration, engine stalls, and throttle unresponsiveness have been reported as safety concerns.
The most prevalent complaint is cracked bellows in the front exhaust pipe (Subaru Service Program Bulletin WUJ-95R), which allows exhaust fumes to leak into the cabin. Owners describe strong exhaust smell, rattling sounds at cold start, and visibility of fumes outside the vehicle. Subaru limited the recall to vehicles manufactured 12/09/2013 through 9/30/2015, but multiple owners outside that window report identical failures at various mileages. Repair costs run $2,600 to $3,700 for manifold and catalytic converter replacement.
The second significant issue is cam carrier oil leaks due to factory gasket or sealant design defects. Owners report heavy oil seepage requiring engine removal, smoke entering the cabin, and fire risk. One owner experienced the same problem recur after a dealer repair. Subaru acknowledged this as a known chronic issue but has only partially subsidized repairs.
Additional engine concerns include excessive oil consumption without visible leaks, cold-start surging when shifting into gear with brakes applied, unexplained engine stalls while driving, unintended acceleration, and transmission shift lock-up at intersections. One owner reported valve spring failure destroying the engine. Reports also mention engine seal failures and an unusually intense chemical off-gassing smell from interior materials.
Same Subaru Outback engine reports on nearby years: 2013 · 2014 · 2015 · 2017 · 2018
Failure modes owners describe
Exhaust Pipe Front (EPF) Bellows Cracking
Cracks develop in the bellows section of the front exhaust pipe, allowing exhaust gases and fumes to leak into the cabin. The defect appears to be a manufacturing design flaw rather than rust-related corrosion. Subaru issued Service Program Bulletin WUJ-95R to address the issue, but limited it to vehicles produced 12/09/2013 through 9/30/2015, leaving many affected 2016 Outbacks outside the coverage window.
When: Occurs within first few years of ownership; failures reported at mileages ranging from under 4 years of age to over 170,000 miles. Some owners report the problem was present when they purchased used vehicles.
Symptoms owners cite: Strong smell of exhaust fumes in cabin, especially noticeable when heater is activated; Abnormal rattling or growling sound from engine bay at cold start or around 2500 RPM; Abnormal knocking sounds from engine area; Fumes visible or detectable outside the vehicle
Repairs/costs cited: Replacement of exhaust manifold and catalytic converter required. Owners report repair costs ranging from $2,600 to $3,700 (parts and labor combined). One owner cited repair estimate of $2,700 parts plus $1,000 labor. Some dealers claim parts under the Service Program Bulletin are not available.
Recalls/TSBs owners mention: Service Program Bulletin WUJ-95R issued but applied only to limited production window (12/09/2013 - 9/30/2015); vehicles outside this date range denied coverage despite identical failures. Subaru has not extended recall to cover all affected model years. Manufacturer referenced NHTSA ID 10199936 and 10182196 but VINs outside the specified production window are excluded from assistance.
Cam Carrier / Cam Tower Oil Leak
Oil leaks develop from the cam carrier gasket or cam tower sealant due to factory design defect. Dealers have identified this as a chronic, recurring problem requiring engine removal for proper repair. Leaking oil poses fire risk and is flammable.
When: Failures reported as early as 59,000 miles; one case at less than 70,000 miles. Recurrence noted after dealer repair, suggesting incomplete or temporary fixes.
Symptoms owners cite: Heavy oil leak from cam carrier area; Smoke or large amounts of smoke filling engine bay and entering cabin air system; Low oil warning light illumination; Breathing difficulty and vision obstruction from smoke in cabin; Visible oil dripping on floor when parked
Repairs/costs cited: Requires engine removal and resealing. Very labor-intensive and expensive repair. One owner reported dealer repairs failed and same issue recurred at 112,000 miles after previous repair at 59,000 miles. Subaru has offered to cover approximately one-third of repair costs in at least one case.
Recalls/TSBs owners mention: Dealer confirmed this is a known, common problem with 2016 Subaru Outbacks. Subaru offered partial cost coverage (approximately one-third) in one case. Dealer noted high risk of engine fire and acknowledged the issue since at least 2019.
Excessive Oil Consumption
Engine consumes oil at abnormally high rates without visible leaks on floor. Oil disappears despite regular maintenance performed by Subaru dealer.
When: At 72,000 miles with all scheduled maintenance performed by Subaru dealer
Symptoms owners cite: Requiring oil top-up every 3,300 miles; Low oil warning illuminating twice in two months on highway and city driving
Cold-Start Engine Surge / Idle Creep
Engine surges or creeps forward immediately after cold start when transmission is placed in Forward or Reverse with brakes applied. Surge is approximately 300 RPM cycling and does not occur after brief warm-up.
When: Immediately after cold start; does not occur after engine reaches operating temperature
Symptoms owners cite: Vehicle surges or lurches forward at standstill with brakes applied; Rapid engine speed increase; Engine revving wildly at intersections with foot on brake
Unintended Acceleration / Loss of Throttle Response
On two separate occasions while driving at highway speeds (65-75 MPH), the gas pedal stopped responding to driver inputs and engine shut down. Vehicle had to be towed; it restarted at repair shop with no diagnostic codes present. Also reported: vehicle accelerated on its own while driving at 25 MPH, requiring hard braking to stop.
When: Intermittent; no warning lights present; one case the vehicle would not restart after stalling
Symptoms owners cite: Gas pedal unresponsiveness at highway speed; Complete engine shutoff without warning; Unintended acceleration from standstill; No check engine light or warning indicators
Repairs/costs cited: No repair performed in reported case; vehicle started normally at repair facility with no issues found
Engine Stall During Drive
Engine suddenly stops running while vehicle is in motion on highway in traffic, requiring restart before vehicle is drivable again.
When: Intermittent; occurred while waiting in traffic to take highway ramp exit
Symptoms owners cite: Engine suddenly stops while driving; Vehicle must be put in Park and restarted to resume driving
Transmission Shift Lock / Gear Shift Sticking
On two separate occasions when stopped at intersections with foot on brake, engine revved wildly and gearshift would not move into neutral, forcing driver to turn off engine. After several attempts, driver was able to restart the car.
When: Two incidents in November 2019 and March 2020 while at traffic stops
Symptoms owners cite: Engine revving up wildly while at stop with foot on brake; Gearshift becomes immovable; Unable to shift into neutral; No warning lights illuminated
Valve Spring Failure
A valve spring failed, causing the valve to break and become embedded in the piston, rendering the vehicle inoperable.
When: Mileage and age not specified
Symptoms owners cite: Vehicle becomes inoperable
Engine Seal Failure
Engine seal failed, triggering low oil warning light and requiring replacement.
When: At approximately 110,000 miles
Symptoms owners cite: Low oil warning light illumination
Interior Chemical Odor (New Car Smell)
Intense 'new car smell' from off-gassing of interior plastics and trim materials, accompanied by metallic taste in mouth and lingering effects for hours. Smell did not diminish after two months of ownership. Owner concerned about toxic chemical exposure.
When: Present immediately after purchase in April 2016 and persistent after approximately two months
Symptoms owners cite: Intense new car smell; Metallic taste in mouth after less than five minutes in vehicle; Lingering taste for hours after exiting vehicle; Affects multiple family members
Synthesized from 32 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
Had engine trouble with your 2016 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 2016 Subaru Outback?
It's a meaningful issue. 32 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 10 complaints that reported odometer mileage, most engine failures cluster between 31,000 and 111,500 miles, with the median around 110,000. A quarter of owners report trouble before 31,000; a quarter make it past 111,500. 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/2016/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.