I'm farmiliar with the traditional valve tap er piston slap noise subies make, and this is definetly not that. My engine actually never developed that noise.
The dealer showed me the broken timing belt tensioner, once it had been replaced, and it was obvoiusly broken. The side of it had been chewed on by the timing belt, metal shavings were abound, and it was in obvoius need of repair. Once that had been repaired, one of the noises the engine had been making was gone (a dinstinctive 'clunk' the engine would make when removing my foot from the gas after hard acceleration).
What remains is what I thought was the valve tap noise, but this is *not* the normal subie valve tap. It's loud enough that I can hear it inside the car, w/ the windows up, and the radio up loud, at speed (that's the scenario underwhich I first noticed it). It's extremly loud outside the car obviously.
It doesn't happen as much when the car is cold, more when the car is warm. It does not happen while engine breaking or during normal to hard acceleration. The car seems to have the same amount (if not slightly more) power than usual. It seems to happen when there is a relatively small, consistent pull on the engine (i.e. 60mph in 5th gear on a flat highway). Plus, now that I have the car back from the dealer (to take out my radio, remove bike rack, etc.) It has gotten much worse (and I've driven it probably 50 miles total?).
The engine was overfilled by approx 1 quart I think. I handed the dealer a 5qt container of oil, and from what I can tell they poured the entire thing in.
It's actually making enough noise I'm getting concerned about driving it at all.
Will probably end up w/ a new subie tomorrow or Wednesday, which doesn't concern me a huge amount since I'm actually making a tiny profit in all of this (including a 25% reduction in value of the new car when driven off the lot).
Will sell this one either immediatly, or before the 36k warranty runs out.
Cheers,
Dave