EJ25 JDM that I've put 25,000 miles on (and took it apart!)

[mtnhome]

Double post
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'84 Westy, '93 Subaru ej22 and Subarugears 5speed
Build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=763098&highlight=

[mtnhome]

[Sodo]

[Sodo]

Here's a closeup pic of the wear on the crankshaft main seal.
The black at left is a new seal with a sharp sealing edge.
The brown seal at right is the original Subaru main seal, the starp edge worn flat.

You experienced EJ25ers..... how wide have you seen the seal edge (at how many miles?)?
The flat worn area on the brown seal lip is about 0.4mm wide.
So the red lines are about 0.4mm apart.
The new black seal has a sharp sealing lip of course.

It's a big seal, 3 3/8" diameter.

My simple mind throws out 65,000 mi.
But how many EJ25 seals have I assessed?
You can count them on your balls and have one left over.

The brown rubber is kinda stiff, with a slow rebound,
glad I bought the new one.
It was easy to replace.

I wish I bought one for the pulley end now. But its less than half the diameter, maybe 1/3, and thus a lot slower.
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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[mitch5]

I personally have never paid that much attention to the seal width. But based on that seal being stiff I would replace every seal behind the timing belt. I forgot to order the oring type seal for the cam cover thing, reused it cause of time crunch and ofcourse it leaked.

I am rooting for you that you get a non oil burner and a few thousand saved at the end of this journey.

[Sodo]

[Sodo]

Side task to improve upon a gangly brass oil-pressure Tee.
I used it for a test-guage to check oil pressure back when I first got the engine.
Intending to get a better guage & sender later but didn't do it.
I plugged the Tee, ready-in-waiting.

I decided that I really want to know oil pressure.
And wanted to clean up the install a bit.

That brass fitting is a 1/8-27NPT jammed a few threads into the 1/8-28BSP Subaru hole.

I had to cut/reorganize the ports and re-weld the stainless Tee to fit as I wanted below the alternator.
That's a 1/8-27NPT stainless “Branch Tee” from Amazon ($12).
I ran a 1/8-28BSP die over the NPT threads.
The BSP has a steeper taper, so it “cuts more” and the rethreaded fitting then screws in deeper.
It has thread sealant, hopes & prayers.

If someone wants to re-thread 1/8-27NPT to 1/8-28BSP....the better way to do it is to grind off the die's lead-in so you can screw the die down about 3 more threads.
The thread is tapered, so the re-threader will cut 3 threads deeper.
It's like a "bottoming die".
I didn't wanna grind my die so I didn't do it, but I may order a spare and grind it for future projects.....
I believe you can make 1/8NPT fit 1/8BSP very well with a "bottoming die".

I stuffed the engine in tonight.
With luck I will run it tomorrow.
More hopes & prayers.

EJ25 fellers may notice the engine stand.
It's two 4x6 x 9" blocks screwed to a 23X9" 1/2" plywood.
A 1/2" plywood shim adapts it perfectly to the Smallcar cast oilpan.
The 4x6 blocks have 3/8 holes just pounded onto the 10mm exhaust bolts.
This engine cradle is super easy to make.

Much easier to install the engine with a floorjack.
You can crib it up, lifting incrementally under each block.
Then when high enough, just roll the floorjack under.

10mm studs go into 3/8 holes (in wood) kinda tight.
I pried the blocks off the exhaust studs with a wrecking bar.
They don't come off real easy.

My wife returns from a trip tomorrow.
She will be happy to see this project almost done.
She says I've been "like a zombie."
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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[Abscate]

Documenting that installation cradle is the work of the Creator, Casey, take notes. Here’s to a clean easy start and running this weekend.

I’ll swag another 3.75 inches of lift on the jack to get the height right
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.ssS!

[mtnhome]

As usual, Tom powers thru another project. Great idea on the engine cradle for lifting.
Wish I could weld like you do. For the Subaru oil galley plug, I used a couple of these for my oil pressure and temperature gauges.

https://www.amazon.com/gp/product/B096LB1DJH/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

Can't wait to hear that you're back on the road.
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'84 Westy, '93 Subaru ej22 and Subarugears 5speed
Build thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=763098&highlight=

[Zeitgeist 13]

Wait, am I late to the party? I predict it will never work. Never.

_________________
Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik?

[IdahoDoug]

Fingers crossed for a good startup tomorrow. I will be in Seattle tomorrow on business, and will doubtless hear your cries of joy.
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1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1988 Toyota Supra 5 speed targa, 2002 BMW 325iX, 1982 Toyota Sunrader

[dobryan]

[a914622]

I know it’s a little late but, instead of the T, there is another port in the flywheel side that can be drilled ant tapped for your 1/8-27. Iv got that in the svx in the 914 and the 2.5 in the vanagon.
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87 gl powerd buy 2.5subaru
75 914 getting 2.2t subaru scratch that SVX subaru

[Sodo]

After welding my adapter-tee I was told of that port and the adapter 1/8-27NPT EJ $13 ON AMAZON
Goot to know about....but it's not all that accessible back there. I think you have to add a 45° street elbow too, to clear the reverse-manifold.

Here's the welded TEE.
It's below the alternator, but at least there's a straight shot access to it.
For whenever its time to add the oil pressure gauge.

Almost everything is on.
I'm down to the headers, muffler skidplate etc.
But I broke the wire that goes to the power-steering pump, so all the belts have to come off to fix that.
It's just the throttle increase input, so I'm gonna kick that can down the road for now.

Hopefully gonna start it soon.
Haven't heard from IdahoDoug.
I sure hope this oil-rings-replacement works.
There will be some yippees if the oil consumption heals.

An oil pouring friend holding no stock in Exxon sent me a pro shop estimate
that he got for head rebuild and $2200 Subaru EJ25 short-block install.
His uses a quart every 500 miles and he's tiring of the task.
It's pretty much the same job that I just did..... except the feller gets a spankin' new block.
$7700+$790tax = $8500
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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[Shonandb]

Good to see that you are almost back on the road again! I hope the new rings, new timing kit, and head refresh reduce your oil consumption.

Did you replace the intake and exhaust valve seals as well?
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76 Westy with a 2.5L Subaru SOHC + Vanagon (010) Automatic Transaxle
Build & Trip Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=758760
Previous 1973 Panel Bus:
Click to view image

[Sodo]

Yes all new intake & exhaust seals but the valve stems were all clean so I don't think the seals were leaking oil.
I would have liked to see all of the parts and I thought they would have saved them for me but they didn't.
Only saved the four the bent valves.

I thought the heads were kinda "low miles" (perfect etc)
and only needed 4 new valves for a quickie seat/dent inspection
and re-assemble (& new seals for sure ! ).
But they said a full rebuild was necessary.

855-253-137A "exhaust sealing donut"
I superglued this together and it held for assembly!
In-use, the 3 bolts, and the taper compresses the segments together.
------>This dumb donut..... doesn't even know its cracked !

So this pic again.
I unbolted all the 'stuff, suspended it with ratchet straps
and crapped the longblock out below.

Because where the van was parked, stuck, on a slanted driveway.
I wanted to just drag the longblock out from under, then into the garage,
without jacking the body higher.
It all worked out.

Then I jacked the longblock up stuffed it in, lowered all "the stuff", manifold, pumps etc onto the longblock.
It all worked OK.

Well anyway, when it was time to restart the van, I turned the key and it lit instantly, like I had shut it off yesterday.

I don't know whether the "crap out a longblock" method is good or bad, but it was kinda fun that it lit instantly.

I drove it around today and it drives just like it did 14 days ago.

So now I have do some more shakedown, and also finalize my "Fox oil change and Schwenk Springs" project.

We head for the WA desert next week to bumble around a little, then ending up at the Othello Sandhill Crane Festival
_________________


'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[jimf909]

Well wishes. And don't forget to do the oil conservation jig and sage out the oil consumption demons this time.
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- Jim

[Shonandb]

Congratulations! It's awesome when it starts right back up as if nothing had happened.
_________________
*******************************
76 Westy with a 2.5L Subaru SOHC + Vanagon (010) Automatic Transaxle
Build & Trip Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=758760
Previous 1973 Panel Bus:
Click to view image

[IdahoDoug]

Hey, nice job, Tom!!! I had lunch in Seattle and am back home again. Look forward to hearing good reports.
_________________
1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1988 Toyota Supra 5 speed targa, 2002 BMW 325iX, 1982 Toyota Sunrader

[dobryan]

Awesome! I hope it is a teetotaler now.
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Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

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