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Old 04-27-2009, 01:31 AM   #1
GriffithBuilt
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Default Swapping '99 SOHC EJ25 Long Block into '93 Legacy (EJ22)

I've got a VW Vanagon that has an EJ22 in it, lots of miles and has developed a rod knock. I picked up a '99 2.5RS long block with 65k on the clock and I'd like to just swap the long block into the place of the failed EJ22 long block, using all of the EJ22 bits - intake, ecu, aftermarket headers, etc.

Is there any reason why the '93 EJ22 engine management system will not work with the EJ25? Looking at the ports on the head, etc it appears as though there may be a slight difference in port size - 100 thou larger on the EJ25 heads with larger injector clearance in the EJ25 head ports as well.

Is there any dealbreaker on using the EJ22 ECU, harness, sensors & intake with the EJ25 long block?

Thanks,

Jason
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Old 04-27-2009, 02:35 AM   #2
RallyColtTurbo
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An SOHC EJ25 intake manifold has a different bolt pattern then the old EJ22 SOHC. The EJ22 ECU is going to be looking for the old style IAC, while I believe the the EJ25 you have will have the new style.

A '96 -'99 EJ25 DOHC will accept your throttlebody and should work with the older ECU.
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Old 04-27-2009, 11:33 PM   #3
GriffithBuilt
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Well, that is unfortunate.

So now I need to source a number of different parts to make this EJ25 long block work in my application. Obviously the simplest solution would be to source all parts off another EJ253 and use that harness/ecu as well. Unfortunately, this leaves me with two vehicles in 1999 to work from as the 05+ vehicles have the I-Active valve system which my long block does not have.

First question: Is there another variant of EJ25 (251 or 252) whose components will mechanically work with this long block? If I am going to have to transplant a different harness and ECU into the vehicle, I don't have any problem switching to MAP instead of MAF.

Second question: Will the exhaust manifolds from the EJ22 fit this block? I have a custom header for this application that I need to use.

Jason
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Old 04-28-2009, 04:34 AM   #4
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Ok I had a chance to compare the exhaust manifold, looks identical.

Intake is obviously different.

From what I can tell at this point, the newer IAC is a six wire, whereas mine is a 3 wire.

I am curious if there are any major disparities between the injectors:
Lb/Hr, Impedance, (I believe the connector style is different).

Also, are any disparities between the cam/crank reluctor wheels and sensors in these two engines. I have heard that there are but the sensor bosses are identical and I'm curious what the differences are.

I'd prefer to keep my MAF setup and not swap over to the EJ253 MAP setup if possible.

Thanks,

Jason
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Old 04-28-2009, 06:17 PM   #5
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Elsewhere I've heard that there is a document floating around that shows all of the differences between the EJ251, 252, 253 in terms of pinouts, sensors, etc. Anyone know where I can find that?

Jason
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Old 04-29-2009, 06:46 AM   #6
xrturbo
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Ryan at area 1320 recently did the same swap to a lifted 92 Lego wagon I sold him awhile back. You may want to contact him. I believe his only major issue was the IAC which he wound up just snugging up on the throttle cable to make it idle. I drove it since it was done, it did seem very quirky running and idling was a little tricky till it warmed up. When I was contemplating swapping the wagon when I had it, after research I was leaning more toward a DOHC 2.5, seemed alot more straight forward. And also you will be fine with any dual port exhaust setup.
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Old 04-29-2009, 01:08 PM   #7
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Quote:
Originally Posted by xrturbo View Post
Ryan at area 1320 recently did the same swap to a lifted 92 Lego wagon I sold him awhile back. You may want to contact him. I believe his only major issue was the IAC which he wound up just snugging up on the throttle cable to make it idle. I drove it since it was done, it did seem very quirky running and idling was a little tricky till it warmed up. When I was contemplating swapping the wagon when I had it, after research I was leaning more toward a DOHC 2.5, seemed alot more straight forward. And also you will be fine with any dual port exhaust setup.
Ok so this seems relatively straightforward then. Someone earlier mentioned that the Cam angle & Crank angle sensors were different, which was my main concern. As for the IAC, I'll fab an adapter and call it a day. Now, the factory '93 IAC connects to the TPS on the EJ22 throttle, so I have to compare the TPS from the EJ25 intake that I have still not picked up and potentially adapt my TB over as well. It does look like there are a number of different styles of IAC, some integrated with a throttle, others not. Some 3 wire, others 6. That difference I would guess is the difference between a PWM & Stepper type setup or something involving the method of functionality for the internals of the IAC. I'll need to stick with the 3 wire variant to get my ECU to talk to it. ANd the plumbing might be interesting if I can't find a three wire throttle integrated unit as my IAC has the coolant passage in it.

Jason
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Old 05-01-2009, 09:40 AM   #8
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The 92 uses the same style mounting for the cam and crank sensors, they just have a lead coming off of each of them and they have their own connectors going to the ECU harness depending on the year will be located at the bell or the side of the engine. If you are going to run the 2.2 intake harness you could just swap the 2.2 sensors to the 2.5. If you can figure out all of the IAC wiring you described, the cam/crank sensors will be even easier.
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