I bought a 2004 Subaru Impreza Outback Sport (2.5L EJ251 SOHC) a year ago and have found a leaking crankshaft seal. When going in to replace it, I see that the leak is probably caused by a small gouge (~ 1x1x2 mm) in the aluminum engine block on the sealing surface, toward the front of the block.
The repairs I feel I can do myself given my tools and experience are to
1. pound the seal into the shaft housing deep enough to clear the gouge, which would be about 2-3 mm deeper than flush. would this cause a problem? seems like there's plenty of space back there ...
2. fill with epoxy and file smooth with emery cloth. i've heard that JB Weld might do the trick, but also hear concerns about aluminum expanding differently than the epoxy. i don't want to cause more problems than i already have.
3. both of these?
Unfortunately, i am unable to weld aluminum (or any metal for that matter), so would have to bring to a machinist for this.