'96 Legacy 2.2 - major engine problem

J

JeffD

Hi everyone -- I haven't read this group in awhile, but it was a big
help in my deciding to purchase my used '96 Legacy, in March of 2002.
The car was basically "mint" with only 46,000 miles when I bought it
from a local Subaru dealer. The previous (original) owner also bought
the car there and the dealer had a complete record of its service
history, which showed the car was exceptionally well-maintained.

Anyway, so far I couldn't be happier with the car. I have nothing but
good things to say about it and it has run like a watch since I bought
it -- up until a few weeks ago when the engine began "missing" while
idling at stop lights, etc. As soon I accelerated, the roughness would
disappear, but then a few days later the car began to miss & sputter
sometimes during acceleration as well -- until the "Check Engine" light
finally came on. It stayed lit for 2 days, during which time the car
ran completely normally (no missing at all), then the CE light was off
the next time I started the car. It remained off for 3 or 4 days (car
still running normally), then came back on right after the engine began
missing again while idling at a stoplight. Once again, as I powered
away from the stop, the engine smoothed out. Got to the next stoplight
(about 1000' down the road) and car beagn to idle EXTREMELY roughly, as
though it wanted to stall -- and then got worse when I accelerated, at
which time the CE light then began *flashing*. I pulled in to my work-
place (only another few feet down the road), turned off the car and went
into work. Lunchtime, 4 hours later, the car started right up, idled
smoothly, though the CE light was still on (but not flashing anymore).

Left work that night, engine alternated between smooth/normal and
missing during the short ride home. I then brought it to my regular
mechanic who put it on his computer, which showed a misfire on cylinder
#4. He suggested & did a complete tune-up (new wires, etc.). The car
then ran fine for almost 2 weeks until the symptoms reappeared (but
NO "Check Engine" light). Two days later brought it back to my mechanic
(the CE light finally came back on on my way there). Once again, the
computer reported a misfire on #4, so this time he replaced the coil
pack
(at the suggestion of a Subaru dealer he called). Later that day, he
called to say the car was ready and that he had test driven it (even
getting stuck in traffic, with plenty of idling time), and that the car
seemed to be running fine. No sooner then I go and pick it up, it
starts
doing the same thing at idle, before I can even get out of his lot, and
also on acceleration. So, I turned right around and went back. He then
apologized and told me just to take it to Subaru (though he had also
warned me earlier that if the coil pack didn't fix it, I was going to
have to let a Subaru tech diagnose it). So... I immediately drove the
car to Bill Kolb Subaru, a few miles away (not the dealer I bought it
from, which is more than twice as far). I explained the problem to the
2nd "chief" service tech there and also told him what had already been
done to the car. He was EXTREMEY accomodating -- sympathetic, even --
and they took the car right in, even though it was getting to closing
time for the service department. After about 45 minutes he asked me if
I could leave the car overnight so they could continue to diagnose it
the next day (last Thursday).

So, Thursday, just before leaving work, he finally called to tell me
that they went through EVERY possibility for a misfire on #4 -- and that
it turns out, unfortunately, to be a problem with the VALVE GUIDES on
that cylinder (becoming "unseated", I think, or something -- I still
don't really understand it), and that the entire thing has to be
replaced, cost: $1,539.00 (I thought I was going to literally
pass-out;
my wife said I looked as white as a sheet when she picked me up after
work). He said it was very rare for this to happen and that he's only
seen it two other times in the years he's been with Subaru -- and then
only on engines with more than 100,000 miles (my car has only 63K on
it).
When I asked "why" it happens/what could've caused it, he said there
really isn't an answer for that; that it can just "happen" sometimes.
Just out of curiosity, I also wanted to know why the engine wouldn't
be misfiring/running rough ALL the time (rather than "just" MOST of
the time) and why the tune-up I had done seemed to "cure" the problem
for 2 weeks, but they didn't really have an answer for this either.

The next night (last Friday), I went on the internet to see if I could
find any reports of bad valve guides on Subaru 2.2 engines. I was
just about to give up when I found a site called automotiveforums.com.
Within less than 20 minutes of searching, I found at least * 5 * other
Subaru owners who've had the same experience with the same symptoms
('95-'97 model years, if I remember correctly), and the same difficulty
with their regular mechanics attempting to diagnose/fix it. All of
these other folks, however, seem to have had WELL over 100K on their
cars when this happened. Again, I only have 63K on my '96 Legacy.
(...and to think of all the damn research I did befoe I bought this
car -- I thought my eyes were going to blow out of my head!)

Please forgive me for the length of this post (and for my technical
ignorance too), but I really wanted to know if any Subaru owners here
have experienced this same problem with valve guides or have *heard*
of others who have -- especially with only 63,000 miles. Do you know
WHAT causes it/HOW it occurs? Could it have been a problem with the
original manufacturing of the engine (the Subaru tech says not)? Also,
why wouldn't the engine run badly >100%< of the time, rather than, say,
75% of the time as it did (and why did that tune-up seem to cure it for
a couple of weeks)? ANY answers, advice, opinions are greatly
appreciated. Thanks for listening! (Guess it'll be a Nisson or
something next time, but I really love(d) this car)

Best,
Jeff D.
 
Do the symptoms ever appear when the car is cold/(less than 10 minutes
of drive time?)
Or, in other words, does it ONLY happen when the car is hot?

Has the fuel pressure regulator been checked? The crank or cam angle
sensors could be failing intermittently and it may be coincidence that
the first misfire code is cyl#4.

Anyway, you might consider giving you first mech. a chance at confirming
Subaru's diagnosis and see how much he would charge to swap in a rebuilt
engine.

I'd proceed cautiously.

Carl
1 Lucky Texan
 
Post this problem on The Gartland.com Subaru Forum and hope LSG replies.
Like you, I'm somewhat lerry of the diagnosis. I've seen similiar
problems posted elsewhere. Solutions ranged from a cracked intake
manifold vacuum line to a loose spark plug. I've never read about a valve
guide loosing, although I guess it is possible. Anyways, before i spent a
dime on this repair, I'd listen to LSG's suggestions.
 
JD,

I don't have the answer, just some perspective. Bearing in mind that
money doesn't grow on trees, your news isn't that bad. It's a nine
year old car! Regardless of its mileage and brand, you're gonna have
to do some engine work on a nine year old car.

Also, the car is probably paid for. Before I spent $1500, you should
get a second opinion from another Subaru dealer. But, if you need to
spend that amt of money on a car that's paid for and will go for
several more years with the repair, it's well worth it. Heck, $1500 is
less than 4 months of car payments on an inexpensive used car.

In 02, we bought a mint, but very high mileage 99 Subaru Outback. We
immediately needed to spend about $2,000 for new brakes/rotors, drive
belts, timing belt, t-belt tensioner, water pump and cam seal. Nothing
had broken - it was just preventive maintenance. I still love the car
and feel like we came out way ahead b/c we factored in most of the
service in our purchase price and the car will last for many more
years.

My two cents,
LK
 
I had exactly the same symptoms and CEL code on my 1998 Forester back
when it had 72,000 miles on it. The dealership diagnosed it as an
intermttent short on the plug wire on cyl #4. They replaced the plug
wires and it cured the problem.
 
johninKY said:
Post this problem on The Gartland.com Subaru Forum and hope LSG replies.
Like you, I'm somewhat lerry of the diagnosis. I've seen similiar
problems posted elsewhere. Solutions ranged from a cracked intake
manifold vacuum line to a loose spark plug. I've never read about a > valve guide loosing, although I guess it is possible.

Thanks for the info, although, as I said, my search on that automotive
forums site found 5 different owners who experienced the same problem/
diagnosis w/ their Subarus. Of course, I was leary too when the tech
called me with the news, but I went over there and they physically
showed me the problem (my car was still up on the lift). I was still
leary even then, since we've all heard horror stories about dealer
service departments, but when I read the above reports from other
owners, I felt a bit "better" (if you can call it that), at least as
far as not being scammed.
owners
Anyways, before i spent a dime on this repair, I'd listen to LSG's >suggestions.

I already authorized the work when they showed me inside the engine.
In fact, I just got back from picking up the car. I will, however, take
a look at the forum you recommended anyway. And thanks again.

Best,
Jeff
 
jeff,

i'd suspect electrical issues, rather than mechanical issues. all four of
my plug wires at the moment are intermittently arcing, causing much the same
type of response. i just haven't gotten around to replacing them, but that
will happen this weekend.

i suspect that in my case, the excessive salt used by the DOT exacerbates
the problem. don't know if you live in an area where salt on the roads is
used and necessary.

tim
 
Tim said:
jeff,

i'd suspect electrical issues, rather than mechanical issues. all four of
my plug wires at the moment are intermittently arcing, causing much the same
type of response. i just haven't gotten around to replacing them, but that
will happen this weekend.

i suspect that in my case, the excessive salt used by the DOT exacerbates
the problem. don't know if you live in an area where salt on the roads is
used and necessary.

tim

Hi Tim,
New plugs & wires were among part of the tune-up, the first thing done
to correct the problem by my regular mechanic - and which were later
ispected by the Subaru service to make sure they were fine. As I said,
I found reports from 5 other Subaru owners who had the same problem
as me, and finally the same diagnosis. Thanks for your suggestion
though!

Jeff
 
JD,

I don't have the answer, just some perspective. Bearing in mind that
money doesn't grow on trees, your news isn't that bad. It's a nine
year old car! Regardless of its mileage and brand, you're gonna have
to do some engine work on a nine year old car.

Plus, your car's mileage is so low that the body is probably very
good, so investing in the engine might be quite worthwhile. Sorry
you're experiencing this trauma, though, but you seem to have an
otherwise solid vehicle that might be worth keeping/repairing.
 
I also suspect some electrical anomaly. I also think that if by some
chance it is a valve guide that a replacement motor is NOT needed and
that only fixed or rebuilt cylinder head or heads are in order.
 
It does sound like an electrical problem. My 98 Legacy suddenly
developed a weird intermittent rough running, usually when
cold/damp....CEL came on, engine ran on 1-4 cylinders...I didn't know
if I could get it to the dealership under its own power. Turns out it
was a cracked coil....the solution is to coat the coil with grease to
keep the moisture out, or to replace the coil...grease is cheaper...
 
I would like to know how anyone without removing the cylinder head can
state "Your problem is a dropped valve guide."

I see you also haven't bothered to visit that other site I recommended.
Too bad as LSG is a master at diagnostics.
 
Since it is only bad valve guides couldn't you simply put new heads on
it, or have the old heads reworked. If you could probably have the
work done at a shop somewhere near you for around $1000. That probably
wouldn't include the costs you've already incurred diagnosing the
problem up to this point.
 
johninKY said:
I would like to know how anyone without removing the cylinder head can
state "Your problem is a dropped valve guide."

They did do that -- though the tech said it was the last thing they
checked for (in trying to diagnose the problem) because it was "rare",
and he hadn't thought that would've been the problem.
I see you also haven't bothered to visit that other site I recommended.
Too bad as LSG is a master at diagnostics.

Actually I did "bother", or at least I tried. The URL, "Gartland.com"
brings me to some guy's personal webpage from Minnesota, nothing to do
with Subarus, and "TheGartland.com" doesn't exist. Meanwhile I found
the Ultimate Subaru message board and looked around there for awhile.

_As I said_ in the original post, I did find 5 other Legacy owners on
automotiveforums.com who experienced the SAME symptoms as my car, had
the same initial trial & error (mis) diagnosis, with all ending up to
have the SAME valve guides failure --although I believe they all had
well over 100K on their cars (whereas I have only 63K).

The work has now already been done (cylinder head replaced); the car
runs fine, I'm out the money. At this point I just want to know how/
why it happened and exactly HOW common or "rare" it really is, that's
all -- or if it's some sort of "hush-hush" semi-rare problem that
Subaru knows about. But thanks again -- and thanks to all of those
who responded.

Best,
Jeff
 
Having a valve guide come loose most be very rare as I have never heard of
it before. The valve guide is just sort of a hollow tube that is a press
fit in the cylinder head. The OD of the guide was slightly too small or
the hole in the head was slightly too large or the head cracked around the
valve guide. These are about the only ways I can think of a guide coming
loose. I also guess it is possible the stem of the valve welded itself to
the guide and the valve action then ripped the guide loose. Glad to hear
the engine has been repaired. Sory to hear it had to cost so much.
 
very crude
Hallan Blaggit said:
It does sound like an electrical problem. My 98 Legacy suddenly
developed a weird intermittent rough running, usually when
cold/damp....CEL came on, engine ran on 1-4 cylinders...I didn't know
if I could get it to the dealership under its own power. Turns out it
was a cracked coil....the solution is to coat the coil with grease to
keep the moisture out, or to replace the coil...grease is cheaper...
 
Likely causes would be like possible incorrect tolerances between valve
guide and cylinder head
 

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