Subaru Forester 2.0D SJ

The EE20 diesel's DPF system is highly sensitive to driving patterns. Short urban trips prevent the exhaust from reaching the temperatures needed for passive regeneration, causing rapid soot accumulation. When the DPF soot load gets too high, the ECU attempts active regeneration by injecting extra fuel post-combustion, but if the drive is interrupted before completion, the cycle restarts — meanwhile diesel fuel leaks past the piston rings into the sump oil, causing oil dilution. A professional DPF clean costs approximately €300-500 at a specialist. If the filter is beyond cleaning, a replacement DPF costs €800-1,500 for an aftermarket unit or €1,500-2,500 with fitting at a Subaru dealer. Subaru themselves advise against buying the diesel variant if the car is primarily used for suburban driving. A monthly motorway run of at least 30 minutes at sustained speed is considered the minimum to keep the DPF healthy.

Every active DPF regeneration injects extra fuel that is meant to be burned off in the exhaust. If regeneration is interrupted repeatedly (by turning the engine off mid-cycle), unburned fuel passes the piston rings into the crankcase. The oil level rises visibly and viscosity drops, which can destroy bearings and accelerate engine wear. Checking the dipstick for a rising oil level or fuel smell is a critical pre-purchase check. On rare occasions, a cracked fuel return pipe under the valve cover can also pump neat fuel into the sump. If caught early, an oil change resolves the immediate issue (€100-200). If ignored, internal engine damage can require a partial rebuild or engine replacement at €3,000-4,000 or more.

The EGR system recirculates exhaust gases back through the intake, and on the EE20 this leads to heavy carbon buildup over time. A stainless steel gauze filter between the DPF and EGR is designed to limit soot entering the valve, but once this gauze clogs — often from repeated forced regenerations — fault code P049B (EGR insufficient flow) appears and the car enters limp mode. Cleaning the EGR valve itself costs around €200-400 if it can be saved. However, the intake manifold also fills with thick, sticky sludge where EGR soot meets oil vapor, requiring removal and thorough cleaning of both upper and lower manifolds. A complete EGR and intake clean at a specialist runs €400-800. Full EGR valve replacement with manifold clean is €800-1,200. Using a solvent-based cleaner on the EGR is not recommended as it can destroy the internal diaphragm.

The EE20's turbocharger can develop bearing play and shaft wear, particularly on cars driven at low RPM in high gears for extended periods, which allows carbon to accumulate around the turbo internals. One forum owner reported significant turbo play and scuffing at 177,000 km. On 2018 models, Subaru issued a recall (SRT268) for turbo oil supply pipes with undersized internal diameter, which could starve the turbine bearing of oil and cause premature seizure. A remanufactured turbo unit costs approximately €600-900 in Europe from specialist suppliers like Turboservice24, with fitting adding another €400-600. A new OEM turbo from Subaru is approximately €1,500-2,000 plus labor. Keep the engine above 2,000 RPM regularly and avoid switching off immediately after hard driving to let the turbo cool.

The most serious EE20 defect affects primarily Euro 4 engines (2008-2010) and some early Euro 5 units (2010-2013). The aluminium block uses steel inserts at the cylinder bridges for rigidity, but stress cracks can develop from these inserts to the crankshaft journals, eventually causing catastrophic crankshaft failure. This typically occurs between 80,000 and 130,000 km. The SJ generation (2013+) uses a revised Euro 5 or Euro 6 (from 2015 facelift) engine block that largely addressed this issue. Euro 6 owners have not reported crankshaft failures. However, early 2013-2014 SJ models still used the older block design and carry some residual risk. Engine rebuild with reinforced steel bridges costs approximately €3,200-4,000 at European specialists like Kings Boxer Diesel in Slovenia. Complete engine replacement runs €5,000-7,000. Subaru never officially acknowledged this defect, though many warranty claims were honoured.

The EE20 uses four glow plugs, one per cylinder. When a plug fails, it can short to ground and blow the glow plug fuse, triggering the check engine light, traction control warning, and sometimes limp mode. The plug behind the alternator is the most failure-prone due to heat exposure. Access to the glow plugs on the boxer engine is difficult — metal covers must be removed and the plugs are barely visible. A dealer quoted approximately €500 for replacement and fuse repair. At an independent workshop, expect €300-500. Snapped glow plugs during removal (a known risk on seized plugs) can escalate the cost significantly, potentially requiring specialist extraction.

Manual-gearbox versions use a Sachs dual mass flywheel that absorbs drivetrain vibrations from the boxer diesel. Over time, typically after 100,000-150,000 km, the DMF develops excessive play, causing a rattling noise at idle and juddering during clutch engagement. Replacement is best done together with the clutch, as labor overlaps. A DMF plus clutch kit costs approximately €600-900 for parts. Labor on the boxer engine is significant due to the layout, adding €400-800. A single mass flywheel conversion kit is available as an alternative for roughly the same price, which eliminates future DMF failures but slightly increases drivetrain harshness.

Subaru issued a global recall (WUT-05) for Foresters built between March 2013 and October 2018. Stone chips damage the spring coating, allowing corrosion to progress until the spring fractures. Symptoms include one corner sitting lower, metal flakes under the car, or clunking from the rear. Replacement springs with improved corrosion protection are free through the recall. If the recall was already completed, the risk of recurrence is low. If not yet done, verify with a Subaru dealer using the VIN. Outside the recall, replacement springs cost approximately €200-300 per pair plus fitting.