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Build Your Own Six-Star Head Gasket Kit (Non-Turbo)

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Build Your Own Six-Star Head Gasket Kit (Non-Turbo)
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Build Your Own Six-Star Head Gasket Kit (Non-Turbo)

(9 customer reviews)

Get what you want, and only what you want by building your own gasket kit. Every car has different needs and a custom kit will keep you on budget. Includes a PDF of our exclusive install guide! “This install guide applies to 2.5L Phase-2 SOHC”.

Please make sure you enter your full VIN before you place your order so we can make sure you get the correct parts for your car.

$116.94

  • *Model

    Reset options
    Head Bolt Set

    Genuine Subaru (OEM) head bolts for head gasket replacement for Impreza, Forester, Outback, Legacy and Baja models. Includes full set for both heads.

    Intake Manifold Gaskets

    Intake Manifold GasketIntake leaks can cause poor running and other damage, these are very easy to replace with a head gasket repair.

    Exhaust Manifold Gaskets

    Exhaust Manifold GasketWhile not as critical as the intake gaskets, exhaust leaks can also cause headaches with fueling as well as noise. These are the gaskets for the bottom of the heads.

    Valve Cover Gaskets

    Valve Gasket Covert KitThe valve covers are removed to get to the head gaskets, and the gaskets are almost never reusable. (Cam Plugs/Half Moons are NOT included)

    Camshaft Seals

    Cam Shaft SealsWhile they do not have to be removed for head gasket repairs, these seals will leak over time and to replace them later would require removal of the timing belt. Very easy to do now.

    Crank Shaft Seal (Front)

    Crankshaft Seal - FrontJust like the camshaft seals, this is a 5 minute job now or a 4 hour job later.

    Crank Shaft Seal (Rear Main)

    Crank Shaft Seal RearNot accessible unless you are removing the engine (our recommended method). If you are, pick one of these up as it is usually the only time you will be looking at this seal.

    Rear Piston Access Cover Oring

    Rear Piston Access Cover OringNext to the rear separator plate, this oring is a 5 minute job and should be done with the other rear engine seals.

     
    Cam Plugs

    Cam PlugsCam Plugs are key for completing your full engine reseal. It is wise to reseal the cam plugs while your motor is apart.

     
    Separator Plate Kit

    Separator Plate KitOlder models came with a plastic plate at the rear of the engine that would warp and leak oil. This is the updated Subaru Genuine metal replacement kit.

     
    Coolant Crossover Pipe Orings

    Coolant Crossover Pipe OringsThe crossover pipe runs underneath the intake manifold. These o-rings get brittle over time and if a leak develops it can cause overheating. They are very easy to replace now.

     
    O-Ring for Oil Filler Tube

    Oring for Oil Filler TubeFor the SOHC engines (2000 model year and newer in most cases, we'll notify you when selecting your car after checkout if this doesn't apply), this o-ring is for the oil filler tube where it bolts to the valve cover. This is removed when replacing a head gasket and is a great time to replace it. This area is subject to a lot of heat and this o-ring tends to get brittle and leak as a result.

     
    Oil Pan O-Ring

    Oil Pan O-RingThe oil pan is an important part of an engine reseal and most of the time is overlooked. Removing the oil pan to reseal it and install a new O-ring is a good idea when resealing the engine.

     
    Oil Pump O-Ring

    Oil Pan O-RingPart of an engine reseal is making sure your oil pump isn’t leaking. This O-Ring is easy to replace and goes along with installing the crank seal.

     
    Oil Filter & Crush Gasket

    Oil Filter and Crush GasketPart of an engine reseal is making sure your oil pump isn’t leaking. This O-Ring is easy to replace and goes along with installing the crank seal.

     
    Water Pump & Gasket

    Water Pump & GasketWhile Subaru has no replacement interval for water pumps, a failure can be catastrophic. With a timing belt life of 105k miles, this is always recommended when the belt is off or the engine apart as good insurance and peace of mind.

    Thermostat
    ThermostatAn often overlooked and inexpensive piece of insurance for the cooling system. We’ve seen problems after overheating or with cheap aftermarket alternatives, make sure you grab a Six Star quality thermostat.
     
    Timing Belt

    Timing BeltThe timing belt has to be removed to replace head gaskets, and is much harder to replace later. Subaru recommends replacement every 105k miles.

    Timing Belt Tensioner
    Timing Belt TensionerJust like the water pump, the timing belt tensioner is a crucial component that failure could result in major damage. Replacement now requires no additional labor.
     
    Timing Belt Idler Pulleys (Set, tensioner not included)
    Timing Belt Idler Pulleys (Set, tensioner not included)Same as the tensioner, the timing belt pulleys are critical to the engine and will become rough and wear over time.
     

$116.94

  • *Model

    Reset options
    Head Bolt Set

    Genuine Subaru (OEM) head bolts for head gasket replacement for Impreza, Forester, Outback, Legacy and Baja models. Includes full set for both heads.

    Intake Manifold Gaskets

    Intake Manifold GasketIntake leaks can cause poor running and other damage, these are very easy to replace with a head gasket repair.

    Exhaust Manifold Gaskets

    Exhaust Manifold GasketWhile not as critical as the intake gaskets, exhaust leaks can also cause headaches with fueling as well as noise. These are the gaskets for the bottom of the heads.

    Valve Cover Gaskets

    Valve Gasket Covert KitThe valve covers are removed to get to the head gaskets, and the gaskets are almost never reusable. (Cam Plugs/Half Moons are NOT included)

    Camshaft Seals

    Cam Shaft SealsWhile they do not have to be removed for head gasket repairs, these seals will leak over time and to replace them later would require removal of the timing belt. Very easy to do now.

    Crank Shaft Seal (Front)

    Crankshaft Seal - FrontJust like the camshaft seals, this is a 5 minute job now or a 4 hour job later.

    Crank Shaft Seal (Rear Main)

    Crank Shaft Seal RearNot accessible unless you are removing the engine (our recommended method). If you are, pick one of these up as it is usually the only time you will be looking at this seal.

    Rear Piston Access Cover Oring

    Rear Piston Access Cover OringNext to the rear separator plate, this oring is a 5 minute job and should be done with the other rear engine seals.

     
    Cam Plugs

    Cam PlugsCam Plugs are key for completing your full engine reseal. It is wise to reseal the cam plugs while your motor is apart.

     
    Separator Plate Kit

    Separator Plate KitOlder models came with a plastic plate at the rear of the engine that would warp and leak oil. This is the updated Subaru Genuine metal replacement kit.

     
    Coolant Crossover Pipe Orings

    Coolant Crossover Pipe OringsThe crossover pipe runs underneath the intake manifold. These o-rings get brittle over time and if a leak develops it can cause overheating. They are very easy to replace now.

     
    O-Ring for Oil Filler Tube

    Oring for Oil Filler TubeFor the SOHC engines (2000 model year and newer in most cases, we'll notify you when selecting your car after checkout if this doesn't apply), this o-ring is for the oil filler tube where it bolts to the valve cover. This is removed when replacing a head gasket and is a great time to replace it. This area is subject to a lot of heat and this o-ring tends to get brittle and leak as a result.

     
    Oil Pan O-Ring

    Oil Pan O-RingThe oil pan is an important part of an engine reseal and most of the time is overlooked. Removing the oil pan to reseal it and install a new O-ring is a good idea when resealing the engine.

     
    Oil Pump O-Ring

    Oil Pan O-RingPart of an engine reseal is making sure your oil pump isn’t leaking. This O-Ring is easy to replace and goes along with installing the crank seal.

     
    Oil Filter & Crush Gasket

    Oil Filter and Crush GasketPart of an engine reseal is making sure your oil pump isn’t leaking. This O-Ring is easy to replace and goes along with installing the crank seal.

     
    Water Pump & Gasket

    Water Pump & GasketWhile Subaru has no replacement interval for water pumps, a failure can be catastrophic. With a timing belt life of 105k miles, this is always recommended when the belt is off or the engine apart as good insurance and peace of mind.

    Thermostat
    ThermostatAn often overlooked and inexpensive piece of insurance for the cooling system. We’ve seen problems after overheating or with cheap aftermarket alternatives, make sure you grab a Six Star quality thermostat.
     
    Timing Belt

    Timing BeltThe timing belt has to be removed to replace head gaskets, and is much harder to replace later. Subaru recommends replacement every 105k miles.

    Timing Belt Tensioner
    Timing Belt TensionerJust like the water pump, the timing belt tensioner is a crucial component that failure could result in major damage. Replacement now requires no additional labor.
     
    Timing Belt Idler Pulleys (Set, tensioner not included)
    Timing Belt Idler Pulleys (Set, tensioner not included)Same as the tensioner, the timing belt pulleys are critical to the engine and will become rough and wear over time.
     
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Description

*Base price is for the pair of head gaskets. Select 1 add-on to qualify for pricing and free install guide.

If you are here then you may already know about the headaches regarding Subaru head gaskets. We feel you, and want to offer the best possible

replacement parts so that this is a job that only needs to be done once for the remainder of the long life of your beloved Subaru.

Subaru head gaskets have been trouble since the mid-90s and despite numerous efforts to make changes and improve the gaskets being used, we would still see repeat failures even after repairs were done properly. Being an independent Subaru-only repair facility, we sought to find a better alternative.

Six Star head gaskets are the best gaskets you can get for your Subaru. Period. Six Star has taken the “updated” version of Subaru’s factory multi-layer steel gaskets and improved them by beefing up the compression sealing surfaces and adding a high strength Viton coating on all surfaces. The combination of these features make these far more resistant to sudden temperature changes and any stretching or movement of the aluminum engine components, both factors that we believe contribute to factory head gasket failures.

As an engine warms up, aluminum will expand slightly. Since Subaru engines use two aluminum heads and an aluminum block in the middle, there is a lot of room for shifting and strain to occur during this time. Repeat this warm-up several thousand times over the course of many miles and eventually the gaskets that sit in between these components will fracture and leak. This is why we will see gasket failures as early as 40-60k miles in cases where cars are mainly driven short distances (and engines are just constantly being warmed up and cooled down). In cars that see mainly highway miles and long distance driving, we may see gaskets last until 150-200k miles.

Since switching over to Six Star at our repair facility about 10 years ago, we have never looked back. There is no longer a need to use that pesky Subaru Coolant Conditioner, no special copper spray coating required either. Just follow the proper installation procedures and proper head torque sequence (included with gasket purchase) and you’ll never have to do this again. Make sure you enter your full VIN before placing your order so we can make sure you get the right parts for your car.

Subaru coolant conditioner is NOT recommended.

Please make sure you enter your full VIN before you place your order so we can make sure you get the correct parts for your car.

Additional information

Weight 5 lbs
Dimensions 14 × 12 × 3.5 in
Model

2003-2006 Baja 2.5L (Non-Turbo), 2003-2005 Forester 2.5L AT, 2003-2005 Forester 2.5L MT, 2006 Forester 2.5L AT, 2006 Forester 2.5L MT, 1999-2005 Impreza 2.5L, 2006-2011 IMPREZA, 2000-2003 Outback/Legacy 2.5L, 2004 Outback/Legacy 2.5L "California Emissions", 2004 Outback/Legacy 2.5L "Federal Emissions", 2005 Outback/Legacy 2.5L "California Emissions", 2005 Outback/Legacy 2.5L "Federal Emissions", 2006-2009 Outback/Legacy 2.5L

At Smart Service (and Smart Quality Parts), we have been carrying and using the Six Star brand in our repair facility for over 15 years. Since the majority of our in-house technicians are Subaru factory trained we understand the benefit and need for correctly fitting and functioning replacement parts. The benefit of being an independent facility is that we are not required to use the Genuine Subaru stamped parts but unlike other independents, we didn’t want to use aftermarket parts just to cut costs and increase our margins.

We found Six Star in that search for the perfect balance between OEM quality and a more affordable price by cutting Subaru out as a middleman. We supplement with the Genuine Subaru parts where we feel that is needed or required if Six Star doesn’t manufacture a certain part, but we mostly use Six Star because more often than not the part is identical to what you would buy at the dealer.

The description below outlines the color and sticker system on the parts you may receive. Please know that 90%+ of the Six Star parts we carry are the Gold Star OEM designation and the Red Star options are just as good in our opinion (see our replacement oil filter for example, you can see it cut open next to a Genuine Subaru filter there is no difference at all).

 

We offer our own private Six Star label parts that identifies OEM parts with a gold star:


and alternative source parts with a red star:

 

  • Genuine = Exact part you would purchase at your Subaru dealer.
  • OEM = Original Equipment Manufacturer. The part was made by the exact same manufacturer that made the original part for your car. For example if you open a genuine Subaru wheel bearing you will find that the bearing is an NSK bearing. If you buy that same bearing OEM you’re getting the same part.
  • Alternative Source = These are parts that are manufactured by an indepedent aftermarket parts facility. Our alternative source parts are put through the rigors at Smart Service before we offer them online.

9 reviews for Build Your Own Six-Star Head Gasket Kit (Non-Turbo)

  1. Jeff L. –

    Great customer service. Melissa handled a shipping issue- was able to get parts needed as promised to keep on schedule with the big repair. I’ve got two more boys heading to driving age. They’ll have their turn to get and keep an older Subaru on the road. I’ll be getting more kits from Smart Quality Parts.

  2. Michael S. –

    I was visiting Subaru forums to find the best headgasket set for my 96 Outback. Everytime I visited these forums; SmartQualityparts.com kept getting mentioned. So I decided to try out this website for myself, and I am glad I did. I ordered a Head gasket kit from SmartQualityparts.com. The kits are complete for the job I am performing on my car. Not only that when you get a parts kit, this company provides a detailed PDF instruction manual more detailed then a Haynes Technical Manual. When I needed assistance with technical data on the head gasket. The customer service returned my phone call immediately, and patiently answered all of my questions. I will continue and have recommend this company to all of my Suby friends. I will use you again, thanks SmartQualityparts.com!

  3. Michael S. –

    I was on multiple Subaru Forums searching for the best parts for my Subaru. Forums kept talking about Smart Quality Parts.com. So I click on the link and I am sure glad I did. I am very impressed with the quality of the parts kit and with their customer service.The customer service was expedient to return my phone call when I had questions about the web site and technical specs for the parts that I purchaced. They were friendly and patience to answered all of my questions. Other things I thought were great is that depending on the parts purchased they provided detailed color illustrated maintenance instructions. It was more detailed then my Haynes manuals. I have already made recommendations to other Subaru friends about this Parts Store. Thanks again SmartQualityparts.com.

    Michael S.

  4. Andrew B. –

    My experience with Smart Service has been fantastic. Great info on the web site and prompt and courteous follow-up questions to make sure I got exactly the right stuff. Sadly, I installed my gaskets backwards (make sure the Six Star logo is facing the heads not the block!) and get to do this job again. Smart Service went over and above diagnosing MY screw-up and rushing out the new parts so I can get this done and get back on the road. They sell the right stuff at a fair price and they treat you how you want to be treated. I just wish they were closer to North Carolina!

  5. Douglas M. –

    I have been a professional technican for 22 years, 17 of that was working on Subaru’s, everything from maintenance to crazy builds.

    Now that I have changed professions, I am very pleased to continue purchasing OEM or better quality parts for my projects. I still continue to fix friends and family members Subaru’s, without paying the high dealership prices for parts.

    SMART Quality Parts products are the best a DIY guy can get. They will continue to have my on-going business.

  6. Brandon G. –

    We install these when we can. No problems, not one comeback.

  7. Ray V. –

    Glad i found this website. Was crucial in rebuilding my 02 forester. Also for maintaining by 02 forester and 02 wrx. Highly recommend! Keep it up!

  8. Timothy S. –

    I’ve used this site for 3 cars now – reliable good parts.

  9. Daniel L. –

    I have put about 8000 miles on since installing the head gaskets and no problems. After having the heads machined, there was still a small blemish on one of the heads I was concerned about that could not be machined out, but the gasket has held as it should! Definitely gets my recommendation.

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