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Old 05-14-2005, 07:44 AM   #1
EcksJay
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Member#: 77677
Join Date: Dec 2004
Location: Maine
Vehicle:
1997 OBS
'07 KLR 650

Default Just picked up a 2.5 engine...couple of questions..

Well, I made the trip down to NJ to pick up a 2.5, exhuast, and some other stuff. Couple of questions now:
The motor is a 2001, with 52k on it. I know that I want to put some reground cams in. Should I do any other repairs, since it's out of the car? ie; gaskets, seals, timing belts
It came with a clutch. OK to re-use?
It also came with a hacked up engine harness. Will this effect me adversely?

Seth

BTW, those RS seats are WAY better than old 93' L seats
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Old 05-14-2005, 07:57 AM   #2
Kreeger
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I would say that at 52k miles, if the main (crank) seals are not leaking, don't bother changing them. They tend to last 100k or more. Change the cam seals if you will replace the cams, though. Timing belt, yes change it. On the last thing, I have known of others to run a 2.5 motor on their 1.8 ECU and harness successfully... search it on the N/A forum.
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Old 05-14-2005, 08:00 AM   #3
kevinsUBARU
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If you can, do yourself a favor (peace of mind) and refresh everything you can so you know the engine is sound.

I would say the clutch is ok to reuse, but measure the surface material left on it to see if it's basically new or basically dead.

Engine wiring....I don't know enough about wiring to give you a good response, however, I do know that electrical problems in any car can be a pain to figure out. If your budget didn't allow you to source out a engine wiring harness in one piece, I would at least go over the hacked up one very oh so very carefully and make sure everything is connected where it should be and stuff like that.

Have fun
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Old 05-14-2005, 12:01 PM   #4
Matt Monson
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Don't bother with the timing belt at that mileage. Just mark it properly on removal and reuse it. Clutch should be fine to reuse as well, especially if it is still bolted to a flywheel and attached to the engine.

The only thing I would bother with is the cam seals when you change cams.

Shoot me a PM if you need help with the wiring. It is pretty straightforward to move your 1.8l wiring harness over to the new engine. You just do it while the manifold is off of it. There are a couple of things that need to be changed and spliced, and as long as the connectors themselves are good on the cut harness, you are good to go...
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Old 05-14-2005, 01:47 PM   #5
EcksJay
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I'll post pics of everything this afternoon. The harness is a pretty sorry state of affairs, though.....I think....I've never really seen one before, so I may be wrong.
The engine has know noticeable leaks, though.
However, I transported it laying on it's back (flywheel side) and I noticed that when I got home, the inside of the throttle body had a bit of oil in it. I was in such a hurry to get home that I failed to check it. Are they related? The whole intake plumbing (air filter and ducting) is clean as a whistle, though.

Seth
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Old 05-14-2005, 02:03 PM   #6
Kreeger
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Since you tipped the motor up that way, it is likely that oil seeped into the intake manifold from the PCV hose inlet. The motor should always sit oil pan side down...
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Old 05-14-2005, 05:36 PM   #7
EcksJay
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Yeah, I kinda figured that was the problem. Would it ruin anything? I wanted to transport it standing up, but I didn't have a good way of securing it in the back of my wifes minivan (pontiac montanna, which by the way, is a very comfortable ride)

Here are the pics:

One end of harness:


Other end of harness:


Engine: yes, I know I'll get flack for leaving it on a tire, but who cares.



Here's the throttle body:


Here's the clutch:




Seth
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Old 05-14-2005, 09:16 PM   #8
EcksJay
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Also, do I want to use a RRFPR, or a S-AFC?
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Old 05-14-2005, 09:24 PM   #9
Kreeger
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The motor will be okay... just replace the plugs and change the oil. Unless you plan to turbo it, your stock fuel pump is plenty. Clutch and P/P look okay BTW.
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Old 05-14-2005, 09:27 PM   #10
EcksJay
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Well, since it's being run by a 1.8 ecu, I've read that the stock fuel sytem will not be "adequate".

edit: Also, the clutch measures .280" thickness. I have no idea what they are stock.....
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Old 05-14-2005, 09:32 PM   #11
Kreeger
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I have not personally done this swap, but read alot on it.... I have read that it will work using the stock system. The guy transplanted a 2nd gen EJ25 into his EJ18 Brighton and had no probs. From what I know, it still runs fine to this day. The swap was done more than a year ago.

Check here: http://forums.nasioc.com/forums/show...EJ18+EJ25+swap

Here is a quote from the guy I was talking about:

Quote:
Originally Posted by Hawk296
Arg! I have done the swap. I have removed a 1.8l from my 95 OBDI L and installed a SOHC 2.5l from a 2001 (OBDII) car.

It depends... It will run perfectly fine off the 1.8 ECU, it will run rich though. if you want it act 100% like a 2.5 RS then change the harness and ECU Etc.

I did it cause my 1.8l had so many oil leaks i was sick of chasing down and wanted more power.

2.5 bolts right into the mounts and trans, i used a stock 2.5l flywheel clutch and pressure plate althoug the 1.8s will work.

Due to the idle air control setup and connections to the ECU, the 1.8 throttle body was retained. a blockoff plate was made to cover the idle air port on the newer 2.5 manifold.

the new style fuel injector connectors were spliced onto the 1.8 harness becuase i used the newer style injectors on the 01' 2.5.

crank and cam sensors, engne temp sensor, and oil press switch all plugged right in to the 1.8 wiring.

the temp gauge sensor was rewired, the older 1.8 had a small sensor with 1 wire whereas the newer 2,5 had a newer 3 wire sensor, i changed the connector to the newer sensor, blocked off two of the pins and ran the bottom wire to the temp guage.

I used the 1.8 coil pack and had plug wires made. if using a DOHC 2.5 stock 2.5 wires should work. I needed old style connectors on the coil end and newer style on the plug end. GOt them custom made and overnighted for 50 bucks from kingsborne wire werks.

EGR did not exist on the 2.5 so i hooked the harness to the solinoids which i retained and just plugged them off.

Knock sensor is not used

stock 1.8 intake and MAF sensor are used.

the only thing i can say to watch out for is the crank trigger on the timing sprocket that triggers the crank sensor.

the older cars it was all the same one, but for the newer (i think 2000 and up) there is a different ring on the manual trans cars. So if you want to use the 1.8 ECU you need to switch it over to the other timing spocket, or reuse the 1.8s

thats all i can think of.
Ive got over 7,000 miles on the 2.5 with the 1.8 ECU. I drive it hard too. it does run alittle too rich, occasionally when going WOT it bogs slightly cause when the ECU switches modes is over fuels, after a week i was used to this and learned to drive at 99% throttle and it does great, no problems. it will bog when really cold out for the same reason unless you let it warm up. if you start and drive it when cold it bogs if you get on it, if you let it warm up for a few min. it runs like normal.

Gas mileage on the 2.5 with the 1.8 ECU is around 26-28 MPG and i hit WOT at least 3 times every time i drive it.

Some vacuum lines will need to be rerouted, just sit down with a service manual and match them up. they will match up, just takes some time. My local dealer photocopied the pages i neededform the service manual for me. I am really happy with the results, it only cost me about 200 bucks because I already had the engine.

if you have all the parts ready to go and everything all planned it it should take a weekend max. to do. good luck, any questions PM me or email me at HAWK296@AOL.com

Last edited by Kreeger; 05-14-2005 at 09:45 PM.
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