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Old 10-16-2019, 12:35 PM   #1
Orthok
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Join Date: Dec 2004
Default 02 WRX engine rebuild estimate/advice

My stock 197,000 mile 02í WRX with rebuild transmission that Iíve owned since 2003 and 20k miles started throwing flashing CEL with all four cylinders misfiring and some timing codes yesterday resulting in little power to the wheels and very rough idle, some metal noises, and it looked like one of the pulleys was seizing up. This was a sudden onset issue and only other previous issue with the vehicle was a P0457 evaporative system leak that Iíve had for a long time (started off as the small leak code) with no performance impact.

The mechanic is going to do an initial assessment to see what might be the problem, but if I need to rebuild the engine due to bent valves or timing related damage what would be the cost range for a rebuild of the motor?

I intend to keep the vehicle for the long term and remain stock. Maybe reinstall Cobb stage 1 93 octane map, but I generally use it as a daily driver and only sometimes use all the power.

With this in mind
1. What might I expect for price range wise for a stock rebuild repair?
2. How long might a rebuild motor last in daily driver conditions with occasional power pulls during the commute.

Thanks
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Old 10-16-2019, 12:40 PM   #2
hybrid gti 2
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Location: (818) 300k+ ej205 ppg 5mt
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02 vf30 pnp wagon
silver and cf

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You can do a JDM non-avcs ej205 for as little as $750 depending on where you live. Ej205 with avcs for as little as $1150. Best options are ej207 version 7, 8, or 9 but they start at $3k to as much as 4500. So it depends on your budget and goals.
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Old 10-16-2019, 12:51 PM   #3
Orthok
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Thanks for the reply, what is AVCS? I’m in Springfield VA, my goal is to keep the vehicle running well but no intent to modify it aside from basic stage 1 ECM maps. I’d like to keep it for the long term and reuse the original engine if it can be rebuilt to save money. While I may buy a new car in 4 years, I love this wagon so much I may keep it after that as well.
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Old 10-16-2019, 04:27 PM   #4
trueno92
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wow, this is like a time-machine post sent from 2004..

AVCS is used on most all NON USD ej205 engines. AVCS is intake valve phasing and noticeably improves the low end drivability of these engines, provided you have high octane fuel (93/94 oct) that can make the most of the 9.1:1 compression ratio. It also needs the ECM and harness wiring to have the ecm control it.

an engine rebuild will probably cost more vs install of a new one, but you will at least know the history of your ej205 and it should run as new.

You have a few options, but with the stock td04, the power levels are quite tame and as a result, you should have another good 150,000 miles to go, easily.
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Old 10-16-2019, 06:24 PM   #5
Shik
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'15 WRX 6spd CWP, '02 WRX

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You can still get a brand new oem EJ205 short block from Subaru with a 1 year unlimited mile warranty for under $2000 from most dealers. I believe these short blocks have the newer crankshaft(better oiling) as well.

With labor and machine work for the heads and all the other little various things(fluids, gaskets, etc.), maybe $3500 or so?

A bit of a pricier option, but if you plan on keeping the car, as you said, you are unlikely to find a more reliable option. There are some wonderful engine builders out there, but it is hard to beat the factory in Japan.
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Old 10-16-2019, 06:54 PM   #6
hybrid gti 2
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Building any block will run into several things to determine an accurate price. Engine condition. Pistons worn? Rod bearing moving? Mains in food shape? Blah blah blah. I would say without upgrades most places will charge near $2000 for a quality rebuild. Some people will say for that kind of money you get a fresh ej257 from dealer. Yet that would be a hybrid build. You may want to look at compression issues. As the 2.0 heads have a slightly smaller combination chamber. This can be machined. Personally I don't like 2.5 due to all the issues. I got 300k out of my ej205. This is why I want a ej207. Nearly a plug and play deal while using the JDM harness.
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Old 10-16-2019, 06:57 PM   #7
snow_bound26
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Default 02 WRX engine rebuild estimate/advice

I'd agree with the above post. A new OEM short block will be your best and most affordable option if your heads are in good shape. If not, a non-avcs JDM option would be next best. This way you can just use your USDM ECU and not have to worry about anything. If you get something with avcs then you'll need the corresponding ECU and a custom tune to run it properly. Your Cobb AP will also be pointless for that option. Yes you can use an avcs engine and not wire it up while using the USDM ECU and it will work but you'll still need a custom tune to account for the cam position when the avcs isn't utilized.
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Old 10-17-2019, 10:40 AM   #8
trueno92
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As someone that has had to consider this option TWICE (Engine #3 now) I went with the cheapest option both times. It was the JDM Ej205. I have commit to 94 octane and built the harness to run avcs and had an ECU for it.

It sounds like your car is in pretty good shape. I would also mention that the JDM ej205 is a quick turn around if you need the car back on the road quickly. That was the initial plan as we had the 2nd engine out in a weekend and if we had the replacement available, it went in and cranked over in 2 days as well.

A rebuild would take some time on top of engine removal replacement.

Also keep in mind that a jdm205 is used, and it may have had a hard life, low compression on a cyl, etc. Most of the time they are not, and my experience has had 2 out of 2 times great engines. (I blew the first jdm ej205 with aggressive timing and launch control). My new ej205 had the cleanest valvetrain I had ever seen on a used motor:
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Old 10-17-2019, 02:33 PM   #9
subaru_gc8
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Quote:
Originally Posted by Orthok View Post
My stock 197,000 mile 02í WRX with rebuild transmission that Iíve owned since 2003 and 20k miles started throwing flashing CEL with all four cylinders misfiring and some timing codes yesterday resulting in little power to the wheels and very rough idle, some metal noises, and it looked like one of the pulleys was seizing up. This was a sudden onset issue and only other previous issue with the vehicle was a P0457 evaporative system leak that Iíve had for a long time (started off as the small leak code) with no performance impact.

The mechanic is going to do an initial assessment to see what might be the problem, but if I need to rebuild the engine due to bent valves or timing related damage what would be the cost range for a rebuild of the motor?

I intend to keep the vehicle for the long term and remain stock. Maybe reinstall Cobb stage 1 93 octane map, but I generally use it as a daily driver and only sometimes use all the power.

With this in mind
1. What might I expect for price range wise for a stock rebuild repair?
2. How long might a rebuild motor last in daily driver conditions with occasional power pulls during the commute.

Thanks
dont rebuld, get a new block from Subaru if you want new. if you want cheap I would do a jdm ej205.
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Old 10-17-2019, 03:01 PM   #10
Orthok
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So the mechanic called and stated some of the 4 bearings on one of the cams(?) failed, they replaced all four bearings and it works again, valves and water pump all still look good and it seems to be running fine. Looks like about $800, hopefully they are right and she keeps running well past 200k thanks for your help, I hope it’s a long time if at all that I need to ask about rebuilds in the future, now I just need to figure out this P0457.

Thanks again
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Old 10-17-2019, 05:37 PM   #11
subaru_gc8
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Quote:
Originally Posted by Orthok View Post
So the mechanic called and stated some of the 4 bearings on one of the cams(?) failed, they replaced all four bearings and it works again, valves and water pump all still look good and it seems to be running fine. Looks like about $800, hopefully they are right and she keeps running well past 200k thanks for your help, I hope itís a long time if at all that I need to ask about rebuilds in the future, now I just need to figure out this P0457.

Thanks again
bearings on the cams?
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Old 10-17-2019, 09:34 PM   #12
Orthok
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I have a terrible memory, I was wrong it was the idler bearings that had gone out and are now replaced
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