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New to USMB, Rebuilding '99 EJ25 DOHC looking for guidance


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Brief History:

'99 Leg OB Limited with 165K, bad piston slap, leaking lots of oil, and now blown HG. This is the wife's Fav car (we have many (don't ask)). Eng is out and on the stand, I am 50% into tear down. Before I order parts I want to make sure I get the best parts and figured some of you may have some suggestions.

 

I plan on getting new pistons and rings, main and rod bearings, oil pump, water pump, Timing belt.....

 

I also plan to have the block checked (bored and honed if necessary), the heads checked and tested (worked if necessary), and maybe new lifters (or tappets if you prefer).

 

Most of my serious wrenching has been on older Mercedes diesels, so while I feel comfy working in the EJ25, I feel that some advice from some SOOB peeps is needed.

 

Thanks in advance for any input.

 

Diesel Dean

 

99 Legacy Outback Limited 165K+ Wifey's Fav

87 Mercedes 300SDL 275K+ My daily driver

99 Honda CRV 155K+

98 Dodge Ram 1500 178K+

87 Mercedes 300 TDT Wagon 250K+

87 mercedes 300D 247K (RIP):dead:

Edited by deanot442
sorry about the font color, hope this is better
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To the OP. Aside from the very good suggestions about your project.

 

May I suggest that you change the color of your text. I believe it gets my vote for the hardest to read post since the upgrade.

 

And Welcome. There is a lot of excellent information and members here.

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yeah but he has a 99 so unless he's very lucky, the wiring harness is different, at least the trans part is.

 

dean, what is the trans ID number on the id tag, driver strut tower. it's either a TZ102Z2DBA or TZ1A2ZJEBA. if it's the first, you can drop in the 95 2.2L no problem, not sure if it's the ...JEBA trans. you might be able to if you swap the wiring harness???

 

anyone know?

 

I've swapped 3 different 99's with the 2.2 no issues on any of them. I did not look at the trans numbers on any of them. But as far as I have seen the only ones with the 2 plug engine wiring harness are the 99 legacy phase 2 2.2

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well you can't use a 99 phase 2 auto trans on a 98 or 99 phase 1 car, the trans wiring is different, and since the connectors are right next to each other i figured the were part of the engine harness, but i really don't know.

 

thanks for the correction. i should probably put question marks on the end of all my posts.?

 

All the connectors for the transmission plug into the body harness, not the engine harness.

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After viewing your suggestions, I decided to call around to the Local yards and there was 1 place out of the 4 I called that had a 95 but someone beat me to the Eng. I haven't looked at the trans yet for the number and plugs. In the event that the 95 2.2 proves difficult to obtain, are there any suggestions for getting the correct coated pistons, head gasket set, and block sealant. So that I can at least put this eng back together so that it can last for a few years.

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Search Dealer Parts on the List, there are several that sell online.

 

Used: http://www.car-part.com

http://www.junkyarddog.com

 

I got my last 95 with 76K on it for $300 and $200 for shipping.

 

Hey, forget I told you about these sites, all the 95 2.2 will be gone before I know it :>)

 

I'm running into this already in my area - a bit of a shortage. And I didn't do THAT many swaps in the last year or so.

 

And then the JY's and I are bidding on the same car at some of the salvage auctions. Either way I end up paying more. I just prefer to hear them run and do a compression check if possible.

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I'm running into this already in my area - a bit of a shortage. And I didn't do THAT many swaps in the last year or so.

 

And then the JY's and I are bidding on the same car at some of the salvage auctions. Either way I end up paying more. I just prefer to hear them run and do a compression check if possible.

 

:) after calling around and some web crawling last night, I am leaning towards just refreshing the 2.5 I already have. While time is not exactly critical on this project, this is/was the wife's daily driver and we all know that when "momma's happy" we are much happier. and if she's waitin she's not happy.

 

Dean

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You might want to consider the 2.2 instead of the 2.5 from ccr. It is much less expensive and it is a more reliable engine. They deal with 2.5 to 2.2 calls all the time:)

 

Why is everybody so anxious to DOWNGRADE there Subaru?

 

All these people who are recommending a 2.2 swap are just feeding the fires of misconception that the 2.5 is somehow inferior.

 

It makes more power, and is a more sophisticated design (dohc). Now because it has the largest bore of any EJ, it does often lose it's headgasket at 150k instead of 250k, but really, that's not that bad. . The rest of the car will begin to have trouble by 300k when the HG might go again. So you will have gotten the perfect lifespan.

 

A Chevy motor will selfdestruct entirely at 150k

 

Anyhow. To the OP.

 

Rebuild you're 2.5. I commend you. too many people are too quick to do *junkyard* swaps. (there is always a reason a car ends up there:rolleyes:)

 

A worn, high milage 2.2 WILL NOT be superior to a completely rebuilt 2.5.

 

Use Threebond 1215 for the Case halves. Make sure you get the new O-rings for between them.

 

get your headgaskets form Subaru. Timing belt set and waterpump are good ebay items., although you may want to get the belt from Subaru and only use the tensioners from the kit.

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A Chevy motor will selfdestruct entirely at 150k.

 

 

I believe that was a slanderous statement:rolleyes: I have had chevys that go 250,000 with no problems and while I was a tech I have seen them with 300,000 + (one with 600,000 with original engine, not rebuilt) But anyhow, I think this guy just wants opinions on what everyone thinks, and he can make up his own mind on what he wants to do. If he rebuilds it, I say more pwer to him. If mine were to go south (98 2.5 OBW) I would more than likely go with the 2.2 for the cost, reliability, and to some, it being superior to the 2.5.

 

My .02

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I believe that was a slanderous statement:rolleyes: I have had chevys that go 250,000 with no problems and while I was a tech I have seen them with 300,000 + (one with 600,000 with original engine, not rebuilt) But anyhow, I think this guy just wants opinions on what everyone thinks, and he can make up his own mind on what he wants to do. If he rebuilds it, I say more pwer to him. If mine were to go south (98 2.5 OBW) I would more than likely go with the 2.2 for the cost, reliability, and to some, it being superior to the 2.5.

 

My .02

 

My 91 suburban has 240,000 and runs fine, doesn't leak or burn anything. It is rusted out badly though. Kind of like a subie actually.:lol:

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Why is everybody so anxious to DOWNGRADE there Subaru?

 

All these people who are recommending a 2.2 swap are just feeding the fires of misconception that the 2.5 is somehow inferior.

 

 

Use Threebond 1215 for the Case halves. Make sure you get the new O-rings for between them.

 

get your headgaskets form Subaru. Timing belt set and waterpump are good ebay items., although you may want to get the belt from Subaru and only use the tensioners from the kit.

 

Thanks for the info! I have also heard that either OEM or some aftermarket company makes some coated pistons that work well to quiet the "Slap".

 

I welcome all of your opinions BTW.

 

Most of my focus over the last 8-10 years has been towards GM, VW and Mercedes Diesels. and as we all know, every manufacturer has its querks and tricks.

 

thanks all!

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