[MuseChaser]

Well, I guess it's time to post what I HOPE is a final update on my car and the four month saga...


VERY short recap -

Since about 60K miles, when I had the plugs replaced (recommended maintenance) and the timing chain cover resealed (warranty), slight reduction in gas mileage and power.

Four months ago, had recall done.

500 miles later, checked oil... none visible. Overfilled accidentally, drained a quart, and noticed serious shrapnel in the oil.
Another 100 miles, car starts hesitating, stumbling, backfiring, and smoking like crazy upon startup, a little over a month after the recall procedure

Back to dealership, and they agreed to do a full engine replacement under warranty; master tech and I examined obviously worn and shot bearings and journals.

Master tech informs me that someone had been inside my engine before, as he noticed sealant and shrapnel in the oil pan when he performed the recall, but neglected to mention it at the time hoping that it would be OK. I informed him the only other time any one had been "in the engine" was when it was at this same dealership for the timing cover reseal. He confirmed, but said he didn't do that reseal; it was one of the other guys in his crew. That's where the trouble started, and why he went out of his way to make sure I got a new engine. Much appreciated, but would have rather everyone been completely up front about that from the onset.
As a thank you, and just preventatively, I also had them install a new clutch and TOB at my expense along with the new engine; they were very fair about the parts cost and didn't charge any labor.

Another month goes by, get call, car is ready. Go pick it up. Check engine light comes on the next day, and car sounds like a loud sewing machine. Immediately back to shop.
Code shows mixture problems and misfire (cylinder 3, I think). I asked whether they had changed the injector seals. "No, they didn't come with the recall or engine replacement parts list." They proceded to swap out injectors as part of their troubleshooting procedures, without replacing seals. I insisted that they replace the seals after they figure out what's wrong and prior to returning the car to me. They agree.
More than another month goes by. Tech could NOT figure out why the car was running poorly. I finally get a call saying car is ready last week, and I've been driving it. It's running GREAT.

The answer? The tech was at his wit's end, so he called Subaru and spoke with one of their engineers, describing the problem. The Subaru guy said to him, "You're really fussy, aren't you, and very careful?" The tech answered in the affirmative. Engineer told him that he has the valves shimmed to tight, and that these engines like to be adjusted to the middle of the allowed range rather than to the tightest tolerance.

He reshimmed the valves for the fourth time, taking this advice into account, and the car runs awesome.


Soooo.. that's the story. Not thrilled with the four months without my car, but can't fault the service manager or master tech for much.. they took good care of me.


That's the tale.