'04 Legacy spewing oil from passenger valve cover vent nipple. Should I get a reman'd long block?

[rogo]

I currently have an 183,000 mile 2004 EJ259 PZEV ('04 2.5L California Emissions) that spews oil from passenger valve cover vent nipple with hose off (goes up to intake with hose on), makes harsh noise, and white smokes like a mf'er out muffler. Idles goofy then stalls. Car ran pretty good before job, and actually ran fine first  time starting up. This happened the 3rd time I started it about 40 seconds after starting it 2 days later during idle. The car wasn't driven yet or revved.

 

Seems like massive blow by/over pressurization....driver's side does not do this however.

PCV valve has maybe 1k miles on it as a replacement.

 

Compression checked out ok on those 2 cylinders 105 and 110.

 

This is all after a HG/reseal job. Done by myself and had someone experienced with Subaru's help with reassembly, using FSM/Haynes manual. I did nothing to the block other then clean mating surface with white roloc disc, and pistons with same disc.

 

Everything else has been resealed with parts from OEM gasket kit except Six Star head gaskets and Permatex RTV. Heads were machined with valves redone by engine building shop.

 

If I were to order a replacement engine, could I plug and play any 00-04 long blocks? Does it have to be a California Emissions?

 

I'm in Michigan and don't need the PZEV, can I swap in similar year standard manifold/headers/ECM to go non-PZEV?

 

Money is tight so would like to avoid a new engine but I'm dedicated to get it running right, just need advice.

 

Thanks for any and all help!

Edited May 30, 2013 by rogo

[nipper]

That compression is pitiful, on a healthy engine it should be 180. 

 

Valve timing is off on that one side of the engine.

[Cougar]

I suggest you try replacing the PCV valve with an OEM one. The installed one may be bad even though it isn't very old.

[idosubaru]

what nipper said - that compression is really low and both being bad does suggest the cam is lined up wrong or some kind of timing issue.

 

that it ran before hand and first time after suggests your block is good - so unlikely to need a block

 

if it's not timing - blow by out that vent cover (and not the other) suggests something may be wrong with the heads...valve stem seals or valve guides...in which case it may be warrantied by the shop that did the work, most reputable shops warranty valve jobs.  you probably need the head reworked (warranty?) or buy a used head.

 

i guess it could be blow by at the rings but i'm unfamiliar with the symptom differences between that and valve issues...and sounds unlikely given it ran fine before hand.

 

the Subaru Turbo EJ25 gasket is the best choice for that motor, they do not fail. six star is good and all but if price is a concern you may want to compare.

[1 Lucky Texan]

in addition to the above, triple check PCV and breather hose routing. I read one post where it ended up a guy heard gurgling in the dipstick tube and it was caused by hose misrouting!

[hankosolder2]

This is perhaps a silly question, but you said "six star head gaskets and permatex RTV." You didn't put any sealant on the head gaskets, did you?

 

Also, did any coolant get into the bores during your HG replacement? If so, rings can rust if the car sits during the job, resulting in mechanical havoc later.

[Gloyale]

Double check the timing belt alignment.

 

If that's all good drive that sucka......probably just crap in the exhaust pipe.

 

gotta at least get it going 60 for a little bit to see if it all clears up.

[Fairtax4me]

The head gasket has failed. The compression ring seal has failed and is allowing compression to blow out into the oil drain passages at the bottom of the head. If you put RTV on the head gaskets, that is the reason. RTV on head gaskets = No no.

Other causes could be: head and or block surface warped, incorrect torque sequence, or surfaces were not clean enough.