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Old 05-18-2005, 07:09 AM   #1
EcksJay
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Join Date: Dec 2004
Location: Maine
Vehicle:
1997 OBS
'07 KLR 650

Default Best method of swapping in a 2001 2.5 into my 93'

I just picked up an EJ25 and next weekend I will be swapping it in (hopefully).
What is the best route to take? I will be re-using the 1.8 ECU. Would my 1.8 intake manifold and all fit onto the 2.5? Or am I better off doing a little re-wiring of the engine harness?
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Old 05-18-2005, 01:03 PM   #2
Hawk296
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Baja

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The FAQ at the top has the info youre looking for. I did it to my 95', its the same on a 93'. there really isnt much "rewiring" Its very minimal if you decide to take that route.
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Old 05-18-2005, 02:05 PM   #3
EcksJay
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Thanks! I just re-read the sticky, and a few of your posts, and I would like to understand a few things: Do I use any part of the 2.5 engine harness? ie; connectors down at the flywheel, sensors, etc. If not, can I just rip everything off to get it ready for my 93' harness?
I know that I need to re-use my 1.8 crank trigger sprocket.
I know that I need to retain my 1.8 throttle body, and my 1.8 coil.
Aside from the injectors and temp sensor, is there anything else that needs to be re-wired? I have a set of plug wires coming. Anything else?
Are all the other sensors okay? I just plug my 1.8 leads into them?
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Old 05-18-2005, 09:08 PM   #4
Hawk296
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Baja

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The crank trigger should be fine as long as the one in your 2.5 is a 6 tooth. Just the 4 injectors need to have the new connector put on it. (In my opinions this is just as quick as swapping manifolds) If you dont swap over your temp sensors, then you need to rewire both of them from your 1.8 harness into the 1 single new style connector for the 2.5s temp sensor.

If you have the 2.5 harness, just salvage the fuel injector connectors and possibly temp sensor connector from the engine harness. Take these and put them on the existing 1.8 engine harness. that way you use 1.8 wiring and everything.
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Old 05-19-2005, 05:40 AM   #5
EcksJay
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'07 KLR 650

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Cool! For some reason I seem to remember reading about re-using the 1.8 crank sprocket. But, the 2.5 has the 6 tooth ring, so that saves a hassle.
I didn't know that re-using the temp sensor was an option. Are you saying that I can? Or would I be better off merging the wiring into the 2.5 sensor?
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Old 05-19-2005, 10:13 AM   #6
Hawk296
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You only have to Re-use the crank sprocket IF the 2.5 doesnt already have the 6 thooth one. This will depend if the engine came from an automatic or manual car. Temp sensor is your choice. I initially used the 1.8s, then later on rewired them to use the single temp sensor from the 2.5 (just to use 1 sensor instead of two).
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Old 05-19-2005, 09:31 PM   #7
cybin
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You might want to check out this thread over at i-club. A guy over there even rewired the 2.5L coil to work with the 1.8L harness. So you don't need special plug wires.

For some reason I can't link over to i-club. Check out under the conversions forum:FAQ The thread is called "The Ultimate EJ18/EJ22 -> EJ25 Swap Thread"

-Cybin

Last edited by cybin; 05-19-2005 at 09:36 PM. Reason: Wrong address
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Old 05-19-2005, 11:31 PM   #8
EcksJay
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Thank you. I have already considered that option, but I may go with new wires anyway. (tune-up)
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Old 05-20-2005, 01:28 AM   #9
EcksJay
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'07 KLR 650

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Also, do i have to remove the intake manifold to remove the harness? I'm working on it now, and I'm having sort of a tough spot there. I dunno, I might just hang it up for the night. (morning, actually)
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Old 05-20-2005, 03:04 AM   #10
EcksJay
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Never mind. I got it out.
Also, when I re-do the fuel injectors, I just cut and splice the two leads of each plug, right? Only reason I'm asking is because as I was unraveling the tape around the injector wires, I came to a sort of terminal, 3 wires merging into 1. ???
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Old 05-20-2005, 10:17 AM   #11
Hawk296
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1995 Impreza L
Baja

Default

Heck, Ide try removing the actual pins from the connector still attached to the wires and swap the plastic bodies of the connectors. THat can be tough in which case, just cut them off leaving about an inch or alittle more on the connector side so you have enough wire to connect to.
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Old 05-30-2005, 09:05 AM   #12
EcksJay
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Hawk,

PM'ed you
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