Replacing an JDM EJ205 in a 2004 WRX...Looking for guidance and part number help.

RocketFoot · 11-21-2019, 11:42 AM

So, my son bought a 2004 WRX with a JDM EJ205 wired to US ECU already swapped in. He drove it home 200 miles and the timing belt snapped in our driveway! Took it to a shop and confirmed catastrophic engine damage so we are going to buy another JDM EJ205 from Dallas JDM Motors.

I have a fairly well appointed garage with engine stand and engine lift so we are going to attempt to replace the dead engine on a limited BUDGET!

With the engine replacement figured out, we need to get a few other things ordered up...and we could use some tips & tricks from those who are more knowledgeable on these WRX's than we are! LOL!

1. Timing Kit? Looking for something inexpensive but bulletproof!

2. OEM Replacement style clutch: I am eyeing up a Duralast clutch from Autozone for under $200 but the one that crosses with the Amazon clutch kits says it fits a 2.5 engine? Does anyone know what Exedy OEM part number will work with the 2.0 Turbo? My search says FJK1006 would be a good choice? AZ changes it to NU31365 which I can get for way less than it shows in the link...but again, it doesn't specify the EJ205 engine??

3. Gasket kit for all the stuff that needs attached to the long block?

I'd like to use this thread as a help thread for our project as it progresses...again, any help, tips, guidance, etc...is GREATLY appreciated! In case you missed our intro thread...here are some pics of the blue bomber! 2004 WRX with 2006 front clip swap.

sig · 11-21-2019, 09:06 PM

Check rockauto.com it should have all the part numbers listed for your car as well as some of the best prices. For the clutch I'd go with a brand like Exedy or ACT. All of the parts that fit the USDM should work for the JDM, just make sure you swap the needed USDM parts from the blown engine that the previous owner most likely did.

JDM Ej205 vs USDM Ej205 - EVERYTHING YOU NEED TO KNOW - Swap - YouTube

watch this video it will tell you what you will need to swap over. Also be aware that some ej205's that you buy are actually ej208s which were twin turbo engines from the legacy B4 so it will have capped off oil and coolant lines but the engine will work and is basically the same.

Good luck

Cobrakai · 11-22-2019, 07:36 PM

Timing kit: Aisin TKF-004, comes with everything you need - rockauto carries them. I believe everything but the timing belt is made in Japan.

Clutch: Exedy KSB03 The Exedy OEM replacement clutches are fine, you can find them on amazon for relatively cheap.

Just resurface the flywheel and get a new pilot bearing for it and you're good to go.

RocketFoot · 11-23-2019, 06:32 AM

Does this clutch look good for EJ205? There seems to be a ton of different part numbers for the same thing, LOL!

https://www.amazon.com/EXEDY-CLUTCH-.../dp/B01M8M26DE

Also, is there a gasket kit good for long block swap? This is what I came up with on Rock Auto...if it all looks good, I will pull the trigger!

trueno92 · 11-23-2019, 07:37 PM

hey dude, i sent you a message with link to my google gallery of my swap i did earlier this year.

to help others tho, post into this thread if you have any issues, so it can help iothers.

I hope you got some justice with a swapped engine snapping its timing belt in your drive way. Thats pretty nuts and I'd love to know what the issue was with it.

If you get any 2004+ ej205 it will drop right in, you won't need to change anything.

watch for the clutch fork pinion when you are ready to pull the engine out and remember to put the lower dowel pins back into the block when you are ready to drop the new engine in so it lines up with the bell housing!!

since its out, get a VF48 on it and some bigger injectors.. lots of fun for little cash...

RocketFoot · 11-25-2019, 01:21 PM

Quote:

Originally Posted by Cobrakai

Timing kit: Aisin TKF-004, comes with everything you need - rockauto carries them. I believe everything but the timing belt is made in Japan.

Clutch: Exedy KSB03 The Exedy OEM replacement clutches are fine, you can find them on amazon for relatively cheap.

Just resurface the flywheel and get a new pilot bearing for it and you're good to go.

TKF-004 says it is for a 2.5, we have a 2.0 turbo...should it be a TKF-008 Timing Belt Kit?

Cobrakai · 11-25-2019, 07:16 PM

Quote:

Originally Posted by RocketFoot

TKF-004 says it is for a 2.5, we have a 2.0 turbo...should it be a TKF-008 Timing Belt Kit?

I went directly on Aisin’s website and looked it up, TKF-004 should work just fine.

Used it on my 207 swap

RocketFoot · 11-26-2019, 11:02 AM

Quote:

Originally Posted by Cobrakai

I went directly on Aisin’s website and looked it up, TKF-004 should work just fine.

Used it on my 207 swap

Thanks! Looks like the 004 covers more years than the 008.

Engine is coming today...we are getting pumped for this swap!

trueno92 · 11-23-2019, 07:38 PM

gasket kit is good mainly for the valve covers, but i'd rather get the rear main seal and the cam seals and front main but those are more work.. esp those cams.

also, watch out for engine differences as there are slight differences with auto and manuals with timing belt guides, oil cooler etc.

trueno92 · 11-23-2019, 07:39 PM

get the mani gasket in case you get a drive by wire engine.. you will need to swap out your drive by cable manifold.

trueno92 · 11-26-2019, 11:23 AM

Sounds great, good luck and it should be straight forward.

look for drive by cable and look at the timing belt covers for AVCS sprockets.

RocketFoot · 11-26-2019, 01:43 PM

Here is the long block! Not sure what I am really looking for with Drive by Wire and AVCS sprockets? Also, what size bolts do I need to bolt it to my engine stand?

D-Rodman · 11-28-2019, 12:18 AM

I don’t see AVCS, water pipe on top is wrong for wrx, also make sure to install a timing belt guard, that motor won’t have one originally.

Shinji N · 11-28-2019, 01:44 PM

That water pipe makes me think that might be a Forester motor.
Also, Since there's no intake manifold, can't say if it's drive by wire or cable. You'll just reuse your manifold.

RocketFoot · 11-29-2019, 10:58 AM

Thanks for the pointers! Keep them coming...we will be ripping into this thing starting today!

trueno92 · 11-29-2019, 11:16 AM

its an auto, take off everything from the crank and bin it. swap over everything from your old engine.

do a comp test on her before anything and if any cylinders are really low, squirt some oil in there, the rings may be dry from sitting.

trueno92 · 11-29-2019, 11:29 AM

this is the guide/guard that d-rodman mentioned, steal it from your old engine. auto engines did not have this part installed but its required if you are using this engine with a manual tranny

RocketFoot · 11-29-2019, 03:45 PM

What has to come off the crank? You talking about the gears the belt rides on? Do the come off easy or anything special to know when swapping them out?

D-Rodman · 11-30-2019, 09:10 PM

Yes, use the gear the belt rides on, it slides off by hand once the belt is removed.

RocketFoot · 12-01-2019, 04:54 PM

Getting down to business...

RocketFoot · 12-02-2019, 02:27 PM

Are there gaskets available for:

Oil Filler Tube
Dipstick tube
Water Manifold

...or is all just silicone/RTV?

RocketFoot · 12-03-2019, 08:12 AM

Looks like we got a JDM engine set up for automatic transmission...but the car is manual. Question is, are the timing belts/kits all the same? I know about the timing belt guide (that we do need to find) but what about the tensioners and idlers? Would they all be the same no mater what kit?

We bought an Aisin kit for manual so I'm not sure if we should send it back and get one for the auto or not? One diff we did notice was the 3rd nipple on the water pump, but it can be plugged.

BTW, the old engine was missing the timing belt guide...could be why the belt jumped in the first place!

CarmMontana · 12-03-2019, 11:54 AM

My research on the ej206 I got was that the idler pulleys and timing belt setup were all the same. The added belt guide was not on mine either.

I have researched this a bit and it's possible that it caused the slipped belt, one-two teeth from what I understand but it's rare. I have seen a few people say don't worry about it but if your there you may as well have one. One conern I have seen is installing it too tight to the belt and causing premature belt failure.

I didn't do mine, didn't know until it was already in there. I will add it later but the risk is low as I live in a valley with very few hills. The main issue is backward motion as the tension is lost. If you have hills and park on hills id get one for sure.

RocketFoot · 12-03-2019, 04:15 PM

Quote:

Originally Posted by CarmMontana

My research on the ej206 I got was that the idler pulleys and timing belt setup were all the same. The added belt guide was not on mine either.

I have researched this a bit and it's possible that it caused the slipped belt, one-two teeth from what I understand but it's rare. I have seen a few people say don't worry about it but if your there you may as well have one. One conern I have seen is installing it too tight to the belt and causing premature belt failure.

I didn't do mine, didn't know until it was already in there. I will add it later but the risk is low as I live in a valley with very few hills. The main issue is backward motion as the tension is lost. If you have hills and park on hills id get one for sure.

Wonder if there is any benefit to one of these performance guides compared to the OEM version? This one has a spacer tool so the belt isn't too close to the guide:

https://aaperformance.ca/en/produit/...q013WDpa_9M2mc

D-Rodman · 12-03-2019, 11:01 PM

The guide comes into play also when you step hard on the gas pedal and just lift off the gas pedal, avoid doing stuff like that if you are running no guide. The oem guide is adequate but bends easy, my guide got all bent up when a cog bearing failed and a cam gear imploded. Ironically, the belt did not snap, sadly it did bent valves. The aftermarket guides are much stronger. Gates timing belt kit comes with a tool for setting up the proper gap on the guide.

11-21-2019, 11:42 AM	#1
RocketFoot Scooby Newbie Member#: 508477 Join Date: Nov 2019 Chapter/Region: MAIC Vehicle: 2004 WRX Rally Blue	Replacing an JDM EJ205 in a 2004 WRX...Looking for guidance and part number help. So, my son bought a 2004 WRX with a JDM EJ205 wired to US ECU already swapped in. He drove it home 200 miles and the timing belt snapped in our driveway! Took it to a shop and confirmed catastrophic engine damage so we are going to buy another JDM EJ205 from Dallas JDM Motors. I have a fairly well appointed garage with engine stand and engine lift so we are going to attempt to replace the dead engine on a limited BUDGET! With the engine replacement figured out, we need to get a few other things ordered up...and we could use some tips & tricks from those who are more knowledgeable on these WRX's than we are! LOL! 1. Timing Kit? Looking for something inexpensive but bulletproof! 2. OEM Replacement style clutch: I am eyeing up a Duralast clutch from Autozone for under $200 but the one that crosses with the Amazon clutch kits says it fits a 2.5 engine? Does anyone know what Exedy OEM part number will work with the 2.0 Turbo? My search says FJK1006 would be a good choice? AZ changes it to NU31365 which I can get for way less than it shows in the link...but again, it doesn't specify the EJ205 engine?? 3. Gasket kit for all the stuff that needs attached to the long block? I'd like to use this thread as a help thread for our project as it progresses...again, any help, tips, guidance, etc...is GREATLY appreciated! In case you missed our intro thread...here are some pics of the blue bomber! 2004 WRX with 2006 front clip swap. Last edited by RocketFoot; 11-21-2019 at 03:17 PM.

11-23-2019, 06:32 AM	#4
RocketFoot Scooby Newbie Member#: 508477 Join Date: Nov 2019 Chapter/Region: MAIC Vehicle: 2004 WRX Rally Blue	Does this clutch look good for EJ205? There seems to be a ton of different part numbers for the same thing, LOL! https://www.amazon.com/EXEDY-CLUTCH-.../dp/B01M8M26DE Also, is there a gasket kit good for long block swap? This is what I came up with on Rock Auto...if it all looks good, I will pull the trigger! Last edited by RocketFoot; 11-23-2019 at 07:12 AM.

11-26-2019, 01:43 PM	#12
RocketFoot Scooby Newbie Member#: 508477 Join Date: Nov 2019 Chapter/Region: MAIC Vehicle: 2004 WRX Rally Blue	Here is the long block! Not sure what I am really looking for with Drive by Wire and AVCS sprockets? Also, what size bolts do I need to bolt it to my engine stand? Last edited by RocketFoot; 11-26-2019 at 01:55 PM.

12-03-2019, 11:01 PM	#25
D-Rodman Scooby Specialist Member#: 110078 Join Date: Mar 2006 Location: Long Island N.Y. Vehicle: 02 Bugeye JDM STi OBP BLACK	Replacing an JDM EJ205 in a 2004 WRX...Looking for guidance and part number help. The guide comes into play also when you step hard on the gas pedal and just lift off the gas pedal, avoid doing stuff like that if you are running no guide. The oem guide is adequate but bends easy, my guide got all bent up when a cog bearing failed and a cam gear imploded. Ironically, the belt did not snap, sadly it did bent valves. The aftermarket guides are much stronger. Gates timing belt kit comes with a tool for setting up the proper gap on the guide. Last edited by D-Rodman; 12-03-2019 at 11:07 PM.

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11-22-2019, 07:36 PM	#3
Cobrakai Scooby Specialist Member#: 176408 Join Date: Apr 2008 Chapter/Region: SCIC Location: South OC Vehicle: 2005 EJ207 STy White	Timing kit: Aisin TKF-004, comes with everything you need - rockauto carries them. I believe everything but the timing belt is made in Japan. Clutch: Exedy KSB03 The Exedy OEM replacement clutches are fine, you can find them on amazon for relatively cheap. Just resurface the flywheel and get a new pilot bearing for it and you're good to go.

11-23-2019, 07:37 PM	#5
trueno92 Scooby Specialist Member#: 111755 Join Date: Apr 2006	hey dude, i sent you a message with link to my google gallery of my swap i did earlier this year. to help others tho, post into this thread if you have any issues, so it can help iothers. I hope you got some justice with a swapped engine snapping its timing belt in your drive way. Thats pretty nuts and I'd love to know what the issue was with it. If you get any 2004+ ej205 it will drop right in, you won't need to change anything. watch for the clutch fork pinion when you are ready to pull the engine out and remember to put the lower dowel pins back into the block when you are ready to drop the new engine in so it lines up with the bell housing!! since its out, get a VF48 on it and some bigger injectors.. lots of fun for little cash...

11-23-2019, 07:38 PM	#9
trueno92 Scooby Specialist Member#: 111755 Join Date: Apr 2006	gasket kit is good mainly for the valve covers, but i'd rather get the rear main seal and the cam seals and front main but those are more work.. esp those cams. also, watch out for engine differences as there are slight differences with auto and manuals with timing belt guides, oil cooler etc.

11-23-2019, 07:39 PM	#10
trueno92 Scooby Specialist Member#: 111755 Join Date: Apr 2006	get the mani gasket in case you get a drive by wire engine.. you will need to swap out your drive by cable manifold.

11-26-2019, 11:23 AM	#11
trueno92 Scooby Specialist Member#: 111755 Join Date: Apr 2006	Sounds great, good luck and it should be straight forward. look for drive by cable and look at the timing belt covers for AVCS sprockets.

11-28-2019, 12:18 AM	#13
D-Rodman Scooby Specialist Member#: 110078 Join Date: Mar 2006 Location: Long Island N.Y. Vehicle: 02 Bugeye JDM STi OBP BLACK	I don’t see AVCS, water pipe on top is wrong for wrx, also make sure to install a timing belt guard, that motor won’t have one originally.

11-28-2019, 01:44 PM	#14
Shinji N Scooby Specialist Member#: 3987 Join Date: Feb 2001 Location: Los Angeles, CA Vehicle: 1998 2.5RS Blue	That water pipe makes me think that might be a Forester motor. Also, Since there's no intake manifold, can't say if it's drive by wire or cable. You'll just reuse your manifold.

11-29-2019, 10:58 AM	#15
RocketFoot Scooby Newbie Member#: 508477 Join Date: Nov 2019 Chapter/Region: MAIC Vehicle: 2004 WRX Rally Blue	Thanks for the pointers! Keep them coming...we will be ripping into this thing starting today!

11-29-2019, 11:16 AM	#16
trueno92 Scooby Specialist Member#: 111755 Join Date: Apr 2006	its an auto, take off everything from the crank and bin it. swap over everything from your old engine. do a comp test on her before anything and if any cylinders are really low, squirt some oil in there, the rings may be dry from sitting.

11-29-2019, 11:29 AM	#17
trueno92 Scooby Specialist Member#: 111755 Join Date: Apr 2006	this is the guide/guard that d-rodman mentioned, steal it from your old engine. auto engines did not have this part installed but its required if you are using this engine with a manual tranny

11-29-2019, 03:45 PM	#18
RocketFoot Scooby Newbie Member#: 508477 Join Date: Nov 2019 Chapter/Region: MAIC Vehicle: 2004 WRX Rally Blue	What has to come off the crank? You talking about the gears the belt rides on? Do the come off easy or anything special to know when swapping them out?

11-30-2019, 09:10 PM	#19
D-Rodman Scooby Specialist Member#: 110078 Join Date: Mar 2006 Location: Long Island N.Y. Vehicle: 02 Bugeye JDM STi OBP BLACK	Yes, use the gear the belt rides on, it slides off by hand once the belt is removed.

12-01-2019, 04:54 PM	#20
RocketFoot Scooby Newbie Member#: 508477 Join Date: Nov 2019 Chapter/Region: MAIC Vehicle: 2004 WRX Rally Blue	Getting down to business...

12-02-2019, 02:27 PM	#21
RocketFoot Scooby Newbie Member#: 508477 Join Date: Nov 2019 Chapter/Region: MAIC Vehicle: 2004 WRX Rally Blue	Are there gaskets available for: Oil Filler Tube Dipstick tube Water Manifold ...or is all just silicone/RTV?

12-03-2019, 08:12 AM	#22
RocketFoot Scooby Newbie Member#: 508477 Join Date: Nov 2019 Chapter/Region: MAIC Vehicle: 2004 WRX Rally Blue	Looks like we got a JDM engine set up for automatic transmission...but the car is manual. Question is, are the timing belts/kits all the same? I know about the timing belt guide (that we do need to find) but what about the tensioners and idlers? Would they all be the same no mater what kit? We bought an Aisin kit for manual so I'm not sure if we should send it back and get one for the auto or not? One diff we did notice was the 3rd nipple on the water pump, but it can be plugged. BTW, the old engine was missing the timing belt guide...could be why the belt jumped in the first place!

12-03-2019, 11:54 AM	#23
CarmMontana Scooby Newbie Member#: 507853 Join Date: Oct 2019	My research on the ej206 I got was that the idler pulleys and timing belt setup were all the same. The added belt guide was not on mine either. I have researched this a bit and it's possible that it caused the slipped belt, one-two teeth from what I understand but it's rare. I have seen a few people say don't worry about it but if your there you may as well have one. One conern I have seen is installing it too tight to the belt and causing premature belt failure. I didn't do mine, didn't know until it was already in there. I will add it later but the risk is low as I live in a valley with very few hills. The main issue is backward motion as the tension is lost. If you have hills and park on hills id get one for sure.