2.2 to 2.5 Engine SWAP, how difficult

[DerElf]

Hey guys and gals!

 

I Expect there is a thread that would help me out but I'll be damned if I can find it so I will start a new one.

 

1996 Impreza Outback 2.2 5 Speed Manual. Has a 1997 RS gearbox in it (don't tow a formula car with an impreza...trust me on this). Second engine died after 160,000 miles (man, what a piece of crap, right?). Car has 315,000 on it (just broken in). Looking to put a new engine in it and was wondering how had it would be to put a 2.5 engine in it. I expect this would require making sure that I got the computer from the 2.5 litre car as well but beyond that what else is required?

 

I have heard that it is a SNAP to do this conversion elsewhere on here but I'd sure like to be able to read some articles, posts, websites about how hard/easy this is.

 

Thanks in advance

 

Bucky

 

www.teamelf.com

[Olnick]

Welcome aboard, Bucky. Your question is going to strike a lot of people here funny--many are dumping their EJ25s for uber-dependable EJ22s!

 

That said, if you do it make sure you replace HGs, timing belt and re-seal before you install it.

 

Good luck.

[DerElf]

Wow, I did not know! I was just looking for a newer engine/more horsepower. Now I think I will stick to dropping a good old reliable 2.2 in my good old reliable Scoobie Doo!

[Olnick]

Hey, don't get me wrong. EJ25 is a fine engine but head gaskets are a well known weakness. Use the search function and you can read a lot of discussion about the problem.

 

If you stay with the 2.2 be aware that they were non-interference up through '96. They became interference engines from the '97 model on.

 

Good luck.

[DerElf]

OK school me here..."Interference"?

[GeneralDisorder]

Valves hit pistons if the timing belt breaks. 90 through 96 EJ22's can freewheel - no damage if the belt breaks.

 

If you do put in a 2.5 (not reccomended), it would have to be a phase II - '00 model year or newer to be a simple swap. But you would also need to swap the exhaust as your '96 exhaust is single port and the 2.5's will all be dual port like the early 2.2's

 

Stick with the 2.2 - they are generally good to 300k+

 

GD

[themoneypit]

Valves hit pistons if the timing belt breaks. 90 through 96 EJ22's can freewheel - no damage if the belt breaks.

 

If you do put in a 2.5 (not reccomended), it would have to be a phase II - '00 model year or newer to be a simple swap. But you would also need to swap the exhaust as your '96 exhaust is single port and the 2.5's will all be dual port like the early 2.2's

 

Stick with the 2.2 - they are generally good to 300k+

 

GD

 

since his car is a 96, i would think he would need a phase I motor, no?? ive got a phase I 2.5 and was told the direct swap for me was a 95-98 2.2l out of an impreza or legacy with EGR. preferably a 95 as they had the proper exhaust ports. you sure he would want a phase II 2.5 for that swap???

[johnceggleston]

preferably a 95 as they had the proper exhaust ports.

 

95, 97, and 98 all have the same exhaust, only 96 is the odd duck. but 95 is non-interference, that is a plus.

[DerElf]

Well Here's a follow up to this thread:

 

I decided to stick with the 2.2 and located one with 66K on it (just broken in for a Subaru). Installed simply save for the engine arrived from

 

ENGINEANDTRANSMISSIONWORLD

 

with an oil leak, probably from the oil pump. When I called them to find out if my "warranty" covered this they asked me if I had "checked for an oil leak before I installed the engine".

 

Yeah...I threw that sucker on my pocket DYNO and FIRED THAT BABY UP! (who asks questions like that?)

 

I told him that a surface check of the engine was futile as the engine had arrived on the pallette covered in a coat of silver engine enamel.

 

Short story, they don't cover oil leaks. SO my Scooby runs now, but I can spell out my name in a parking lot like a sky writer.

 

Back to the shop.

[Qman]

Here we go again with the 2.5 haters. Yes, they do have head gasket failures just like every other aluminum motor in the world. Change the head gaskets and reseal the motor and you are golden. More power, slightly less mpg. A phase1 2.5 will bolt in. You may have to change some connectors or do a little wiring but DO NOT let these guys talk you out of it. I have 3 2.5 motors in my cars. All have had the HG's done and all are running just fine. One of them is putting out over 160whp. Another is projected at near 200whp. Enjoy!

[GeneralDisorder]

The phase II's are good engines. The phase I's had *some* issues beyond the head gaskets - piston slap and rod failures are seen more often than in the 2.2's (unheard of).

 

But yes - if you replace the head gaskets before dropping in the used engine they aren't bad engines. And the phase I 2.5 has an MLS gasket now due to the multiple redesign's they went through to get them to seal up. So if you get one that doesn't have piston slap or rod bearing failure issues then an upgrade to the newer head gaskets should insure a good long life.

 

Personally I'm a fan of the 2.2 from 90 to 94. I have a lot of reasons for this, but cheifly it's before they started mucking up the design with "cost saving" changes. In '95 they started in with their modifications to save productions costs and from then on things just started to go south. Little things at first (plastic parts for belt tensioner's, etc) and moving right on up to serious design flaw's in the head gaskets because they didn't want to spend the extra money on using MLS gaskets for the non-turbo's. If they hadn't started counting the dollar-sign's in '95 they wouldn't have alienated a lot of their customer base from the dreaded "HG of doom" that's plauged them all the way through to the current models - though I hear for '10 models they have finally given in to the MLS gaskets for everything.

 

GD