chucktile Posted July 5, 2011 Share Posted July 5, 2011 (edited) 98 outback wagon Limited. I installed my first set of head gaskets on that ej25 a mere 6000 miles ago. Started running hot again around 5400, Im sure it was my fault they went so soon, I considered this my practice HG replacement. Right about the same time a friend borrowed my 96 legacy L wagon, 239000 on the car but 70000 on the ej22 in it. The car was near perfect; until, someone ran a stop sign and slammed into the drivers side marker light, pushing the front end over about 8" just nudging the valve cover bolt and smashing the top of the injector. Perfect donor, right? Yup. I put the whole drivetrain in the 98 outback limited and i could not be more happy. Now. If you asked me 3 days ago you would have gotten a different answer. The removal and install process was fairly easy and painless, thanks to USMB and much research (reading threads on the board). Three and a half days after taking off the first v belt, cover bolt, i was putting fluids back in wondering if I was going to have to change the ECU. The only thing from the 2.5 being used is the MAF sensor and the intake ducting, the intake itself is 2.2. I did swap the injectors because the one was broken and I noticed there was a different number on the 2.5 injectors so I figured I had better swap all of them. When I turned the key it cranked for about three seconds and then started right up. Great! I drove the car home that night, about fifteen miles and parked. The next day I drove across town about two miles and parked, about 2 hours later I went to start the car and it struggled but did start. Barely running, we limped home, lucky we were only two miles away, I don't think she would have gone much further. The next day when I tried to start the car it cranked a couple times then the cranking slowed,then, click,click,click. Ok the battery is low Ill just get the van and jump it. Turn the key and click, turn it again this time no click. Nothing. Nothing? Bad starter? NO! The engine and trans never came apart, I took them out together and put them in together so it couldn't be a loose flywheel bolt. Maybe the engine was damaged internally in the wreck. NO! I did find a bunch of fuel in the intake tube and it was dripping out of the exhaust pipe by the Y. Odd to me. Fuel pump pumping too much fuel? NO!(I did find one of the wires that goes from the fuel pump on the passenger side to the pump on the drivers side was corroded, great, more work.) Three days and hours of reading threads on USMB, I typed hydrolock into the search bar and it wasn't long before the answer came to me. Oh yeah the ECM was throwing a code for cyl 3 misfire, one for fuel temp sensor and one for low voltage to oxy sensor heater, bank 1. Wow someone forgot to plug in the front oxy sensor, would that cause the engine to lock up? NO! Ok so hydrolock, the thread was "90 EJ22 4EAT injector" the more of the thread I read the more convinced I became that this was my cars problem. I decided to check the injectors before I start tearing the engine out again, well lo and behold, the o-rings on 1 and 3 injectors were pinched and apparently fuel was dumping into the cylinders and hydrolocking the engine. I didn't realize that hydrolock would sound like someone threw a monkey wrench in the gears. Let me tell you that is not the sound you want to hear from the engine you just installed, VERY SCARY! I took out the spark plugs and turned the engine with a breaker bar, when piston 3 came up it forced out about 3/4 cup of unburnt fuel out the plug hole, 1 had a little less. Now we're getting somewhere, I put new o-rings on the injectors, oiled and CAREFULLY installed them, changed the oil and filter, reassembled the car and now, the moment of truth. Damn battery, now it really was low, I hope. Get the van, hook it up. Now, the moment of truth, she's turning, she starts! Yes she started and ran rough for about one min. then she cleared up and runs great. The only issue was the EVAP can was in the front of the 96, it's in the back of the 98. I just ran the hoses that used to go to the can in front together and now, smooth as silk, when I stop at a light I can't tell if she's still running. Thanks to ALL who participate on this board, I could not have done this without USMB. I have never had to ask a question myself, I thought this was it but the answer was there, just very hidden. Thanks again. Here are some pics and links, hopefully this helps someone else someday. Edited July 8, 2011 by chucktile Link to comment Share on other sites More sharing options...
chucktile Posted July 5, 2011 Author Share Posted July 5, 2011 (edited) https://picasaweb.google.com/lh/photo/JS-CV9aujK_Efae7jf8-PCXLskZQtZUTbezA3R_auz8?feat=directlink https://picasaweb.google.com/lh/photo/n7xysyhGZEPihjy_4YsIViXLskZQtZUTbezA3R_auz8?feat=directlink Edited July 5, 2011 by chucktile Link to comment Share on other sites More sharing options...
Olnick Posted July 5, 2011 Share Posted July 5, 2011 Fascinating story chucktile. Sounds like you did a good job--and the car looks great. I'm glad you found USMB to be so helpful, even without asking questions! You obviously know how to research and use a resource properly. Just one suggestion--next time could you break your story up into short paragraphs? That was a bear to read!!! Good luck. Link to comment Share on other sites More sharing options...
Fairtax4me Posted July 6, 2011 Share Posted July 6, 2011 That's a hell of a story. Glad you got the fuel issue straightened out. That's one I've definitely never heard before, but the design of these fuel rails certainly allows for it. Lesson learned, be careful installing fuel injectors. Link to comment Share on other sites More sharing options...
wtdash Posted July 7, 2011 Share Posted July 7, 2011 (edited) Hi, If you swapped the Eng/Trans, did you also change the rear diff? If it's an AT, the OB is 4.44 FD ratio; Legacy is 4.11. And the Limited was only avl. as an AT, according to Cars101.com. Those injectors O-rings are PITA, to be sure. The EJ25D's only use 2; some have 4 w/the spacers. PIC GL, Td Edited July 7, 2011 by wtdash Link to comment Share on other sites More sharing options...
chucktile Posted July 7, 2011 Author Share Posted July 7, 2011 Hi,If you swapped the Eng/Trans, did you also change the rear diff? If it's an AT, the OB is 4.44 FD ratio; Legacy is 4.11. And the Limited was only avl. as an AT, according to Cars101.com. Those injectors O-rings are PITA, to be sure. The EJ25D's only use 2; some have 4 w/the spacers. PIC GL, Td Yes I did swap the rear dif. along with the entire exhaust. EJ22=single port exhaust. EJ25 DOHC=dual port. Link to comment Share on other sites More sharing options...
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