Engine swap question

[drsevy]

might be picking up a 96 legacy outback automatic wagon with a blown head gasket. It has a 2.5 engine

Will a 95 legacy L auto wagon 2.2 engine bolt up to the 96 trans okay ? or should I swap the 2.2 engine and trans together ?

Is this a pretty strightforward swap ?

Thanks

[tturnpaw]

Yes, everything bolts up fine, and yes it is straight forward.

Its up to you whether you use either trans. Just be sure to swap your sensors to the 2.2 so the computer has no issues communicating.

Why dont you just replace the 2.5 head gasket?

[mike-tracy]

I think you might need the ECU from the 2.2 since the 96 2.5D ecu is tuned for premium (common swap for 96ers is to put in a 97-99 DOHC ecu in - the motor then runs fine on regular)

[drsevy]

Yep, I might just try that first. The 96 has 215K miles and the 95 has only 125K. but with a rusted rear subframe/cross member. The 96 body is great and I like the higher stance.

I've done head gaskets before on alfas by just pulling the head. Is this the best course or should I pull the whole engine ?

thanks

[wtdash]

I just did my 1st swap of a '95 2.2 into a '99 OB, which has the newer 6-bolt (PITA) housing. (I've done other '90-93 swaps.)

This may be obvious to some so take it or leave it:
Here is some swap info I observed:
- The '99 4EAT tranny has the 6 bolts, and what a PITA they are to get to on the Driver's side! I removed the driver's side CV axle to get @ 'em.
- The EJ22 had the locator pins and so did the tranny - be smarter than me and remove them from one or the other B4 installing the engine.
- The original '99 OB starter worked perfect - both upper and lower mounting bolts were still in place. I was unclear on this but since I didn't swap trannys it was a non-issue.
- The flex plate from '95 won't work - too small @ least on the '99 w/the newer 4EAT. Rule of thumb seems to be to always match the flexplate w/the tranny - not the engine.
- The vac hoses are different as mentioned in previous posts:
--On the EJ22 there are 2 that go to the charcol canister. I looped them back into each other.
--There were also 2 on the passenger side of the intake manifold on the EJ22. There was one hose w/a T-connector that I found on the EJ25. I took the T-connector from EJ25 and used it to connect the longer hose to the sensor on the passenger strut tower, and put the extra EJ22 hose on the T.
- I swapped the AC/Alt bracket from the EJ25 to the EJ22...it may not be necessary but couldn't get that small bracket piece under the AC to work (maybe I just needed a break!). Otherwise, the AC/ALT/PS all connected right up. The PS lines do stick out and won't connect to the EJ22. I removed the brackets from the lines, since they weren't being used.
- Note that neither the AC compressor nor the PS pump need to be disconnected from their hoses - just swing them up and out of the way. When removing/installing the engine just go slow and move the AC hoses out of the way as needed.

I left the '99 ECU alone and the car ran well.

MikeT taught me a new one - hadn't heard about swapping in a '97-98 ECU to avoid the 'premium' issue.

p.s. Doing the head gasket has been done w/the engine in the car, but if it's your 1st one on a Sube, I'd pull it.
Good luck,
TD

[drsevy]

Thanks for the info. I appreciate it.

[ciper]

The 96 EJ25D is also supposed to have different pistons. I've been trying to find one in the junkyard for a while to confirm.

[94.GT.Wagon]

I changed head gaskets on a '97 GT with the engine still in the car. It was no big deal except for some pretty tight clearance on the driver's side that made torquing the head bolts a little challenging. Next time I'll pull the engine but I wouldn't say it's a must-do.

[mike-tracy]

The 96 EJ25D is also supposed to have different pistons. I've been trying to find one in the junkyard for a while to confirm.

It has different heads than the later D's for sure. I hadn't heard about different pistons. Interesting.

[djmtsu]

- The vac hoses are different as mentioned in previous posts:
--On the EJ22 there are 2 that go to the charcol canister. I looped them back into each other.
--There were also 2 on the passenger side of the intake manifold on the EJ22. There was one hose w/a T-connector that I found on the EJ25. I took the T-connector from EJ25 and used it to connect the longer hose to the sensor on the passenger strut tower, and put the extra EJ22 hose on the T.

This is an issue I am having. Is there any way you can snaps some pics?

Please!!

[wtdash]

The car was sold, but if you describe in detail and can provide pics, maybe 'we' can help.

p.s. Check out the USMB.org/forum, too!

TD