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Old 05-30-2005, 06:17 PM   #1
EcksJay
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Member#: 77677
Join Date: Dec 2004
Location: Maine
Vehicle:
1997 OBS
'07 KLR 650

Talking 2.5 swap is done!

Well, after many, many hours of work, the 1.8 to 2.5 swap is finished.
It runs well, idles well, and it goes like a bat out of hell.
After I figured out what had to be done concerning the vacuum and electrical re-routing, it was relatively simple.
Actually, the hardest part was taking the engine out. Normally the engine should just seperate from the tranny. But not this time. I had to take out the tranny and engine in one piece, and then beat the crap out of the seam. Turns out those 2 10mm pins were seriously oxidized to the case.

I used all of the vacuum connectors and electrical connectors off the 1.8, and there is no CEL's. It took me several trys to get all the vacuum leaks fixed, and I think there might be a few small ones left.

The cat converter gets pretty hot, but I'm guessing that is due to the fact that I'm still running the 1.8 exhaust. (constriction)

Unfortunately, I didn't take any photos while I was doing the swap, but I'll post some "after" pics when the sun comes out tomorrow. (yeah right)
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Old 05-30-2005, 06:21 PM   #2
WRenXhaven
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Member#: 43905
Join Date: Sep 2003
Chapter/Region: South East
Location: The CBT
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02 WRXBastardchild
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Congrats on the swap Jay, I too just got done with my 2.5 swap but dang it if I don't have a CEL

WRen
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Old 05-30-2005, 10:40 PM   #3
Hawk296
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Member#: 14555
Join Date: Jan 2002
Chapter/Region: MWSOC
Location: Troy, MI
Vehicle:
1995 Impreza L
Baja

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Congrats! glad to hear it worked out for you.
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Old 05-31-2005, 01:03 AM   #4
Kostamojen
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Join Date: Sep 2000
Chapter/Region: BAIC
Location: haha XD
Vehicle:
2013 Subaru 599 :P
Galaxy Blue Sexy

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Which 2.5 did you use?
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Old 05-31-2005, 10:59 AM   #5
Matt Monson
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'73 914 and 2012 BRZ

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Good job...
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Old 05-31-2005, 12:30 PM   #6
EcksJay
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Member#: 77677
Join Date: Dec 2004
Location: Maine
Vehicle:
1997 OBS
'07 KLR 650

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Old 06-01-2005, 02:26 AM   #7
Qaveboy
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Join Date: Sep 2002
Location: So-Cali
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hey grats on the swap, i had mine done with a couple friends some time now, think its a lil over a year now. I can say that the car is still running strong and pulling hard, however, when i start the car up it idles at around 2k rpm and then it will drop, i think it really depends on the temperature condition.

in ideal conditions the car will idle nicely less than 1k rpm, if not then right around 1k rpm.

let me know how the car drives, i would like to find out some more info about this sort of setup as my car is in store for some major works done to bring it back to a great daily driver. =)
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Old 06-11-2005, 10:46 PM   #8
EcksJay
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Member#: 77677
Join Date: Dec 2004
Location: Maine
Vehicle:
1997 OBS
'07 KLR 650

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In case anybody was wondering, the car is running REALLY well. No CEL's, no weird noises, and best of all, I just finished off a tank of 91 octane, and got 30 MPG on the highway!
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Old 06-11-2005, 10:47 PM   #9
EcksJay
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Member#: 77677
Join Date: Dec 2004
Location: Maine
Vehicle:
1997 OBS
'07 KLR 650

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Also, anyone know a way to hack the 1.8 ECU so I can get past that lame 6k redline?
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