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Old 06-03-2011, 11:55 AM   #1
kpluiten
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Default 2000 2.5RS Project: Daily Driver on the Cheap

I recently bought a 2000 2.5RS with a blown motor. My goal is to turn it into a reliable daily driver to replace my dutiful 1997 Impreza L 2.2 5MT, who while totaled, continues to run like a champ, but is getting a little long in the tooth.

My goals for this project:
1) Get her driving again much quicker than my last project (wagon of doom)
2) Reliable
3) Cheap


Here is what she looks like at this point:







Car details:
-169,555 miles
-2.5L SOHC MAP
-5MT
-$500

The good:
-AGX adjustable struts with stock springs
-Full poly bushing set
-Brand new tires
-New front bumper
-New headlight
-New passenger-side fender

The bad:
-Motor was starved of oil - rod knock - needs to be rebuilt
-Windows are SLOW and tint is tearing off - need to be rebuilt/retinted
-Leather wheel and shifter and gone - need replacement
-Driver-side seat is torn up
-Interior needs a deep clean
-Exterior paint is SHOT
-Sun roof is jammed
-Needs a better/complete stereo


I'm sure there will be more as I get into it.
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Old 06-03-2011, 12:10 PM   #2
SUBAWRECK
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Hey I got a lot of random parts and don't ever mind helping if u need another guy to wrench let me know
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Old 06-03-2011, 12:17 PM   #3
kpluiten
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Quote:
Originally Posted by SUBAWRECK View Post
Hey I got a lot of random parts and don't ever mind helping if u need another guy to wrench let me know
Right on. Thanks! I'll let you know as the need arises. Where are you located?
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Old 06-03-2011, 12:50 PM   #4
kpluiten
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I got a spare NA 2.5 short block from a fellow member on here. I promised to trade him alcohol for it, but I never delivered the goods, so this motor was free. brocksdad is a sucker.

Either way, this motor also had rod knock despite having brand new bearings and despite having only run for a minute or two. What was strange is that this motor was from a 1997 Outback, which should have made it a Phase 1 DOHC 2.5. However, upon teardown, I found that the case and the crank were definitely Phase II as the thrust bearing was on #5 instead of #3 like the Phase I blocks. To compound things, the pistons in this block were definitely the old Phase I square relief ones. My guess is that this car had a warranty replacement motor at some point and Subaru repaired it with the updated block design.

Whatever the case may be (no pun intended) on the doaner motor, it looks like I can use the block and the crank for this build. This saves me the trouble of driving down to Tucson and pulling the motor from the RS only to drag it back up here for disassembly and rebuild.

Here are some pictures of what I found.

#4:




#3:


#2:


#1:


As you can see, the bearings are shot. It seems that the bearing in the rod end (not the cap) on each took the brunt of the damage. This makes sense.


What would you guess caused this? Lack of assembly lube? Not priming the motor? Improper clearances? Improper torque on the cap bolts?
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Old 06-03-2011, 12:52 PM   #5
kpluiten
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These stuck out from the top of the block by about 0.5-1.0mm at TDC.






The skirts seem very worn with even a bit of scoring. They are 99.0mm.




The crank looks to be in good shape with some scoring. I'm pretty certain it can be polished up and used with the correct bearings. What do you think? I know the pictures are not the best.










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Old 06-03-2011, 12:53 PM   #6
kpluiten
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Old 06-03-2011, 01:13 PM   #7
Evil Imports
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+ 13 B8

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should have been my RS
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Old 06-03-2011, 01:38 PM   #8
bObby
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This was one of those good deals I've seen for sale on this forum.
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Old 06-03-2011, 02:32 PM   #9
fastnoypi
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Scrapping old green? I hope blue will handle just as well... flat out.
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Old 06-03-2011, 02:57 PM   #10
chubbsub
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Wow we have similar stories as far as finding a cheap GC with a blown motor haha. Currently waiting for the heads to come back from the shop then its on to reassembly good luck with this build man, and I'm always down to lend a hand if you need!
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Old 06-03-2011, 02:58 PM   #11
SUBAWRECK
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In glendale phx area got a place that will do valve jobs for 120 starting and cheap cheap for seals and things that need to be replaced
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Old 06-03-2011, 04:19 PM   #12
kpluiten
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Default

Quote:
Originally Posted by SUBAWRECK View Post
In glendale phx area got a place that will do valve jobs for 120 starting and cheap cheap for seals and things that need to be replaced
Ok cool. I will be in contact with you about them. I want to freshen up the heads while I have them out. I was looking at a mild grind set of delta cams too. Do you have any experience with those?
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Old 06-03-2011, 07:08 PM   #13
Momosaurus WRX
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Ken I've got a hook up at a machine shop. I can get your heads done for pretty cheap.
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Old 06-03-2011, 07:58 PM   #14
kpluiten
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So I got a pretty reasonable explanation for why this motor got smoked on the forst 30 seconds of running:


Quote:
Originally Posted by Storm View Post
That wasn't rod knock that killed the bearings. Using phase I pistons in a phase II setup is what killed the bearings. Check the heads too for a little dose of hammering, courtesy of those pistons. I'm surprised the builder didn't feel the resistance when hand cranking it during the timing process.....

Source some std size 99+ EJ25 pistons (A's) with but don't buy any bearings until you know what you'll need. I've got a set of + .25mm main/rod bearings and a set of std size main bearings, should you need some quickly. I can't use them, or return them....


Jay
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Old 06-03-2011, 10:26 PM   #15
brocksdad
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Quote:
Originally Posted by kpluiten View Post
I got a spare NA 2.5 short block from a fellow member on here. I promised to trade him alcohol for it, but I never delivered the goods, so this motor was free. brocksdad is a sucker.
Dick...








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Old 06-18-2011, 12:47 AM   #16
kpluiten
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Default

I started the easiest part of the motor build today, buying the components. Here is the list so far:

This car has 169,555 miles so I'm doing some extra maintenance parts while I'm in there.

1) Subaru OEM Gasket Kit - 10105AA860 - Purchased
2) NPR Piston & Ring Kit - Link - Stock size - Purchased (took a risk on these... we'll see.
3) ACL Bearing Kit - Waiting on sizing until after crank polishing. - Pending
4) Timing Belt Kit - PCI Belt, GMB pulleys and tensioner. Link - Purchased
5) Water Pump Kit - GMB Pump. Link - Purchased
6) Clutch Kit - Exedy KSB04.
LinkLink
- Purchased
7) Power Steering Pump Rebuild Kit - Purchased
8) Aluminum oil separator (to replace the crappy plastic one that leaks). - Purchased
9) 3-4" Outside Micrometers (and other sizes) - Purchased
10) 3.5-4" Inside, 3-point Micrometer (for bore size) - Pending
11) Assembly lube/sealant/fluids/filters - Pending
12) A second set of EJ25 SOHC heads - - Still looking


EDIT: I've decided NOT to build a second block. The NPR pistons were a bust... too small. I'm going to rebuild the block that's in the car.

Last edited by kpluiten; 07-18-2011 at 12:53 AM.
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Old 07-18-2011, 12:43 AM   #17
kpluiten
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Ok, a bit of an update. I towed the car up from Tucson a couple of weekends ago. Turns out Jeep Wranglers are NOT a good tow vehicle. It was a SLOW trip.





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Old 07-18-2011, 12:47 AM   #18
kpluiten
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I had some friends over this weekend and we pulled the motor out of the car on Saturday. Today I tore the motor down to the short block.

I have not seen any of the internals yet, but there were signs of bearing damage in the oil.


















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Old 07-18-2011, 12:51 AM   #19
kpluiten
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There were leaks EVERYWHERE on the block, from the PS pump to the cam covers. No wonder it ran out of oil. The heads look to be in good shape though as do the cylinder walls. I think I'll be able to have the heads refreshed with new seals and all, and then just do a re-ring, hone, and new crank/bearings and be on my way. Nothing extreme planned.













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Old 07-20-2011, 11:45 PM   #20
dreadedwaygone
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64 mustang
real cars are red

Default old block

Hey Ill give you some beer for the block you didnt use....
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Old 07-24-2011, 08:39 AM   #21
madmax_087
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Quote:
Originally Posted by kpluiten
Ok, a bit of an update. I towed the car up from Tucson a couple of weekends ago. Turns out Jeep Wranglers are NOT a good tow vehicle. It was a SLOW trip.
Wait, what? You mean that minivan v6 doesn't pull like a Cummins? Weird...
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Old 07-25-2011, 02:04 AM   #22
blkscooby
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Nice Ken. Always loved the RS. Nice with a 2.0L turbo swap though. I tuned one with a 16g. Holy cow was it fast
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Old 07-25-2011, 11:21 AM   #23
SaabaruMike
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Ken, are you still keeping the green car and the wagon? Just curious.

Also, why are you putting so much work into a NA motor? I'm sure a turbo 2.0 could be found on the cheap.
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Old 07-25-2011, 11:54 AM   #24
kpluiten
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Quote:
Originally Posted by dreadedwaygone View Post
Hey Ill give you some beer for the block you didnt use....
I was thinking about making a coffee table with it. If not, I'll let you know!

Quote:
Originally Posted by madmax_087 View Post
Wait, what? You mean that minivan v6 doesn't pull like a Cummins? Weird...
I know right!? That motor sucks. I miss the old tank I6 4.0L. Best jeep motor ever.

Quote:
Originally Posted by blkscooby View Post
Nice Ken. Always loved the RS. Nice with a 2.0L turbo swap though. I tuned one with a 16g. Holy cow was it fast
I love the look of these cars too. These things swapped are nuts. I will keep my eyes open for a wrecked 02-07 wrx swap car in the future.

Quote:
Originally Posted by SaabaruMike View Post
Ken, are you still keeping the green car and the wagon? Just curious.

Also, why are you putting so much work into a NA motor? I'm sure a turbo 2.0 could be found on the cheap.
I'm giving the green car to a friend who needs a car to get on his feet. I'll keep ownership of it though.

I'm looking for a solid daily driver now, not something I want to modify. I have the wagon for that. I'd like to spend about $1500 total on this car ($500 for the car, $1000 on rebuild). Then I will drive her for the next couple of years like I did with the Green car.

If the right donor car comes along however...
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Old 12-29-2012, 09:22 PM   #25
davisclan
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[quote=kpluiten;34393980]I started the easiest part of the motor build today, buying the components. Here is the list so far:

This car has 169,555 miles so I'm doing some extra maintenance parts while I'm in there.

1) Subaru OEM Gasket Kit - 10105AA860 - Purchased
2) NPR Piston & Ring Kit - [URL="http://cgi.ebay.com/ebaymotors/Subaru-2-5L-EJ25-

I am looking at 2.0 WRX pistons how did yours hold up? I want a stock rebuild.
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