BoxersOnly

I have the service manual for the '98 DOHC EJ25 I am working on. The section for the cam installation lists the following torque specs: ft-lb : 14.5 ± 1.4 what does the ± 1.4 mean ? Thanks, Rob.

Ok, my project is progressing although extremely slow. I bought a new gasket set this week and want to install the head back on. Here's my question for the week : How clean does the head and block surface need to be ? Right now there is no gasket on it anymore, but there is some (carbon ?) residue on the surfaces, especially the 1st ring around the cylinder: And, what is the best way of cleaning it ? I'm guessing wirebrushes are not a good idea since I don't want to scratch it ? Thanks, Rob.

The '98 EJ25 I'm putting into my Beetle had fuel temp and fuel tank pressure sensors. Are these sensors used only for the emission CEL ? Or are they actually used to make the engine run properly ? Thanks, Rob.

POR15 is good stuff, but good prep is essential, otherwise it will start to flake and come right off. If you do it right, it will never rust again. Rob.

Will an Alternator off a '2000 RS fit an '98 RS ? Rob.

Anybody know if the '97 GT engine is the same as the '98 RS ? Both are DOHC EJ25's. Thanks, Rob.

Thanks guys, that's what I thought, but I wasn't sure if the damaged piece was from removing the head or if it was the blown gasket. NorthGuy, I guess I should have put 'viewer discretion advised' in the topic :D Frag, I am guessing that the recess in the piston is either for valve clearance, or to create a better 'quench (sp?) area' to improve flame travel over the piston and inside the combustion chamber. Rob.

I bought a used '98 DOHC EJ25 to put in my bug. I'm in the process of replacing the headgaskets. THe PO said one of the gaskets blew just before he pulled the engine. Take a look at this pic. Does this look like a blown gasket ? How can I see if this one is busted or not ? I'm going to replace the gaskets just to be sure, are there any other things I should do while I have the heads off ? Thanks, Rob.

Are the ECU connectors off a '98 EJ25 different than the connectors off a 2000 EJ25 ?? I can't believe that *again* I bought something that I can't use.... Rob.

Well, I've got the cam sprockets off. Check out this marvel of (McGyver) engineering: How's that for a sprocket removal tool ? Now, the next challenge: the head bolts ? Looks like I need a special socket for this. Can someone tell me what these are called and what size I need ? Thanks !! Rob.

Skip, how easy / hard was it to brake loose the bolts from the cam sprockets. I just tried and they wouldn't budge. I looked if I could wedge the wrench somewhere so I could use both hands on the socket, but I'm affraid to damage the block. Any hints / tips ? It's normal right-hand thread, right ? (right = fasten, left loosen). Thanks, Rob.

Great stuff ! Thanks Skip ! Rob.

First: sorry for the long post. Ok, I just started my first 'real' engine project: Head gasket replacement on a '98 DOHC EJ25. The engine is on an engine stand so it's a joy to work on. I have a whole bunch of questions, I'll try to split them up logically. First: timing belt removal. Before I removed the timing belt I checked the marks on the camshaft sprockets. I could have sworn that all double marks lined up and that all arrows pointed to top right. But when I removed the belt, put it away and looked at the engine again, I saw that the topright sprocket had it's single mark lined up with the double mark. Could it be that it turned when I took off the belt ? I tried to turn it (really really careful), but at some point the valve hit the piston (I guess) and it would not turn futher. Second: Cam sprocket removal. Do I really need to get the tool to lock the sprockets in place ? Is it expensive ? Any other safe tricks to lock the sprockets ? Third: Can I remove the cam cover or cylinder head cover (not sure what it is called) without removing the sprockets ? I can't see if the clamp behind the cam sprockets locks the cover in place, and I don't want to use force and screw things up. Fourth (planning ahead) : aligning the cams. When installing the timing belt, I need to align the marks again. This will take care of the positioning of the cams in relation to eachother. But what about the crank ? How do I know that the crank is in the right position ? Again, sorry for the long post, but I'm a newbie at this and don't want to mess up the engine. Thanks, Rob.

How come the 2.5's are unreliable ? I drove a '99 RS for 4 years, no problems at all. Granted, there are a lot of cases (especially with the '98) of blown head gaskets, but are there other problems as well ? Thanks, Rob. BTW. sorry for Hijacking this thread

Dwight, Thanks for the info. Glad to hear it is running well. Do you know if the '96 EJ25 is similar to the '98 EJ25 from an RS ? If that is the case, then I can extend the modelyears I am looking for. I need the harness for a conversion as well (Beetle) Thanks, Rob.

Dwight, Were there already 2.5's in '96 ? Do you also happen to have the complete wiring harness ? Thx, Rob.

SnotRocket, I haven't decided on a Rad location yet, but I am leaning towards the rear parcel shelve area. My car won't have an interior (weight is Evil), so I won't be running a back seat. I thought of hacking a hole in there, and use something like NACA ducts to force the air through there. Keep an eye open for a wiring harness for a '98 EJ 25 :D Rob.

I'm in the process of putting a '98 EJ25 in a Beetle. One piece of advice is to get the engine with the complete wiring harness. I didn't and I'm having a hard time finding one. Where are you going to put the radiator ? You also might want to check this board: http://frost.bbboy.net/vwengineconversions Good luck and keep us posted. Rob.

Thanks for all the tips guys ! I got it off. The engine is on an engine stand in my garage, so I could not use the cranking, or transmission-lock method. First I bought a strap wrench, which broke Then I picked up a chainwrench, and used the strap from the busted strapwrench to protect the pulley. I used a piece of 2x4 to hold the wrench against the alternator stand. Initially I wasn't paying attention and the 2x4 was against the timing belt cover, which broke :madder: Then I used the lever of my jack to turn the socket and voila ! Thanks again...on to taking the heads off. Rob.

Hi All, Does anybody have any tips/tricks on how to remove the crank pulley off an EJ25 withoug buying the special tool ? Thanks, Rob.